Winding Cooling Channels for High-Current Electrical Machines
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Solution Overview
Problem
Concentrated winding machines face challenges in efficiently cooling their windings due to limited exposed surface area for coolant flow, leading to excessive temperatures and potential thermal runaway, which affects current carrying capacity and insulation life.
Innovation Solution
The solution involves spacing apart adjacent turns of the winding pattern to create channels for coolant flow, with a housing facilitating the flow from an inlet to an outlet, allowing direct contact with exposed surfaces of the windings, thereby increasing the surface area for cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If concentrated winding pattern is used to reduce end turn length and increase torque production, then productivity and power density are improved, but cooling efficiency deteriorates due to limited exposed surface area
Solution Approach 1:
The patent introduces cooling channels that extend radially through the winding pack, adding a radial dimension to heat removal. This allows coolant to access heat sources deep within the concentrated windings, overcoming the limited exposed surface area problem while maintaining the compact concentrated winding structure for high torque density.
Solution Approach 2:
The patent introduces coolant as an intermediary substance that facilitates heat transfer from the winding surfaces to the external cooling system. The coolant flows through channels in direct contact with winding surfaces, acting as a thermal mediator that removes heat efficiently without requiring increased exposed surface area.
2Productivity
If higher current densities are used to increase power output, then productivity is improved, but temperature increases leading to reduced reliability and insulation life
Solution Approach 1:
The patent implements continuous coolant flow through the winding pack via dedicated cooling channels. This continuous thermal management action allows sustained high current densities by constantly removing heat, preventing thermal buildup that would otherwise degrade insulation and reduce reliability over time.
Solution Approach 2:
The patent employs hydraulic cooling through liquid coolant flowing through channels within the winding structure. This hydraulic thermal management system efficiently removes heat generated by high current densities, enabling sustained high power output while maintaining insulation integrity and reliability.
3Temperature
If more cooling channels are added to improve cooling efficiency, then temperature control is improved, but device complexity and weight increase
Solution Approach 1:
The patent integrates cooling channels into the existing stator and rotor structures, making these structural components serve dual functions: mechanical support and thermal management. This multi-functionality approach improves cooling efficiency without proportionally increasing device complexity or weight, as the cooling channels utilize existing structural spaces.
Solution Approach 2:
The patent creates a channel network within the winding pack that resembles a porous structure, allowing coolant to permeate through and contact multiple heat-generating surfaces. This porous-like channel distribution provides effective cooling throughout the winding volume without requiring excessive channel material, thus limiting the increase in device complexity and weight.
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 approach enhances cooling efficiency, allowing higher current densities and potentially reducing the weight and size of the machine while maintaining efficiency and extending insulation life.
Implementation Method 1
a housing for housing the set of windings, the housing including a fluid inlet and a fluid outlet each in fluid communication with the at least one channel, the housing facilitating coolant fluid to flow from the fluid inlet to the fluid outlet, via the at least one channel in direct contact with exposed surfaces of the set of windings
Implementation Method 2
coolant fluid to flow from the fluid inlet to the fluid outlet, via the at least one channel in direct contact with exposed surfaces of the set of windings
Data Source
AI summary
There is provided a winding system for use in an electrical, electronic or electromagnetic device or component including: one or more set of windings, each set of windings including an electrically-conductive element arranged in a winding pattern with multiple turns, at least one pair of adjacent turns of the multiple turns being spaced apart to provide at least one channel therebetween for coolant fluid to flow therethrough; and a housing for housing the set of windings, the housing including a fluid inlet and a fluid outlet each in fluid communication with the at least one channel, the housing facilitating coolant fluid to flow from the fluid inlet to the fluid outlet, via the at least one channel in direct contact with exposed surfaces of the set of windings, the exposed surfaces at least partially defining the at least one channel.