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WO2025056384A1 - Machine électrique dotée d'un système de refroidissement supplémentaire - Google Patents

Machine électrique dotée d'un système de refroidissement supplémentaire Download PDF

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Publication number
WO2025056384A1
WO2025056384A1 PCT/EP2024/074642 EP2024074642W WO2025056384A1 WO 2025056384 A1 WO2025056384 A1 WO 2025056384A1 EP 2024074642 W EP2024074642 W EP 2024074642W WO 2025056384 A1 WO2025056384 A1 WO 2025056384A1
Authority
WO
WIPO (PCT)
Prior art keywords
stator
rotor
cooling system
electrical machine
aircraft
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2024/074642
Other languages
German (de)
English (en)
Inventor
Anton Rudenko
Nir Kastner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce Deutschland Ltd and Co KG
Original Assignee
Rolls Royce Deutschland Ltd and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rolls Royce Deutschland Ltd and Co KG filed Critical Rolls Royce Deutschland Ltd and Co KG
Publication of WO2025056384A1 publication Critical patent/WO2025056384A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/19—Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/04—Details of the magnetic circuit characterised by the material used for insulating the magnetic circuit or parts thereof
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30—Structural association with control circuits or drive circuits
    • H02K11/33—Drive circuits, e.g. power electronics
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K16/00—Machines with more than one rotor or stator
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/30—Windings characterised by the insulating material
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/02—Arrangements for cooling or ventilating by ambient air flowing through the machine
    • H02K9/04—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
    • H02K9/06—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/19—Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
    • H02K9/193—Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil with provision for replenishing the cooling medium; with means for preventing leakage of the cooling medium
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/19—Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
    • H02K9/20—Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil wherein the cooling medium vaporises within the machine casing
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/06—Machines characterised by the presence of fail safe, back up, redundant or other similar emergency arrangements

