Interior permanent magnet motor with controlled coolant distribution

Abstract

A built-in permanent magnet motor with controllable coolant distribution is provided. The motor includes a motor housing and a rotating shaft connected to a rotor, and the rotor is rotatably disposed in the housing. The motor also includes a stator unit. The motor also includes an oil groove disposed on the housing above the stator unit. The oil groove includes a reservoir. The reservoir has a hole, which is formed on the end turn portion through the reservoir. The motor also includes a movable nozzle, which has a first open end extending to a second open end. The motor also includes a connector, which is movably disposed in the housing. The motor also includes a cam, which is connected to the connector and contacts the nozzle. When the connector moves, the cam is arranged together with the connector to move the second open end of the nozzle to the end turn portion to distribute cooling oil from the oil groove to the end turn portion.

Description

Technical Field

[0001] The present disclosure relates to distributing coolant in an interior permanent magnet motor, and more particularly, to an interior permanent magnet motor having controllable coolant distribution on a stator unit thereof. Background Art

[0002] Many battery electric vehicles operate using interior permanent magnet (IPM) motors. Many IPM motors are cooled using either coolant or cooling oil or transmission oil. Current IPM motors may experience the undesirable phenomenon of uneven coolant distribution to the IPM motor due to lack of control over coolant distribution, changes in motion, and tilt of the vehicle frame during vehicle operation. Uneven coolant distribution to the IPM motor may result in undesirable hot spots in the motor area. Summary of the invention

[0003] Therefore, while current interior permanent magnet (IPM) motors achieve their intended purposes, a need remains for an improved IPM motor with controllable coolant distribution and a system for controlling coolant distribution in an IPM motor of a vehicle.

[0004] According to one aspect of the present disclosure, there is provided an interior permanent magnet motor with controllable coolant distribution. The motor includes a motor housing and a rotating shaft connected to a rotor. The rotor is rotatably disposed in the housing. The motor also includes a stator unit, which is disposed in the housing and includes a conductive winding arranged around the rotor. The winding has a straight portion extending radially to an end turn portion.

[0005] The motor further includes an oil tank disposed on the housing above the stator unit. The oil tank includes a reservoir having an inner side for containing coolant (or cooling oil or transmission oil) and an outer side arranged above the end turn portion. The reservoir has at least one hole formed through the reservoir on the end turn portion extending from the straight portion.

[0006] In this aspect, the motor further comprises a movable nozzle having a first open end extending to a second open end. The first open end is connected to at least one hole so that the movable nozzle and the reservoir are in fluid communication. The second open end extends from the at least one hole and is positioned adjacent to the end turn portion for coolant distribution. The motor further comprises a connector movably disposed in the housing proximate to the movable nozzle.

[0007] The motor also includes a cam having a first portion extending to a second portion. The first portion is connected to the connector and the second portion is in contact with the nozzle. When the connector moves, the cam is arranged together with the connector to move the second open end of the nozzle onto the end turn portion to distribute cooling oil from the oil tank to the end turn portion.

[0008] In one embodiment, the stator comprises an iron core, the conductive winding is radially arranged in the iron core and extends radially from the iron core. The iron core is arranged around the straight portion of the winding. The end turn portion extends radially from the iron core.

[0009] In another embodiment, the straight portion has a first radial side extending to a second radial side. The end turn portion has a first turn portion extending radially from the first radial side, and a second turn portion extending radially from the second radial side. The core is arranged around the straight portion of the winding. The first turn portion and the second turn portion extend radially from the core.

[0010] In yet another embodiment, the at least one hole is a plurality of holes. Each hole is formed through the reservoir on one of the first turn portion and the second turn portion extending from the core.

[0011] In yet another embodiment, the movable nozzle is a plurality of movable nozzles. Each hole is connected to a movable nozzle so that the reservoir and each movable nozzle are in fluid communication. Each second open end extends from the reservoir and is positioned adjacent to one of the first turn portion and the second turn portion for coolant distribution.

[0012] In another embodiment, the connector is a plurality of connectors, movably disposed in the housing near the plurality of movable nozzles. The plurality of connectors include a plurality of cams. Each cam has a first portion extending to a second portion. The first portion is connected to the connector, and the second portion is in contact with one of the plurality of nozzles. When each of the connectors moves, each cam is arranged to move one of the second open ends of one of the nozzles to one of the first turn portion and the second turn portion to distribute cooling oil from the oil tank.

