EARLIEST PRIORITY DATE:

This Application claims priority from a complete patent application filed in India having Patent Application No. 202041056386, filed on December 24, 2020, and titled “INDUCTION MOTOR COOLING SYSTEM”.

FIELD OF INVENTION

Embodiments of a present disclosure relates to an induction machine, and more particularly to an induction motor cooling system.

BACKGROUND

An induction motor generally comprises a stator which generates a revolving magnetic field inside a cavity and a rotor which is rotatably arranged inside the c avity of the stator. The rotor rotates by interaction with the magnetic field generated by the stator.

To get maximum output power from the induction motor, a machine designer must reduce the losses during operation of a motor. The objective is to keep temperature of the induction motor within a permitted range to achieve maximum efficiency, longevity and reliability. Therefore, the designer must specifically design to provide means of cooling the motor and its components such as stator and rotor.

In conventional approach, a stator core is pumped with coolant axially through designed channels. Such direct cooling method enables fast cooling of stator coils only and will have no effect on rotor temperature. Simultaneously, a cooling mechanism have to be implemented for the rotor to keep the temperature within limits.

Another issue that the conventional approach faces is the non-uniform cooling of the components. Such as, during operation certain regions of the stator gets hotter as compared to the other regions due to imperfect or varied cooling. Therefore, the cooling system needs to be designed and integrated in such a way that the cooling features encompasses whole stator and rotor from every possible end and provide uniform cooling. Further, the implementation of cooling means in the motor also ends up making it bulky and costly in fabrication. Hence, a specific compactly designed cooling system is needed, that enables cooling of the stator and rotor.

Hence, there is a need for an improved induction motor cooling system and a method of operation of the same and therefore address the aforementioned issues.

BRIEF DESCRIPTION

In accordance with one embodiment of the disclosure, an induction motor cooling system is disclosed. The induction motor cooling system comprises a plurality of interconnected cooling channels characterized between inner circumference and outer circumference of the stator frame. The plurality of interconnected cooling channels is fabricated in a pre-designed meandering fashion to envelop the stator frame.

The plurality of interconnected cooling channels enables flow of coolant liquid to dissipate heat produced by the stator coils. The plurality of interconnected cooling channels is characterized on the outer circumference by a coolant liquid inlet valve and a coolant liquid outlet valve.

The induction motor cooling system also comprises a plurality of air ducts characterised between the inner circumference and the outer circumference of the stator frame. Air entry to the plurality of air ducts is enabled by a set of inflow air openings fabricated on the inner circumference of the stator frame first axial end. Simultaneously, air exit from the plurality of air ducts is enabled by a set of outflow air openings fabricated on the inner circumference of the stator frame second axial end.

Each of the plurality of air ducts of pre-defined dimension is axially positioned in equidistance spread to envelop the stator frame. The plurality of air ducts is fabricated to cool the stator overhang temperature and the rotor temperature by inflow and outflow of air.

To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

FIG. 1 is a schematic representation of an induction motor in accordance with an embodiment of the present disclosure;

FIG. 2 is a schematic representation of an induction motor cooling system fabricated over stator frame in accordance with an embodiment of the present disclosure;

FIG. 3 is a schematic sectional representation of a plurality of interconnected cooling channels and a plurality of air ducts of FIG. 1 in accordance with an embodiment of the present disclosure;

FIG. 4 is a schematic side representation of a plurality of interconnected cooling channels and a plurality of air ducts fabricated between inner circumference and outer circumference of the stator frame of FIG. 1 in accordance with an embodiment of the present disclosure;

FIG. 5 is a schematic representation of plurality of interconnected cooling channels of FIG. 2 in accordance with an embodiment of the present disclosure;

FIG. 6 is a left side horizontal cross section representation of plurality of air ducts along with a set of inflow air openings of FIG. 2 in accordance with an embodiment of the present disclosure;

FIG. 7 is a right side horizontal cross section representation of plurality of air ducts along with a set of outflow air openings of FIG. 2 in accordance with an embodiment of the present disclosure;

FIG. 8 is a schematic representation coolant streamline velocity corresponding to the plurality of interconnected cooling channels in accordance with an embodiment of the present disclosure; FIG. 9 is a schematic representation showcasing stator temperature gradient in accordance with an embodiment of the present disclosure;

FIG. 10 is a schematic representation showcasing rotor temperature gradient in accordance with an embodiment of the present disclosure;

FIG. 11 is a schematic representation showcasing shaft temperature gradient in accordance with an embodiment of the present disclosure;

FIG. 12 is a schematic representation showcasing stator coil temperature gradient in accordance with an embodiment of the present disclosure; and

FIG. 13 is a schematic representation showing pressure contour for the coolant in accordance with an embodiment of the present disclosure.

Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated online platform, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, subsystems, elements, structures, components, additional devices, additional subsystems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

Embodiments of the present disclosure relate to an induction motor cooling system. The induction motor cooling system comprises a plurality of interconnected cooling channels and a plurality of air ducts characterized between inner circumference and outer circumference of the stator frame.

The plurality of interconnected cooling channels is designed in a pre-designed meandering fashion to envelop the stator frame. And similarly, each of the plurality of air ducts of pre-defined dimension is axially positioned in equidistance spread to envelop the stator frame. Cooling channels enable flow of coolant liquid to dissipate heat produced by the stator coils. Air ducts helps in cooling the stator overhangs and the rotor by inflow and outflow of air. Air entry and exit to the plurality of air ducts is enabled by a set of inflow air openings and a set of outflow air openings fabricated on the inner circumference of the stator frame.

FIG. 1 is a schematic representation of an induction motor (10) in accordance with an embodiment of the present disclosure. Any induction motor (10) is basically divided into two essential components, that is a stator and a rotor. The induction motor (10) works on the principle of electromagnetic induction. In induction motor (10) operation, electric current in the rotor needed to produce torque is obtained via electromagnetic induction from the rotating magnetic field of the stator winding. During the operation of the induction motor (10), the induction motor encounters heat generated losses such as iron losses, stator copper losses and rotor losses. Such losses affect the efficiency and performance of the induction motor.

FIG. 2 is a schematic representation of an induction motor cooling system fabricated over stator frame (20) in accordance with an embodiment of the present disclosure. A stator frame (30) is characterized with a plurality of interconnected cooling channels and a plurality of air ducts between inner circumference and outer circumference. Irregular octagon shape of the stator enables fitting of the cooling channels and air ducts with minimal volume wastage.

The plurality of interconnected cooling channels is characterized on the outer circumference by a coolant liquid inlet valve (40) and a coolant liquid outlet valve (50). The induction motor (10) is enveloped all around with cooling channels and air ducts.

FIG. 3 is a horizontal cross-sectional representation of a plurality of interconnected cooling channels and a plurality of air ducts (60) of FIG. 1 in accordance with an embodiment of the present disclosure. Plurality of interconnected cooling channels (70) and a plurality of air ducts (80) are fabricated between inner circumference (35) of the stator frame (30) and outer circumference (45) of the stator frame (30). In one specific embodiment, the air ducts (80) are positioned at four specific corners of the stator frame (30). In such specific embodiment, the cooling channels (70) as shown is positioned on each side of the stator frame (30). Here, the each of the cooling channels (70) are interconnected to form one enveloping cooling channel.

Dimensions of each of the air ducts as well as the cooling channels is in accordance with the dimension of the stator frame. FIG. 4 is a cross sectional side representation of a plurality of interconnected cooling channels and a plurality of air ducts fabricated between inner circumference (35) and outer circumference (45) of the stator frame (100) of FIG. 1 in accordance with an embodiment of the present disclosure.

FIG. 5 is a schematic representation of plurality of interconnected cooling channels (70) of FIG. 2 in accordance with an embodiment of the present disclosure. The plurality of interconnected cooling channels (70) is fabricated in a pre-designed meandering fashion (110) to envelop the stator frame (30). In one specific embodiment, the pre-designed meandering fashion fabrication (110) of the plurality of interconnected cooling channels (70) comprises helical loop fashion fabrication of the plurality of interconnected cooling channels (70) enveloping the stator frame (30). It is pertinent to note that the helical loop fashion design enables covering more area over stator frame (30) to enable more cooling.

The plurality of interconnected cooling channels (70) enables flow of coolant liquid to dissipate heat produced by the stator coils. The coolant liquid comprises water and glycol in a ratio of 1:1. Here, glycol is basically used to maintain temperature consistency. In such embodiment, the plurality of interconnected cooling channels (70) is characterized on the outer circumference by a coolant liquid inlet valve (40) and a coolant liquid outlet valve (50). A coolant liquid inlet valve (40) is configured to allow inlet of the coolant liquid and a coolant liquid outlet valve (50) is configured to enable discharge of the coolant liquid.