Definitions

  • the present disclosure relates in particular to an electric machine, to an arrangement comprising a plurality of electric machines, to an aircraft and to a method for producing an electric machine.
  • Vehicles are powered in a variety of ways.
  • Internal combustion engines such as piston engines or gas turbine engines, enable long ranges and high speeds.
  • Drives with one or more electric motors enable the use of sustainably generated energy and are sometimes particularly low-maintenance and quiet.
  • Advances in battery and fuel cell technology are opening up ever-expanding areas of application for electric drives.
  • EP 3 893 366 A1 describes a cooling system for electrical machines in which water is sprayed into cooling air to achieve increased cooling performance. This allows the cooling system to be smaller and, despite the additional components, to have a reduced overall weight.
  • Cooling systems based on cooling by a circulating coolant can provide strong cooling performance, but typically have an increased risk of failure compared to systems cooled by ambient air.
  • the object of the present invention is to improve the cooling of an electrical machine.
  • an electric machine is specified, in particular for an aircraft.
  • the electric machine comprises a stator, a rotor rotatable relative to the stator, and a machine controller configured to adjust the power of the electric machine.
  • the machine controller is further configured to store a threshold value that determines a maximum adjustable power during normal operation of the electric machine.
  • the electric machine further comprises a cooling system for cooling the stator and/or the rotor, wherein the cooling system is configured to dissipate at least a maximum normal operating heat output (in particular continuously), which can be maximally dissipated during normal operation of the electric machine, and an additional cooling system with a reservoir for receiving a consumable fluid that can be discharged to the stator and/or the rotor for cooling the stator and/or the rotor.
  • the auxiliary cooling system can also be constructed particularly small and lightweight. Since the consumable fluid is only used in the event of a fault, not during normal operation, it does not need to be refilled during normal operation, i.e., provided no fault occurs, it never needs to be refilled over the lifetime of the electrical machine (and the aircraft). However, since maintenance or immediate replacement is carried out in the event of a fault, there is no additional need for a maintenance appointment. Since the cooling system does not have to maintain reserves in the event of a fault, it can be particularly be small and lightweight. Typically, this weight reduction is significantly greater than the additional weight of the auxiliary cooling system. This makes it possible to improve the cooling of the electric machine, particularly by enabling particularly effective cooling during normal operation and in the event of a fault, while maintaining a low weight.
  • the maximum adjustable power during normal operation of the electrical machine is, for example, the rated power of the electrical machine.
  • the rated power is predefined.
  • the auxiliary cooling system can have one or more outlet openings for discharging the consumable fluid.
  • the consumable fluid can be sprayed from the outlet openings, e.g., each with a nozzle.
  • the consumable fluid can dissipate a particularly large amount of heat through evaporation.
  • the one or more outlet openings are aligned with one or more coils of the stator. This allows the coils to be cooled particularly effectively.
  • the outlet openings are aligned with particularly hot areas, especially the coils.
  • the stator coils can be coated with a hydrophobic coating, particularly by being enclosed by the hydrophobic coating. This prevents the coils from short-circuiting despite the application of the consumable fluid and ensures that they remain operational.
  • the hydrophobic coating comprises or consists of polytetrafluoroethylene (PTFE).
  • PTFE polytetrafluoroethylene
  • This material is particularly durable, lightweight, and has advantageous electrically insulating properties.
  • PTFE also exhibits low adhesion resistance to surface contaminants, making it particularly advantageous in combination with a cooling system designed for ambient air cooling.
  • the coils of the stator can each be arranged in a direct line between two outlet openings arranged on opposite sides of the respective coil This allows for particularly fast and direct cooling of the coil. This eliminates the need for heat to be dissipated through a heat conductor, which can prevent the coil from overheating in the event of a fault with particularly rapid heat buildup.
  • the cooling system can define an air flow path along which a gas or gas mixture, in particular ambient air, can flow to cool the stator and/or the rotor.
  • At least two outlet openings can be arranged spaced apart from one another along the air flow path. One outlet opening is thus arranged further upstream in the air flow path, the other further downstream. This allows for distributed and particularly uniform cooling.
