Patent Application
20220376566
The present disclosure relates to electric machines such as electric motors, generators and motor-generators, and more particularly to cooling electric machines.
There is an ongoing need to improve power density in electric machines such as electric motors and generators. Increased power density leads to increased need for heat removal by cooling. Traditional techniques for cooling electric machines have been considered adequate for their intended purposes, but as the trend continues for more and more power-dense electric machines, there is an ongoing need for improved ways of cooling electric machines. This disclosure provides solutions for this need.
The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever-present need for improved systems and methods for cooling electric machines. This disclosure provides a solution for this need.
A system comprises a stator core defining a plurality of winding slots between circumferentially spaced apart teeth. A respective cooling channel is defined within each of the circumferentially spaced apart teeth for circulation of coolant fluid through the stator core. The stator core is a laminated structure, where the teeth, winding slots, and cooling channels are part of a common laminated structure within the stator core.
The stator core is part of a stator. A rotor is mounted within the stator for rotary movement relative to the stator. Each tooth includes a pair of circumferentially spaced apart walls, and wherein the respective cooling channel of each tooth is defined within the tooth between the pair of circumferentially spaced apart walls for fluid isolation of the respective cooling channel and circumferentially adjacent ones of the winding slots.
The pair of circumferentially spaced apart walls of each tooth are not parallel, giving each tooth a trapezoidal axial cross-sectional shape, and wherein the respective cooling channel is triangular. A first cooling channel wall is parallel to a first one of the pair of circumferentially space apart walls of the tooth, and a second cooling channel wall is parallel to a second one of the pair of circumferentially spaced apart walls of the tooth.
Each respective cooling channel includes a base wall that is circumferentially aligned with a base wall of each circumferentially adjacent one of the plurality of winding slots. Each respective cooling channel has a constant cross-sectional size and shape in each layer of the common laminated structure. At least one winding phase is seated in each winding slot.
A rotor shaft disposed within the rotor for driving an environmental control system (ECS) compressor, such that the rotor rotates about the shaft. An insulator is sealed to an inner diameter of the stator, defining an air gap barrier between the rotor and the shaft and bounding an inner portion of the cooling channel. Coolant flow through the respective cooling channel of each tooth defines a first coolant flow path, and further comprising a shaft cooling channel defined through the shaft defining a second coolant flow path. At least one air bearing can be disposed on the shaft. A sleeve can be disposed on an outer diameter of the rotor.
In certain embodiments, a plurality of fins disposed in each respective cooling channel of the teeth. In certain embodiments, the respective cooling channel of each tooth includes a plurality of cooling channels defined in each tooth, wherein the plurality of cooling channels are parallel to and distributed about an outer perimeter of an adjacent winding slot, wherein coolant enters the cooling channel through a radial bore in the stator.
In embodiments, the respective cooling channels are fed by a coolant loop, and further comprising a pump in the coolant loop in fluid communication with the cooling channel, upstream of the motor relative to coolant flow. A condenser in disposed in the coolant loop in fluid communication with the cooling channel upstream of the pump relative to coolant flow, wherein the cooling channel forms an evaporator for two-phase cooling in the motor.
In certain embodiments, an environmental control system (ECS) heat exchanger can be disposed in the coolant loop fluid communication with the condenser. In certain embodiments, an ECS condenser can be disposed in the ECS heat exchanger, and an ECS ram air flow air mover can be included external to the coolant loop at a downstream side of the ECS heat exchanger, relative to ram air flow.
A method comprises evaporating coolant in cooling channels in a stator core of an electric machine. The stator core can define a plurality of winding slots between circumferentially spaced apart teeth, where the cooling channels are defined within each of the circumferentially spaced apart teeth, and such that the stator core is a laminated structure, wherein the teeth, winding slots, and cooling channels are part of a common laminated structure with the stator core.
These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings.