The plurality of interconnected cooling channels (70) is designed in a pre-defined shape with one or more vertical protrusions on base side. In such embodiment, the protrusions are configured to evenly spread the coolant liquid inside the plurality of interconnected cooling channels. It is pertinent to note that the height of each of the one or more vertical protrusions increases with distance from the base side corners. In one embodiment, the one or more vertical protrusions may be fabricated in a rectangular shape structure.

FIG. 6 is a left side horizontal cross section representation of plurality of air ducts (80) along with a set of inflow air openings of FIG. 2 in accordance with an embodiment of the present disclosure. FIG. 7 is a right side horizontal cross section representation of plurality of air ducts (80) along with a set of outflow air openings of FIG. 2 in accordance with an embodiment of the present disclosure.

Each of the plurality of air ducts (80) of pre-defined dimension is axially overlayed in equidistance over the stator frame (30) starting from one axial end of the induction motor (10) to another axial end of the induction motor (10). In one specific embodiment, the plurality of air ducts (80) is spread to envelop the said stator frame (30) horizontally. In such embodiment, the plurality of air ducts (80) is fabricated to cool the stator coil temperature and the rotor temperature by inflow and outflow of air. Air enters the plurality of air ducts (80) via set of inflow air openings (120) and exits the plurality of air ducts (80) via a set of outflow air openings (140).

For cooling, air entry to the plurality of air ducts (80) is enabled by a set of inflow air openings (120) fabricated on the inner circumference (35) of the stator frame (30) first axial end. As the air traverses (130) through the air duct (180), the stator coil temperature and the rotor temperature decrease gradually. The flowing air gets cooled as it passes on the heat to the adjoining flowing coolant liquid through the interconnected coolant channels (70). After axially crossing (130) the air duct, air exit is enabled by a set of outflow air openings (140) fabricated on the inner circumference (35) of the stator frame second axial end.

For circulation of the air, the air exit from the set of outflow air openings (140) is circulated back into the plurality of air ducts (80) by the set of inflow air openings (120) via a plurality of rotor air vents. In such embodiment, the rotor is fabricated with rotor air vents of predefined dimensions. A specially designed fan, coupled at the end of rotor stack, is configured to suck the hot cool air passing from the rotor vents and push it inside the plurality of air ducts present in the stator frame (30) for heat dissipation.

The present invention was tested to identify coolant streamline velocity in the design. FIG. 8 is a schematic representation coolant streamline velocity (150) corresponding to the plurality of interconnected cooling channels in accordance with an embodiment of the present disclosure. In the showcased representation, the streamline velocity of the coolant liquid is in the range of O.OOOe m/s to 4.532e m/s.

Furthermore, the present invention was tested to identify stator temperature in the design. FIG. 9 is a schematic representation showcasing stator temperature (160) gradient in accordance with an embodiment of the present disclosure. In the showcased representation, the temperature gradient is in the range of 6.309e+001 °C to 9.392e+001 °C. It was found that outer periphery of the stator experiences low temperature gradient, while inner periphery of the stator experiences high temperature gradient. The present invention was tested to identify rotor temperature in the design. FIG. 10 is a schematic representation showcasing rotor temperature gradient (170) in accordance with an embodiment of the present disclosure. In the showcased representation, the temperature gradient is in the range of 1.198e+002 °C to 1.310e+002 °C. It was found that outer axial end of the rotor experiences high temperature gradient.

Additionally, the present invention was tested to identify shaft temperature in the design. FIG. 11 is a schematic representation showcasing shaft temperature gradient (180) in accordance with an embodiment of the present disclosure. In the showcased representation, the temperature gradient is in the range of 1.155e+002 °C to 1.265e+002 °C.

The present invention was tested to identify stator coil temperature in the design. FIG. 12 is a schematic representation showcasing stator coil temperature gradient (190) in accordance with an embodiment of the present disclosure. In the showcased representation, the temperature gradient is in the range of 1.200e+002 °C to 1.550e+002 °C. It was found that inner region of the placed stator coil experiences low temperature gradient.

The present invention was tested to identify pressure contour for coolant in the design. FIG. 13 is a schematic representation showing pressure contour for the coolant (200) in accordance with an embodiment of the present disclosure. In the showcased representation, the pressure is in the range of 0.00e+000 Pa to 1.359e+005 Pa.

Present disclosure provides a specifically designed cooling system to help in reducing temperature of the stator and rotor. The design uses specifically laid coolant channels and air ducts to cool the motor. The coolant channels are laid in meandering fashion to cover maximum area over the stator frame. The air ducts enable passage of air to traverse through the stator frame and exchange heat with the coolant channels as the air passes through the rotor.

While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependant on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.