  • At least a portion of the air flow path runs at an angle, in particular perpendicular to a rotational axis of the rotor relative to the stator. This enables particularly effective cooling.
  • the auxiliary cooling system can be designed so that, upon activation, it completely releases the consumable fluid stored in the reservoir to the stator and/or the rotor. As soon as it is activated, the auxiliary cooling system releases the entire stored consumable fluid in a particularly uninterrupted release process. This ensures sufficient cooling in the event of a fault. The release occurs, for example, over a period of up to 200 seconds or up to 400 seconds to ensure a safe landing. After activation, the reservoir must be refilled or replaced if it can be reused.
  • the auxiliary cooling system may include an ignition device by means of which a (e.g., explosive) propellant charge can be ignited to release the consumable fluid located in the reservoir to the stator and/or the rotor.
  • a (e.g., explosive) propellant charge can be ignited to release the consumable fluid located in the reservoir to the stator and/or the rotor.
  • the auxiliary cooling system includes a gas generator.
  • the auxiliary cooling system can be provided as a maintenance-free module for decades.
  • the auxiliary cooling system may include a pump for delivering a adjustable amount of consumable fluid to the stator and/or rotor. This allows the amount to be adjusted as needed and, for example, additional cooling over a longer period of time.
  • the auxiliary cooling system can be configured to be activated based on a signal from a temperature sensor and/or a torque of the electric machine. If the temperature, e.g., of a coil of the electric machine, exceeds a temperature threshold, and if the torque demand exceeds a torque threshold, the auxiliary cooling system can reliably detect that a fault has occurred and normal operation is no longer possible, and that the auxiliary cooling system must be activated.
  • the auxiliary cooling system is only activated in the event of a fault, e.g., only as a result of a detected defect.
  • the electric machine may comprise several electrically separated winding systems, the current supplying which (independently of one another) causes the rotor to rotate relative to the stator.
  • the motor controller may be configured to detect a fault in one of the winding systems and, in response, activate the auxiliary cooling system to continue operating the other, non-faulty winding system (despite significant heat generation from the defective winding system and/or a power requirement exceeding the rated power of the non-faulty winding system).
  • the fault could be, for example, a short circuit in the faulty winding system. As already mentioned, this can result in significant heat generation, which can be dissipated by the auxiliary cooling system.
  • the cooling system is designed, for example, as an air-cooled system. This enables particularly simple and fail-safe cooling.
  • the consumable fluid can comprise or consist of water, or another liquid, particularly one with a boiling point below the temperature of a surface contacted by the consumable fluid that would occur in the event of a fault. This allows particularly large amounts of heat to be dissipated through evaporation of the consumable fluid.
  • an arrangement is provided, in particular for an aircraft.
  • the arrangement comprises a plurality of electrical machines, each having a stator, a rotor rotatable relative to the stator, and a cooling system for cooling the stator and/or the rotor, and an additional cooling system having a reservoir for receiving a consumable fluid which can be delivered to the stator and/or the rotor of each of the plurality of electrical machines for cooling the stator and/or the rotor of each of the plurality of electrical machines.
  • an aircraft comprising the electric machine according to any embodiment described herein and/or the arrangement according to any embodiment described herein for driving one or more rotor units, each having a plurality of rotor blades.
  • the electric machine according to any embodiment described herein and/or the arrangement according to any embodiment described herein for driving one or more rotor units, each having a plurality of rotor blades.
  • Normal operation may include takeoff, flight, and landing of the aircraft.
  • the cooling system is sufficient, and the auxiliary cooling system is not activated.
  • a method for producing an electric machine with a stator and a rotor rotatable relative to the stator comprises determining a maximum normal operating heat output dissipated during normal operation of the electric machine; installing a cooling system for cooling the stator and/or the rotor, wherein the cooling system is configured to be able to dissipate at least the maximum normal operating heat output; and installing an additional cooling system with a reservoir for receiving a consumable fluid, which can be transferred to the stator and/or rotor to dissipate additional heat output of the electric machine that exceeds the maximum normal operating heat output.