So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an embodiment of a system in accordance with the disclosure is shown in
As electric propulsion and electric aircraft advance, high power motors are often required for electric environmental control systems (ECS) or electric propulsion applications. But compact high-power motors (e.g. 30-50 krpm and 300-1000 kW) can have high heat density, not easily cooled by traditional back iron oil jacket cooling or back iron and end winding air cooling. The system 100 as described herein provides an alternative method for cooling a high power motor 102, for example using two phase cooling without the need for jacket cooling around the outer diameter of the stator.
The system 100 comprises the motor 102, for driving an ECS compressor 104, for example. The motor 102 includes a stator 106 having an inner diameter 108 and an outer diameter 110, and a rotor 112 having an inner diameter 114 and an outer diameter 116. The rotor 112 is mounted to a rotor shaft (e.g. a hollow shaft) for rotational movement relative to the stator 106 with the rotor shaft 118. The rotor includes a plurality of magnets 120 disposed therein, for example any suitable permanent magnets (e.g. bread loaf magnets).
The stator 106 includes a stator core 122 defining a plurality of winding slots 124 configured to house a respective winding 126, the winding slots 124 defined between circumferentially spaced apart teeth 128. A respective cooling channel 130 is defined within each of the circumferentially spaced apart teeth 128 for circulation of coolant fluid 132 through the stator core 122. The stator core 122 can be a laminated structure, where the teeth 128, winding slots 124, and cooling channels 130 are part of a common laminated structure with the stator core 122, for example.
Each tooth 128 includes a pair of circumferentially spaced apart walls 134, 136, such that the respective cooling channel 130 of each tooth is defined within the tooth 128 between the pair of circumferentially spaced apart walls 134, 136. In this manner, the cooling channels 130 and adjacent winding slots 124 are fluidly isolated from one another. As shown, the pair of circumferentially spaced apart walls 134, 136 of each tooth 128 need not be parallel, thereby giving each tooth 128 a trapezoidal axial cross-sectional shape and each respective cooling channel 130 a triangular axial cross-sectional shape.
Each cooling channel 130 includes a first cooling channel wall 138, parallel to a first one of the pair of circumferentially space apart walls 134 of the tooth 128, and a second cooling channel wall 140, parallel to a second one of the pair of circumferentially spaced apart walls 136 of the tooth 128. A base wall 142 of each cooling channel is circumferentially aligned with a base wall 144 of each circumferentially adjacent one of the plurality of winding slots 124. Each respective cooling channel 130 has a constant cross-sectional size and shape in each layer of the common laminated structure, for example as shown.
An insulator 146 is sealingly engaged to the inner diameter 108 of the stator 106 (e.g. using adhesive), defining an air gap barrier 148 between the stator 106 and a sleeve 150 on an the outer diameter 116 of the rotor 112 so that coolant is prohibited from flowing from the stator 106 to the rotor 112. In certain embodiments, such as in
In embodiments, for example as shown in
A pump 164 is disposed in the coolant loop 158 in fluid communication with the cooling channel 130, directly upstream of the motor 102 relative to coolant flow, to pump coolant flow from a condenser 166 to the cooling channels 130. The condenser 166 is in disposed in the coolant loop 158 upstream of the pump 164 relative to coolant flow. The condenser 166 and associated tank 168 house the coolant 132 in liquid phase for pumping to cooling channels 130, where the cooling channel forms 130 an evaporator for two-phase cooling in the motor 102. A heat exchanger 170 can be disposed in the coolant loop 158 in fluid communication with the condenser 166 for cooling the coolant.
In certain embodiments, such as in
A method comprises evaporating the coolant 132 within the cooling channels 130 of the stator core 122 of an electric machine 102. The methods and systems of the present disclosure, as described above and shown in the drawings, provide for a more compact motor, reducing weight and volume of the overall system. Further, two phase cooling provide acceptable temperatures for higher rotor speeds, and thus increased motor reliability.
While the apparatus and methods of the subject disclosure have been shown and described, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.
