End winding support and heat sink for liquid-cooled generator

• US 9,819,239 B2
• Filed: 05/07/2015
• Issued: 11/14/2017
• Est. Priority Date: 05/07/2015
• Status: Active Grant

• Current Assignee: Hamilton Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: Hamilton Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Pal, Debabrata, Krecklow, Joshua J.
• Primary Examiner(s): Luks, Jeremy
• Application Number:
  US14/706,338
• Publication Number:
  US 20160329765A1
• Time in Patent Office: 922 Days
• Field of Search: 310 54, 310 64, 310 65, 310269, 310216074, 310216091, 310270
• CPC Class Codes: H02K 3/24 with channels or ducts for cooling medium between the conductors
• CPC Class Codes: H02K 3/38 around winding heads, equalising connectors, or connections thereto
• CPC Class Codes: H02K 3/50 Fastening of winding heads, equalising connectors, or connections thereto
• CPC Class Codes: H02K 3/51 applicable to rotors only
• CPC Class Codes: H02K 3/527 applicable to rotors only
• CPC Class Codes: H02K 5/203 specially adapted for liquids, e.g. cooling jackets
• CPC Class Codes: H02K 7/003 Couplings; Details of shafts means for mounting rotors on shafts H02K1/28
• CPC Class Codes: H02K 9/197 in which the rotor or stator space is fluid-tight, e.g. to provide for different cooling media for rotor and stator
• CPC Class Codes: H02K 9/227 Heat sinks

Abstract

Embodiments of an end winding support and heat sink for a pole of a generator are provided. An aspect includes a flat plate portion, the flat plate portion comprising an internal cooling liquid channel that routes coolant through the flat plate portion. Another aspect includes a plurality of fins extending out from the flat plate portion, wherein wires of the windings of the generator are supported by the plurality of fins.

Claims

1. A rotor pole of a liquid cooled generator, the rotor pole comprising:

a core portion that supports a plurality of layers of wire end windings;

an end winding support and heat sink disposed at each end of the core portion;

each end winding support and heat sink comprising;

a flat plate portion having a first flat surface and an opposing second flat surface, the first flat surface being a core facing flat surface and the second flat surface being an outwardly facing flat surface,

the flat plate portion comprising an internal cooling liquid channel that routes coolant into and out of the flat plate portion, the cooling liquid channel disposed between the first flat surface and the second flat surface; and

a plurality of fins extending out from the second flat surface of the flat plate portion that hold and support each of the layers of wires of the wire end windings against the second flat surface, wherein each layer of wire end winding is supported by two adjacent fins of the plurality of fins.

2. The rotor pole of claim 1, wherein the flat plate portion and the plurality of fins each comprise a conductive material configured to conduct heat from the wires, through the plurality of fins, and into the flat plate portion, such that the heat is dissipated by the internal cooling liquid channel in the flat plate portion.

3. The rotor pole of claim 2, wherein the conductive material comprises copper.

4. The rotor pole of claim 2, wherein the conductive material comprises aluminum.

5. The rotor pole of claim 2, wherein the conductive material comprises a ceramic.

6. The rotor pole of claim 1, wherein each of the plurality of fins is covered with a layer of an insulator coating, such that the insulator coating separates the wires from the plurality of fins.

7. The rotor pole of claim 6, wherein the insulator coating comprises a ceramic insulator coating.

8. The rotor pole of claim 1, further comprising inlet tubing and outlet tubing configured to route coolant into and out of the internal cooling liquid channel of the flat plate portion.

9. The rotor pole of claim 8, wherein the inlet tubing and outlet tubing extend to a coolant channel in a rotor hub of the generator.

10. A rotor for a liquid cooled generator, comprising:

a plurality of rotor poles mounted thereon, each of the plurality of rotor poles comprising;

a core portion that supports a plurality of layers of wire end windings;

an end winding support and heat sink disposed at each end of the core portion;

each end winding support and heat sink, comprising;

a flat plate portion having a first flat surface and an opposing second flat surface, the first flat surface being a core facing flat surface and the second flat surface being an outwardly facing flat surface,

the flat plate portion comprising an internal cooling liquid channel that routes coolant into and out of the flat plate portion, the cooling liquid channel disposed between the first flat surface and the second flat surface; and

a plurality of fins connected to and extending out from the second flat surface of the flat plate portion that hold and support each of the layers of wires of the wire end windings against the second flat surface, wherein each layer of wire end winding is supported by two adjacent fins.

11. The rotor of claim 10, wherein the flat plate portion and the plurality of fins in each end winding support and heat sink each comprise a conductive material configured to conduct heat from the wires, through the plurality of fins, and into the flat plate portion, such that the heat is dissipated by the internal cooling liquid channel in the flat plate portion.

12. The rotor of claim 10, wherein each end winding support and heat sink further comprises inlet tubing and outlet tubing configured to route coolant into and out of the internal cooling liquid channel of the flat plate portion.

13. A rotor hub of a liquid cooled generator, the rotor hub comprising a coolant channel and the rotor of claim 12, wherein the inlet tubing and outlet tubing of each of the end winding support and heat sinks extends to the coolant channel in the rotor hub.