  • the electric motor can be configured to power an aircraft. Normal operation can include takeoff, flight, and landing of the aircraft.
  • Figure 1 shows an aircraft in the form of an eVTOL aircraft with several electrically driven rotor units
  • Figure 2 shows an aircraft in the form of a fixed-wing aircraft with an electrically driven rotor unit
  • Figure 3 shows an electric machine of the aircraft according to Figure 1 with a cooling system and an additional cooling system
  • Figure 4 shows an electrical machine of the aircraft according to Figure 2 with a cooling system and an additional cooling system
  • Figure 5 is a sectional view of part of a coil of the electrical
  • Figure 6 shows a method for manufacturing an electrical machine
  • Figure 7 shows a method for controlling an electrical machine, in particular of an aircraft.
  • Figure 1 shows an aircraft 2 having multiple rotor units 20.
  • the aircraft 2 is configured as a VTOL aircraft, specifically as an eVTOL aircraft.
  • Vertical takeoff and landing aircraft such as airplanes, are regularly referred to as VTOL aircraft, with the abbreviation VTOL being derived from "Vertical Take-Off and Landing.”
  • VTOL aircraft are designed for vertical takeoff and landing.
  • the aircraft 2 comprises several electric propulsion units, each with an electric machine 1 and one of the rotor units 20 for generating lift and/or thrust.
  • the aircraft 2 comprises a fuselage 21 with wings 22, each of which has several electric drive units mounted on it, specifically two electric drive units at the front and two at the rear. At least some of the electric drive units, here, for example, those mounted at the front, are pivotable, allowing switching between a predominantly lift-generating (upward) orientation and a predominantly thrust-generating (forward) orientation.
  • the aircraft 2 further comprises a cockpit, but could also be autonomously controlled.
  • each of the electrical machines 1 comprises a cooling system 12. Furthermore, an additional cooling system 13 is provided.
  • This comprises a reservoir 130 for receiving a consumable fluid 131, which is arranged in the reservoir 130 according to Figure 1.
  • the consumable fluid 131 can be delivered to each of the electrical machines 1, in particular specifically to the stator and/or the rotor of each of the electrical machines 1, for cooling each of the electrical machines 1, in particular a respective stator and/or rotor.
  • the reservoir 130 is connected to each of the electrical machines 1 via a line 137 for the consumable fluid 131 (is thus in fluid communication).
  • a control system 14 is configured to trigger a release of the consumable fluid 131 to provide a temporary additional cooling capacity when at least one of the electrical machines 1 is operating outside of normal operation in an emergency mode, as will be explained in more detail below.
  • Valves are provided on the lines 137 to selectively release the consumable fluid 131 only to the one or more electrical machines 1 that require a cooling capacity exceeding normal operation. If, for example, one or more of the electric drive units should fail, the remaining ones can be operated with a power that overloads the electric machines 1, but which is possible for a limited time due to the additional cooling power, for example to ensure a safe landing despite the major failure.
  • the aircraft 2 thus has an arrangement 3 comprising a plurality of electrical machines 1, each with a stator 10, a rotor 11 rotatable relative to the stator 10 (see Figure 3), and the respective cooling system 12 for cooling the stator 10 and/or the rotor 11.
  • the arrangement 3 further comprises the additional cooling system 13 with the reservoir 130 for receiving the consumable fluid 131, which can be delivered from each of the plurality of electrical machines 1 to the stator 10 and/or the rotor 11 of each of the plurality of electrical machines 1 for cooling the stator 10 and/or the rotor 11.
  • Figure 2 shows an aircraft 2' in the form of an electrically powered aircraft with a fuselage 21', wings 22' and a cockpit.
  • the aircraft 2' comprises an electrical machine 1' in the form of an electric motor and a rotor unit 20 driven by the electric motor.
  • the rotor unit 20 comprises a plurality of rotor blades 200, here two as an example.
  • the rotor blades 200 are mounted on a hub and thus form a propeller.
  • the aircraft 2' comprises a fan instead of a propeller and/or a plurality of electric drive units, each with at least one propeller or fan. This applies analogously to the electric drive units of the aircraft 2 according to Figure 1.
  • the aircraft 2' comprises (as does the aircraft 2 according to Figure 1) an energy supply system 23, which provides electrical energy to the electric machine 1'.
  • the energy supply system 23 comprises an electric battery system in the present case, but could alternatively or additionally also comprise, for example, a fuel cell and/or a combustion engine with a generator.
  • the electric machine 1' can also be operated in generator mode electrical energy is generated and stored in the energy supply system 23.
