Stator Winding Segmentation for Radial Cooling Airflow
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Solution Overview
Problem
Existing alternating current machines face inefficiencies in cooling and heat management, particularly in the stator winding area, due to the limitations in air flow and heat dissipation designs, which can lead to reduced performance and reliability.
Innovation Solution
The design incorporates a claw-pole rotor with alternating claw-pole fingers and a stator winding arrangement that allows for improved air exchange through radially extending fan blades and strategically placed openings for cooling air to flow through the winding overhang, while utilizing a heat sink and diode bridge circuit for enhanced heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling air is introduced into the stator winding area, then heat dissipation is improved, but the air flow path and cooling efficiency are limited by conventional winding arrangements
Solution Approach 1:
The stator winding is divided into multiple independent phase windings (U, V, W phases with positive and negative windings each), allowing cooling air to access different sections independently. This segmentation enables more effective heat dissipation from individual winding sections that were previously bundled together and difficult to cool.
Solution Approach 2:
The patent introduces cooling air flow in a radial direction through the stator iron to the phase windings, adding a new dimension to the cooling path. Instead of relying solely on conventional axial or surface cooling, the cooling medium penetrates through the stator structure to directly reach the windings from the interior, significantly improving cooling efficiency.
2Ease of manufacture
If conventional stator winding arrangements are used, then manufacturing is simplified, but heat management and cooling are insufficient
Solution Approach 1:
The winding arrangement segments phase windings into separate slots with independent routing paths. While this increases manufacturing complexity slightly, it provides superior heat management by allowing cooling air to access each segment independently and by creating natural thermal zones that can be managed more effectively.
Solution Approach 2:
Different regions of the stator winding are designed with different structural characteristics to optimize local heat dissipation. The radial cooling paths, slot configurations, and winding arrangements are tailored to the specific thermal requirements of different stator regions, providing localized heat management solutions.
3Area of stationary object
If coil connectors and connectors are routed in parallel, then space utilization is improved, but heat dissipation and air flow are restricted
Solution Approach 1:
Connector routing is segmented into separate paths for different connector types and functions. Instead of bundling all connectors together in parallel, the patent provides dedicated routing channels that allow cooling air to flow between and around connector groups, maintaining compact space utilization while enabling effective heat dissipation from connector areas.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances cooling efficiency, reduces thermal stress, and improves the overall performance and reliability of the electrical machine by effectively managing heat and facilitating better airflow around the stator winding.
Implementation Method 1
The cooling air is accelerated radially outwards by the rotation of the fans 30, so that it can pass through the winding overhang 45, which is permeable to cooling air. The winding overhang 45 is cooled by this effect.
Implementation Method 2
A heat sink 53 is arranged around this slip ring assembly 49 and acts here as a positive heat sink.
Data Source
Figure 1
Figure 2
Figure 3~4b
AI summary
Stator winding (18) comprising multiple phase windings (12). A phase winding has at least two partial phase windings (120a, 120b) which include coils (123) and coil connectors (126) that run parallel.