Wet Cavity Electric Machine Stator Cooling via Integrated Channels
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Solution Overview
Problem
Conventional wet cavity generator systems face inefficiencies due to retained unwanted heat in components not directly exposed to coolant, leading to reduced performance and increased costs, complexity, and weight from external cooling systems.
Innovation Solution
Incorporating a layer of thermally conducting and electrically insulating material between the stator core and windings to enhance cooling capabilities, allowing for effective heat dissipation without external cooling jackets, thereby increasing power density and reducing system weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external cooling jackets are added to cool the stator, then cooling effectiveness is improved, but device complexity and weight increase
Solution Approach 1:
The patent combines the cooling function with the existing stator structure by integrating coolant flow paths directly into the stator core and windings. The coolant flows through channels in the stator core and is directly exposed to the stator windings, merging the cooling system with the electrical structure rather than adding separate external cooling jackets.
Solution Approach 2:
The stator structure serves its own cooling needs through integrated coolant flow paths. The stator core and windings are designed with internal channels that allow coolant to flow through and directly contact the windings, enabling the stator to cool itself without requiring external cooling systems.
2Temperature
If external cooling jackets are added to cool the stator, then cooling effectiveness is improved, but weight increases
Solution Approach 1:
The cooling function is merged with the stator structure itself through integrated coolant channels. This eliminates the need for separate external cooling jackets and their associated support structures, reducing overall system weight while maintaining effective cooling of the stator windings.
Solution Approach 2:
The stator is designed to cool itself through internal coolant flow paths that are part of its structure. This self-cooling capability eliminates the need for additional weight-bearing external cooling systems while ensuring adequate heat dissipation from the windings.
3Temperature
If external cooling jackets are added to cool the stator, then cooling effectiveness is improved, but costs increase
Solution Approach 1:
The patent merges the cooling function with the stator structure by integrating coolant channels directly into the core and windings. This integration reduces the number of separate components and assembly steps required for external cooling jackets, thereby reducing manufacturing costs and system complexity.
Solution Approach 2:
The stator structure is designed to provide its own cooling through internal flow paths, eliminating the need for complex external cooling systems. This self-cooling approach reduces both manufacturing costs and system complexity by using the existing stator structure for dual purposes (electrical function and thermal management).
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
The solution significantly enhances cooling capabilities, enabling the generator to operate efficiently without external cooling systems, resulting in higher reliability, reduced maintenance, and lower operational costs, while maintaining or exceeding cooling performance compared to conventional systems.
Implementation Method 1
a layer of thermally conducting and electrically insulating material encircling the stator winding between the stator core and the stator winding
Implementation Method 2
at least one fluid port in fluid communication with the channel and the stator winding end turns wherein the end turns will be exposed to liquid coolant passing through the channel
Data Source
AI summary
A wet cavity electric machine includes a stator core having two stator poles formed by a post and a wire wound about the post to form a stator winding, with the stator winding having end turns, and a rotor having two rotor poles and configured to rotate relative to the stator and a channel for liquid coolant to flow through the rotor, and at least one fluid port in fluid communication with the channel and the stator winding end turns wherein the end turns will be exposed to liquid coolant passing through the channel.