  • the aircraft 2′ For cooling the electrical machine 1′, the aircraft 2′ has at least one air inlet 24, here several air inlets 24, through which ambient air L can flow to (here: through) the electrical machine 1′ and thus cool it, as will be explained in more detail below with reference to Figure 4.
  • Figure 3 shows a cutaway view of an electrical machine 1 of the aircraft 2 according to Figure 1.
  • the electrical machines 1 of the aircraft 2 are in this case of identical construction.
  • the electric machine 1 comprises a stator 10.
  • the stator 10 is mounted on one of the wings 22 of the aircraft 2.
  • the stator 10 comprises a plurality of electrical coils 100.
  • the coils 100 have a plurality of windings and are fixed to the stator 10.
  • Power electronics 17 supplies the coils with an alternating current, which then generates a magnetic field.
  • the electric machine 1 further comprises a rotor 11 rotatable relative to the stator 10.
  • a rotor 11 rotatable relative to the stator 10.
  • Several magnets 111 are mounted on the rotor 11, on which forces act due to the magnetic field of the coils 100, causing the rotor 11 to rotate relative to the stator 10 about a rotation axis R.
  • a shaft 110 of the rotor 11 transmits the generated torque to the rotor unit 20, as illustrated in Figure 3 by the thin arrows.
  • the shaft 110 is hollow.
  • the power electronics 17 are arranged inside the shaft 110.
  • the electrical machine 1 comprises a machine control 16.
  • the machine control 16 is configured to adjust a power of the electrical machine 1, e.g., an absorbed electrical power and/or an output mechanical power.
  • a threshold value T can be stored and is stored in the machine control 16, which determines a maximum adjustable power during normal operation of the electrical machine 1.
  • the maximum adjustable power is the rated power of the electrical machine 1. As long as the electrical machine 1 is operated in normal operation, the Rated power cannot be exceeded. As long as there is no fault, e.g., due to a defect, the electrical machine 1 operates in normal mode. Normal operation includes one takeoff, one flight, and one landing of aircraft 2.
  • the electric machine 1 also includes a cooling system 12 for cooling the stator 10 (and/or the rotor 11).
  • the cooling system 12 has air flow paths 120 along which ambient air L can flow through the electric machine 1.
  • the ambient air L is conveyed along the air flow paths 120 by the airstream and the blades driven by the electric machine 1.
  • the shaft 110 forms an air inlet 113 through which the ambient air L can flow.
  • the ambient air L then flows along the heat sinks of the power electronics 17 and cools them.
  • the ambient air L then flows through air passages of the rotor 11 and along the coils 100 of the stator 10 to directly cool the coils 100.
  • the air flow paths 120 initially extend parallel to the axis of rotation R and then radially outward along the coils 100.
  • the cooling system 12 uses ambient air L to first cool the power electronics of the electric machine 1, then the coils 100 of the stator 10.
  • the cooling system 12 is designed to continuously dissipate at least a maximum normal operating heat output, which is the maximum that can be dissipated during normal operation of the electric machine 1.
  • the cooling system 12 is therefore sufficiently dimensioned so that the electric machine 1 can be continuously operated, for example, at its rated power.
  • the cooling system 12 has no, or at least no substantial, reserve that would enable operation beyond the rated power in the event of a fault.
  • the cooling system 12 alone would not be sufficiently powerful for this.
  • the electric machine 1 For a cooling requirement that exceeds the dissipation of the maximum normal operating heat output, the electric machine 1 comprises an additional cooling system 13 with a reservoir 130 for receiving a consumable fluid 131.
  • the consumable fluid 131 is used to cool the stator 10 (and/or the rotor 11). to the stator 10). In this way, the additional cooling power required in the event of a fault can be provided.
  • the additional cooling system 13 comprises outlets 137, which are in fluid communication with the reservoir 130 and have a plurality of outlet openings 132, 133 for dispensing the consumable fluid 131. According to Figure 3, outlet openings 133 are provided on the air inlet 113.
  • consumable fluid 131 can be sprayed into the incoming ambient air L.
  • outlet openings 132 are formed in the interior of the stator 10. From there, consumable fluid 131 can be applied directly to the coils 100, in this case, sprayed on. Those outlet openings 132 are aligned with the coils 100 of the stator 10, in this case such that the coils 100 of the stator 10 are each arranged in a direct line between two outlet openings 132 arranged on opposite sides of the respective coil 100, as illustrated in Figure 3. Furthermore, a plurality of outlet openings 132 are arranged spaced apart from one another along the air flow path 120.