[0013] In one embodiment, the movable nozzle is made of a polymeric material. In another embodiment, the second portion of the cam is in sliding contact with the nozzle via a connection track. In yet another embodiment, the movable nozzle is made of a metallic material. In yet another embodiment, the cam is made of metal, and the second portion of the cam is in sliding magnetic contact with the nozzle via a connection magnet.

[0014] In another aspect of the present disclosure, a built-in permanent magnet motor with controllable coolant distribution is provided. The motor includes a motor housing and a rotating shaft connected to a rotor. The rotor is rotatably disposed in the housing. A stator unit is disposed in the housing and includes an iron core, and a conductive winding is radially disposed in the iron core and extends radially from the iron core. The winding is arranged around the rotor and has a straight portion extending radially to an end turn portion. The iron core is arranged around the straight portion of the winding. The end turn portion extends radially from the iron core.

[0015] In this aspect, the oil tank is disposed on the housing above the core. The oil tank includes a reservoir having an inner side for containing cooling oil and an outer side arranged above the core. The reservoir has at least one hole formed through the reservoir on an end turn portion extending from the core. The movable nozzle has a first open end extending to a second open end. The first open end is connected to the at least one hole so that the movable nozzle and the reservoir are in fluid communication. The second open end extends from the at least one hole and is positioned adjacent to the end turn portion for coolant distribution.

[0016] Further to this aspect, the connector is movably disposed in the housing, adjacent to the movable nozzle. The cam has a first portion extending to a second portion. The first portion is connected to the connector, and the second portion is in contact with the nozzle. When the connector moves, the cam is arranged together with the connector to move the second open end of the nozzle onto the end turn portion to distribute cooling oil from the oil tank to the end turn portion.

[0017] In one embodiment of this aspect, the straight portion has a first radial side extending to a second radial side. The end turn portion has a first turn portion extending radially from the first radial side, and a second turn portion extending radially from the second radial side. The core is arranged around the straight portion of the winding. The first turn portion and the second turn portion extend radially from the core.

[0018] In one embodiment, the at least one hole is a plurality of holes. Each hole is formed through the reservoir on one of the first turn portion and the second turn portion extending from the core.

[0019] In another embodiment, the movable nozzle is a plurality of movable nozzles. Each hole is connected to a movable nozzle so that the reservoir and each movable nozzle are in fluid communication. Each second open end extends from the reservoir and is positioned adjacent to one of the first turn portion and the second turn portion for coolant distribution.

[0020] In yet another embodiment, the connector is a plurality of connectors movably disposed in a housing near a plurality of movable nozzles. The cam is a plurality of cams connected to one of the plurality of connectors. Each cam has a first portion extending to a second portion. The first portion is connected to the connector and the second portion contacts one of the plurality of nozzles. When each connector moves, each cam is arranged to move one of the second open ends of one of the nozzles to one of the first turn portion and the second turn portion to distribute cooling oil from the oil tank.

[0021] In yet another embodiment, the movable nozzle is made of metal material, and the cam is made of metal. The second portion of the cam is in sliding magnetic contact with the nozzle via a connecting magnet.

[0022] In another aspect of the present disclosure, a system for controlling coolant distribution in an interior permanent magnet motor of a vehicle having a frame is provided. The system includes an interior permanent magnet motor, the motor including a motor housing and a rotating shaft connected to a rotor. The rotor is rotatably disposed in the housing. The motor also includes a stator unit, the stator unit being disposed in the housing and including an electrically conductive winding arranged around the rotor. The winding has a straight portion extending radially to an end turn portion.

[0023] The motor further includes an oil tank disposed on the housing above the stator unit. The oil tank includes a reservoir having an inner side for containing cooling oil and an outer side arranged above the end turn portion. The reservoir has at least one hole formed through the reservoir on the end turn portion extending from the straight portion.

[0024] In this aspect, the motor further comprises a movable nozzle having a first open end extending to a second open end. The first open end is connected to at least one hole so that the movable nozzle and the reservoir are in fluid communication. The second open end extends from the at least one hole and is positioned adjacent to the end turn portion for coolant distribution. The motor further comprises a connector movably disposed in the housing proximate to the movable nozzle.

[0025] The motor also includes a cam having a first portion extending to a second portion. The first portion is connected to the connector and the second portion is in contact with the nozzle. When the connector moves, the cam is arranged together with the connector to move the second open end of the nozzle onto the end turn portion to distribute cooling oil from the oil tank to the end turn portion.

