Electrical Machine Housing with Volute Cooling Channel
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Solution Overview
Problem
Existing air propulsion units for forced draft gas-fired systems require large radial motors and complex cooling systems, leading to increased space, weight, and cost due to the need for large cooling air channels and integrated controllers, which introduce localized heating issues.
Innovation Solution
An electrical machine with a volute-shaped housing and integrally formed fan on the rotor assembly that accelerates cooling air to increase velocity and pressure, facilitating efficient cooling of both the stator and controller assemblies through recirculation and forced convection, while minimizing the overall component count and profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large radial motor is used to operate the fan, then the fan can provide sufficient air propulsion, but the space requirements increase due to the physical size of the motor
Solution Approach 1:
The patent replaces the traditional radial motor with an axial flux motor, which uses a different electromagnetic configuration to achieve the same or better propulsion capability with reduced physical dimensions. This substitution of the mechanical/electromagnetic system architecture allows maintaining power output while reducing volume.
Solution Approach 2:
The transition from radial to axial flux configuration changes the dimensional orientation of the magnetic flux and mechanical forces. This dimensional reconfiguration allows the motor to achieve comparable performance in a more compact form factor by utilizing axial rather than radial force vectors.
2Volume of moving object
If an axial flux motor is used to reduce size requirements, then the physical dimensions are reduced, but a large amount of cooling air is needed to cool the electronics due to high power densities
Solution Approach 1:
The patent merges the cooling function with the existing air propulsion system by routing the cooling air through the housing structure. The same fan that provides propulsion also drives the cooling airflow, eliminating the need for a separate cooling system and reducing overall complexity.
Solution Approach 2:
The housing is designed to serve multiple functions: it provides structural support, guides the propulsion airflow, and simultaneously channels cooling air to the electronic components. This multi-functionality reduces the need for additional dedicated cooling components.
3Temperature
If separate cooling systems are added to the motor, then the motors can be cooled effectively, but the air propulsion unit thickness increases and weight and complexity increase
Solution Approach 1:
The cooling system is integrated into the housing structure rather than being a separate assembly. The housing incorporates cooling channels and air pathways that route cooling air directly to the motor and electronic components, eliminating the need for separate cooling assemblies and reducing overall system complexity.
4Ease of operation
If an integrated controller is attached to the end of the unit, then the control functions are provided, but the thickness of the air propulsion unit increases
Solution Approach 1:
The controller is nested within the housing structure rather than being attached externally. The housing is designed with internal space allocation for the controller assembly, allowing it to be contained within the existing dimensional envelope of the propulsion unit, thus avoiding increases in overall thickness.
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 design reduces the size and cost of the air propulsion unit by integrating the fan components directly on the rotor, providing effective cooling with fewer components and a lower profile, thus reducing space requirements and assembly complexity.
Implementation Method 1
The rotor assembly draws cooling air into a housing and accelerates the cooling air in a centrifugal direction using a fan that is integrally formed on the rotor assembly
Implementation Method 2
A portion of the cooling airflow is forced through the stator assembly by the increased pressure of the accelerated cooling airflow. This portion of the cooling airflow is recirculated through the stator assembly and back into the main cooling airflow
Implementation Method 3
The cooling airflow is forced through a cooling air channel formed in the housing such that the cooling airflow passes over the controller assembly
Data Source
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AI summary
A housing for an electrical machine includes an endshield and a cover. The electrical machine has a rotation axis, a rotor assembly including a rotor, and a controller assembly. The rotor assembly includes a bearing assembly. The endshield includes an annular center section including a bore sized to couple to the bearing assembly. The cover is coupled to the endshield. The cover includes a generally axially-extending flange wall formed about a perimeter of the cover, a volute-shaped inner chamber configured to at least partially enclose the rotor coupled to the rotor assembly of the electrical machine, and a cooling channel positioned radially outward from the inner chamber. The cooling channel is configured to at least partially enclose the controller assembly of the electrical machine.