  • the consumable fluid 131 is water in this case, although other cooling fluids, particularly liquids, are also conceivable.
  • the consumable fluid 131 is non-flammable.
  • the consumable fluid 131 does not circulate but is consumed through a single application. It is released into the environment after cooling the electric machine 1.
  • the consumable fluid 131 can also be a mixture.
  • the auxiliary cooling system 13 further comprises a device by means of which pressure can be built up in the reservoir 130.
  • a device by means of which pressure can be built up in the reservoir 130 In the example in Figure 3, an ignition device 134 with a propellant charge 135 is provided. Ignition by the ignition device 134 ignites the propellant charge 135, which then generates a propellant gas. This gas exerts pressure on the reservoir 130, e.g., by a plunger or by being blown into the reservoir 130. As a result of activation of the ignition device 134, the consumable fluid 131 arranged in the reservoir 130 is completely released to the stator 10. The auxiliary cooling system 13 can therefore only be activated once. After activation, it provides consumable fluid to the stator 10 for approximately 200 seconds.
  • a control system 14 is provided to activate the auxiliary cooling system 13.
  • the control system 14 can be integrated with the machine control system 16 or separate from it.
  • the control system 14 detects signals from temperature sensors 15.
  • the temperature sensors 15 are arranged on the coils 100 in this case. If a measured value read from the temperature sensors 15 exceeds a predefined temperature threshold, the control system 14 concludes that an error has occurred and that normal operation is no longer occurring. Based on this, the control system activates the ignition device 134.
  • control system 14 receives values of a torque requested by the electric machine 1 from the machine controller 16. If the torque (or a resulting power) exceeds a torque threshold (or a power threshold), the control system 14 (or the machine controller 16) concludes that an error has occurred and that normal operation is no longer present. Based on this, the control system activates the ignition device 134.
  • the power threshold can be the threshold value T, which determines the maximum adjustable power during normal operation of the electric machine 1, or a value based thereon.
  • the control system 14 can jointly consider the torque value and the temperature value to activate the additional cooling system 13.
  • the electrical machine 1 is a transverse flux machine, although other types of electrical machines are also conceivable, e.g. axial or radial flux machines.
  • FIG 4 shows a schematic sectional view of the rotating electrical machine 1' of the aircraft 2' from Figure 2, which here is designed as a permanent magnet synchronous machine.
  • Figure 4 shows that the electrical machine 1' is designed as an internal rotor, but alternatively, the electrical machine 1' could also be designed, for example, as an external rotor.
  • the electrical machine T comprises a stator 10', which has an opening (not designated), in particular a through-opening, in which a rotor 1T is rotatably mounted.
  • the stator 10' comprises a body, here in the form of a laminated core, to which teeth 102 are fixed, which can also be referred to as stator teeth.
  • the teeth 102 are aligned with an air gap L between the body of the stator 10' and the rotor 11'.
  • the teeth 102 protrude radially from the body, in this case radially inward.
  • the stator 10' has several winding systems W1, W2.
  • the winding systems W1, W2 are electrically separated from one another.
  • Each of the winding systems W1, W2 has electrical windings for three electrical phases U, V, W.
  • the individual winding systems W1, W2 are only illustrated schematically here for the sake of simplicity. Electrical conductors of the winding systems W1, W2 are wound around the teeth 102 of the stator 10' in the form of windings 201.
  • Each of the winding systems W1, W2 is designed for three-phase operation, i.e., it is connected to a three-phase alternating voltage with phases U, V, W. During normal operation of the electrical machine 1', the winding systems W1, W2 are supplied with the respective alternating voltage.
  • the rotor 11' is designed, for example, as a salient-pole rotor, which comprises permanent magnets to provide the magnetic flux.
  • the rotor 11' has exactly one magnetic north pole N and one magnetic south pole S.
  • more magnetic poles can also be provided alternating in the circumferential direction transverse to a rotational axis of the rotor 11' (relative to the stator 10').
  • the rotor 11' is rotatably mounted.
  • the three-phase alternating voltage whose phases U, V, and W are each phase-shifted by 120°, generates a rotating magnetic field that interacts with the permanently excited magnetic field provided by the rotor 11', so that, during motor operation, a corresponding rotational movement of the rotor 11' relative to the stator 10' can be induced.
  • the electric machine 1' serves as a drive motor for the rotor unit 20 of the aircraft 2'.
