Integrated Terminal Block Cooling in Rotary Electric Machines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary electric machines face challenges in cooling efficiency due to air accumulation in cooling flow paths, which hinders heat transfer, and the separate arrangement of terminal blocks and refrigerant flow paths leads to increased size and complexity.
Innovation Solution
The integration of a stator cooling flow path with a refrigerant flow path and electric power wires, arranged alternately and in proximity, forms a compact structure that effectively cools the stator and terminal block, reducing vertical dimensions and maintaining air removal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inlet and outlet of the refrigerant flow path are arranged in the upper portion of the stator to remove air accumulation, then air removal capability is improved, but the vertical dimension of the rotary electric machine increases
Solution Approach 1:
The terminal block and refrigerant flow path are merged into an integrated structure portion. The refrigerant flow path is formed within the terminal block body, combining the electrical connection function and cooling function into a single component. This integration allows the inlet and outlet to be positioned in the upper portion for air removal while avoiding additional vertical space requirements.
Solution Approach 2:
The terminal block serves multiple functions: electrical connection (terminal block function) and refrigerant circulation (cooling function). By forming the refrigerant flow path within the terminal block, the structure achieves multi-functionality, allowing air removal capability without increasing vertical dimension.
2Ease of manufacture
If the terminal block and refrigerant flow path are arranged separately and adjacent to each other, then ease of manufacture is improved, but the overall size increases
Solution Approach 1:
The terminal block and refrigerant flow path are merged into a single integrated structure portion. The refrigerant flow path is formed within the terminal block body, eliminating the need for separate arrangement and reducing overall size while maintaining manufacturability through integrated molding or fabrication processes.
Solution Approach 2:
The refrigerant flow path is nested within the terminal block structure. The flow path channels are formed inside the terminal block body, allowing the cooling function to be embedded within the electrical connection component, thereby reducing overall size without requiring separate adjacent arrangements.
3Temperature
If the stator cooling flow path is provided to extend along the periphery of the stator, then cooling performance is improved, but air accumulation in the upper portion hinders heat transfer
Solution Approach 1:
Air accumulation, which hinders heat transfer, is extracted or removed from the cooling flow path by positioning the inlet and outlet in the upper portion of the stator. This allows air to be naturally vented or actively removed from the cooling channels, preventing air pockets from forming and maintaining efficient heat transfer throughout the stator periphery.
Solution Approach 2:
Instead of positioning the inlet and outlet in the lower portion (conventional approach), the patent inverts the arrangement by positioning them in the upper portion of the stator. This inversion allows air, being lighter than refrigerant, to be naturally expelled or removed from the cooling flow path, preventing air accumulation and maintaining heat transfer efficiency.
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 achieves enhanced cooling performance while minimizing size and weight, preventing interference between components and reducing electrical resistance, thus optimizing the rotary electric machine's design.
Implementation Method 1
the stator cooling flow path, through which a refrigerant circulates, in a manner to extend along the periphery of the stator. Thus, the stator can be cooled effectively.
Implementation Method 2
stator cooling flow path that is provided in the housing in such a manner to extend along a periphery of the stator; through which the refrigerant circulates
Implementation Method 3
the refrigerant flow path and the electric power wire are arranged inside in such a manner to be alternately aligned in proximity... the electric power wire can be cooled effectively. It is possible to suppress an increase in electrical resistance that is associated with a temperature increase.
Implementation Method 4
since air is lighter than the refrigerant, the air accumulates in an upper portion of the cooling flow path when the air enters the cooling flow path
Data Source
AI summary
To achieve excellent cooling performance and compactness, a rotary electric machine includes a housing that supports a shaft in a rotatable manner and accommodates a rotor and a stator; a stator cooling flow path provided in a housing to extend along a periphery of the stator; and an integrated structure portion that is interposed between the stator and an electrical power unit, and constitutes a terminal block that includes an electric power wire for relaying electrical connection of the stator and the electrical power unit, and in which the stator cooling flow path is integrally provided with a refrigerant flow path that relays circulation of a refrigerant. In a state where the refrigerant flow path and an electric power wire are arranged inside in such a manner that is alternately aligned in proximity, the integrated structure portion is arranged in an upper portion of the housing.