Winding Frame Ceramic Plates for Motor Heat Dissipation
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Solution Overview
Problem
High thermal resistance between copper wires and the stator in electric generators leads to inefficient heat dissipation, causing elevated temperatures and reduced service life in high-power density applications like heavy-duty scooters with integrated starter generators.
Innovation Solution
An integrated winding frame structure with ceramic heat conductive plates and insulation members, forming a single piece or assembly with special grooves, reduces thermal resistance and enhances heat dissipation by increasing contact conductivity between copper wires and the stator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Peek insulation material is used between copper wires and stator, then electrical insulation is provided, but thermal resistance increases significantly
Solution Approach 1:
The insulation structure is divided into multiple functional layers: Peek insulation members for electrical isolation and ceramic heat conductive plates for thermal management. This segmentation allows each layer to perform its specialized function without compromising the other, resolving the contradiction between electrical insulation and heat dissipation.
Solution Approach 2:
Ceramic heat conductive plates are introduced as intermediary components between the copper wires and stator. These plates have high thermal conductivity to conduct heat away from the windings, while the Peek insulation members maintain electrical isolation. The intermediary ceramic plates enable simultaneous achievement of electrical insulation and thermal conduction.
2Temperature
If water-cooling system is used to cool the generator casing, then heat dissipation capacity is improved, but internal heat conduction remains insufficient
Solution Approach 1:
The heat conduction function is extracted from the traditional Peek insulation material and assigned to dedicated ceramic heat conductive plates. By taking out the thermal management function from the insulation component, the system can optimize each component for its specific function, enabling effective internal heat conduction that complements the water-cooling system.
Solution Approach 2:
The system employs composite material strategy by combining Peek insulation material with ceramic heat conductive plates. This composite approach allows the insulation members to provide electrical isolation while the ceramic materials provide high thermal conductivity pathways, enabling both functions to coexist and work together effectively.
3Reliability
If traditional Peek insulation members are used, then electrical insulation is achieved, but heat dissipation area is limited
Solution Approach 1:
The winding frame structure is designed to serve multiple functions: it provides mechanical support for the windings, maintains electrical insulation through Peek members, and enables heat dissipation through integrated ceramic plates. This multi-functionality allows the same structural component to address both insulation and heat dissipation requirements simultaneously.
Solution Approach 2:
The heat dissipation solution extends into the radial dimension by placing ceramic heat conductive plates between the copper wires and stator. This dimensional approach creates additional heat conduction pathways perpendicular to the winding direction, significantly increasing the effective heat dissipation area without compromising the insulation function.
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
Significantly reduces temperature differences and improves heat dissipation capacity, extending the service life and performance of electric generators by facilitating rapid heat transfer to the motor casing through air-cooling or water-cooling systems.
Implementation Method 1
the inner side of the windings includes plural ceramic heat conductive plates... greatly increase the contact thermal conductivity between the copper wires and the stator... rapidly conduct the heat generated by the copper wires to the silicon-steel plates
Implementation Method 2
the water-cooling system is mainly designed to cool down the casing of the generator... According to the theory of heat convection, the heat-convective coefficient for a liquid-state flow is about 100 ̃10000 W/m2K
Data Source
AI summary
A winding frame structure for an automation winding machine to conveniently produce the windings of a motor includes two barrier plates, four ceramic heat conductive structures with high heat conductivity, and special-structured grooves. The ceramic heat conductive structures can significantly enlarge the heat dissipation area of the windings. The heat generated by the windings can be swiftly transmitted firstly to the ceramic heat conductive structures, then to the stator inside a space formed by assembling the four ceramic heat conductive structures, and finally to a motor casing. An air-cooling or water-cooling apparatus is introduced to swiftly dissipate the heat at the motor casing. Provided by the winding frame structure, the temperature difference between the inside and the outside of the winding frame structure can be reduced, the heat dissipation process can be more efficiently, and the winding arrangement of the windings for motors can be conveniently performed.