  • Figure 4 schematically shows the sections of the winding systems W1, W2. which are assigned to the respective phases U, V, W.
  • Each of the (here two) winding systems W1, W2 of the electrical machine T is connected to a three-phase inverter of a power electronics unit 17.
  • the respective inverter provides the electrical alternating voltage with the three phases U, V, W for the corresponding winding system W1, W2.
  • the inverters draw the electrical energy required for proper operation from the energy supply system 23 connected to the power electronics unit 17.
  • Each of the inverters has inverter units assigned to provide the phases U, V, W.
  • Each inverter unit has a half-bridge circuit.
  • the respective half-bridge circuit has a series connection of two electronic switching elements (e.g. transistors) that are connected to an intermediate circuit DC voltage of the inverter.
  • the electronic switching elements are operated in a clock mode, which, for example, provides clock patterns in the manner of a PWM signal.
  • the corresponding phase U, V, W of the three-phase alternating voltage is then available at a respective center tap of the half-bridge circuits.
  • the inductance of the windings provides appropriate filtering, so that a corresponding alternating current is generated for each of the phases U, V, W, which can be almost sinusoidal if the inverter units are suitably controlled.
  • the individual inverters are independent of each other. If one of the winding systems W1, W2 or one of the inverters fails, the other inverters and winding systems W1, W2 (here, the second winding system W1, W2 with the respective inverter) can continue to operate.
  • a short circuit e.g., an interturn short circuit
  • adjacent turns within a winding are short-circuited, e.g., due to defective insulation
  • a very large current can be induced in the short-circuited conductor loop by the rotor 1 T continuing to rotate (at least for a certain period of time), even when the current to the affected winding system W1, W2 is switched off. This can lead to high thermal stress.
  • the motor controller 16 or the control system 14 communicatively connected thereto is configured to detect a fault, in particular in the form of a short circuit, in one of the winding systems W1, W2 and, in response, to activate the additional cooling system 13.
  • the short circuit can be detected, for example, by a temperature increase and/or current increase.
  • the propeller blows ambient air L through the interior of the stator 10'.
  • the electric machine T is directly air-cooled.
  • the electric machine T has directly air-cooled coils 100.
  • the auxiliary cooling system 13 is connected to the interior of the stator 10' via one or more lines 137.
  • the auxiliary cooling system 13 here comprises a pump 136 for delivering an adjustable amount of the consumable fluid 131 to the stator 10'. A predetermined number of sprays of the consumable fluid 131 can be carried out by means of the pump 136.
  • FIG 5 shows a cross-section of a section of coil 100 according to Figure 3.
  • Coil 100 has a rectangular cross-section, for example.
  • the electrically conductive material of coil 100 e.g., copper
  • Hydrophobic coating 101 encloses the section of coil 100.
  • Hydrophobic coating 101 is made of polytetrafluoroethylene (PTFE).
  • the rectangular cross-section is only an example and that a coil with, for example, a round conductor cross-section can also be provided with the hydrophobic coating 101.
  • Figure 6 shows a method for producing an electrical machine 1, T with a stator 10, 10' and a rotor 11, 1 T rotatable relative to the stator 10, 10'.
  • the method comprises the following steps:
  • Step S1 Determination of a maximum normal operating heat output of the electric machine 1, T during normal operation.
  • the normal operation includes a takeoff, a flight and a landing of an aircraft 2, 2' with the electric Machine 1, 1'.
  • Step S2 Mounting a cooling system 12 for cooling the stator 10, 10’ and/or the rotor 11, 11’, wherein the cooling system 12 is designed to be able to dissipate at least the maximum normal operating heat output.
  • Step S3 Mounting an additional cooling system 13 with a reservoir 130 for receiving a consumption fluid 131, which can be delivered to the stator 10, 10' and/or the rotor 11, 11' to dissipate additional heat output of the electric machine 1, T, which exceeds the maximum normal operating heat output.
  • Figure 7 shows a method for controlling the electrical machine 1, 1' optionally according to Figure 3 or 4. The method comprises the following steps:
  • Step S10 Determining a current operating mode of the electrical machine 1 , 1 '.
  • Step S11 Check whether the current operating mode corresponds to a fault mode (or normal mode). If the current operating mode corresponds to a fault mode (branch Y), the process continues to step S12. Otherwise (branch N), the process repeats step S10.
  • Step S12 Activating the auxiliary cooling system 13.
  • multiple reservoirs 130 may be provided instead of just one reservoir 130.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Motor Or Generator Cooling System (AREA)

Abstract

L'invention concerne une machine électrique (1, 1') comprenant : un stator (10, 10'), un rotor (11, 11') qui peut être entraîné en rotation par rapport au stator (10, 10'), un dispositif de commande de machine (16) qui est configuré pour régler une puissance de la machine électrique (1, 1') et dans lequel est mémorisée une valeur de seuil (T) qui détermine une puissance de sortie qui peut être réglée au maximum dans un fonctionnement normal de la machine électrique (1, 1'), un système de refroidissement (12) pour refroidir le stator (10, 10') et/ou le rotor (11, 11'), le système de refroidissement (12) étant conçu pour évacuer en continu au moins une puissance calorifique maximale qui peut être délivrée en fonctionnement normal de la machine électrique (1, 1'), et un système de refroidissement supplémentaire (13) avec un réservoir (130) destiné à recevoir un fluide consommable (131) qui peut être délivré au stator (10, 10') et/ou au rotor (11, 11') afin de refroidir le stator (10, 10') et/ou le rotor (11, 11').
PCT/EP2024/074642 2023-09-13 2024-09-04 Machine électrique dotée d'un système de refroidissement supplémentaire Pending WO2025056384A1 (fr)

Applications Claiming Priority (2)

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DE102023124780.8A DE102023124780A1 (de) 2023-09-13 2023-09-13 Elektrische Maschine mit einem Zusatzkühlsystem
DE102023124780.8 2023-09-13

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WO2025056384A1 true WO2025056384A1 (fr) 2025-03-20

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102024116403A1 (de) 2024-06-12 2025-12-18 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Vorrichtung und Verfahren zur Kühlung einer Komponente eines senkrechtstart- und landefähigen Luftfahrzeugs, die Vorrichtung umfassendes senkrechtstart- und landefähiges Luftfahrzeug

Citations (5)

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US7723874B2 (en) * 2008-02-15 2010-05-25 Gm Global Technology Operations, Inc. Cooling systems and methods for integration electric motor-inverters
US8502424B2 (en) * 2008-05-07 2013-08-06 Robert Bosch Gmbh Electric machine having spray and sump cooling
US20160118863A1 (en) * 2014-10-27 2016-04-28 Hamilton Sundstrand Corporation Two-phase electric motor cooler
EP3893366A1 (fr) 2020-04-09 2021-10-13 Hamilton Sundstrand Corporation Système de refroidissement pour machines électriques
US11472544B2 (en) * 2020-03-04 2022-10-18 Textron Innovations Inc. Electric drive system line replaceable unit with integrated collective actuation

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Publication number Priority date Publication date Assignee Title
DE202012012963U1 (de) * 2012-10-29 2014-07-17 Airbus Defence and Space GmbH Elektroantriebsbaueinheit
WO2022223246A1 (fr) * 2021-04-23 2022-10-27 Rolls-Royce Deutschland Ltd & Co Kg Unité d'entraînement électrique
WO2023079024A1 (fr) * 2021-11-03 2023-05-11 Mdgroup Germany Gmbh Machine à aubes et procédé d'exploitation d'une machine à aubes

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7723874B2 (en) * 2008-02-15 2010-05-25 Gm Global Technology Operations, Inc. Cooling systems and methods for integration electric motor-inverters
US8502424B2 (en) * 2008-05-07 2013-08-06 Robert Bosch Gmbh Electric machine having spray and sump cooling
US20160118863A1 (en) * 2014-10-27 2016-04-28 Hamilton Sundstrand Corporation Two-phase electric motor cooler
US11472544B2 (en) * 2020-03-04 2022-10-18 Textron Innovations Inc. Electric drive system line replaceable unit with integrated collective actuation
EP3893366A1 (fr) 2020-04-09 2021-10-13 Hamilton Sundstrand Corporation Système de refroidissement pour machines électriques

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