[0026] In this aspect, the system also includes an actuator, a sensor, a controller, and a power source. The sensor is configured to sense one of a change in motion and a tilt of a vehicle frame. The sensor is arranged to send a signal of one of the change in motion and the tilt of the frame to the controller. The system also includes an actuator in communication with the connector and arranged to move the connector and the cam to move the second open end of the nozzle onto the end turn portion for optimal distribution of cooling oil.

[0027] In this aspect, the system further includes a power source and a controller. The power source is configured to supply power to the actuator. The controller is in communication with the actuator and is configured to control the actuator when receiving a signal from the sensor for optimal distribution of the cooling oil.

[0028] In one embodiment of this aspect, the stator includes a core, the conductive winding is radially disposed in the core and extends radially from the core. The core is arranged around a straight portion of the winding. The end turn portion extends radially from the core.

[0029] In one embodiment, the straight portion has a first radial side extending to a second radial side. The end turn portion has a first turn portion extending radially from the first radial side, and a second turn portion extending radially from the second radial side. The core is arranged around the straight portion of the winding. The first turn portion and the second turn portion extend radially from the core. In this embodiment, the at least one hole is a plurality of holes. Each hole is formed through the reservoir on one of the first turn portion and the second turn portion extending from the core.

[0030] In another embodiment, the movable nozzle is a plurality of movable nozzles. Each hole is connected to a movable nozzle so that the reservoir and each movable nozzle are in fluid communication. Each second open end extends from the reservoir and is positioned adjacent to one of the first turn portion and the second turn portion for coolant distribution. In this embodiment, the connector is a plurality of connectors, which are movably disposed in the housing near the plurality of movable nozzles.

[0031] In this embodiment, the cam is a plurality of cams. Each cam has a first portion extending to a second portion. The first portion is connected to a connector, and the second portion contacts one of the plurality of nozzles. When each connector moves, each cam is arranged to move one of the second open ends of one of the nozzles to one of the first turn portion and the second turn portion to distribute cooling oil from the oil tank.

[0032] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The drawing descriptions herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0034] Figure 1 is a schematic view of a system for controlling coolant distribution in an interior permanent magnet motor of a vehicle.

[0035] Figure 2 is a perspective view of a stator unit of an interior permanent magnet motor.

[0036] Figure 3 is an end view of the stator unit in operation when the vehicle is tilted in a first direction.

[0037] Figure 4 is an end view of the stator unit in operation when the vehicle is tilted in the second direction. DETAILED DESCRIPTION

[0038] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0039] The present disclosure provides an interior permanent magnet (IPM) motor with controllable cooling oil distribution. The motor includes a plurality of nozzles in fluid communication with an oil tank, the oil tank being configured to contain coolant to gravity distribute the coolant to the stator unit of the motor. The nozzle is movably disposed adjacent to the stator unit and is controllable so that the cooling oil can be more evenly distributed to the stator unit during vehicle operation. A plurality of connectors that cooperate with a plurality of cams are movably connected to the nozzles so that when the connectors move, the cams move the nozzles to the stator unit. The movement of the connectors can be controlled by a system having an actuator in communication with the connectors. Therefore, embodiments of the present disclosure help to offset or compensate for potential uneven distribution of cooling oil to the stator unit of the motor. That is, the IPM motor and its system enable relatively optimal distribution of coolant to the stator unit of the motor during vehicle operation.

[0040] According to one embodiment of the present disclosure, Figure 1 A system 10 for controlling coolant distribution in an IPM motor of a vehicle having a frame is shown. As shown, the system 10 includes an IPM motor 12. The IPM motor includes a rotor 18. The rotor has a shaft 16 to transmit rotational motion to a gearbox. The entire IPM motor is located in a housing 14.

[0041] Reference Figure 1 and Figure 2 , the motor 12 also includes a stator unit 20 disposed in the housing 14. The stator unit 20 includes an iron core 22, and an electrically conductive winding 24 is radially disposed in the iron core and extends radially from the iron core. In the present embodiment, the winding 24 is arranged around the rotor 18 and has a straight portion 26 (shown in phantom) extending radially to the end turn portion 30. As shown, the straight portion 26 has a first radial side 32 extending radially to a second radial side 34. In addition, the end turn portion 30 has a first turn portion 40 extending radially from the first radial side 32, and a second turn portion 42 extending radially from the second radial side 34. As shown in FIG. Figure 2 As shown, the core 22 is disposed about the linear portion 26 of the winding 24. The first turn portion and the second turn portion extend radially from the core 22. As will be discussed below, during operation of the electric machine 12, cooling oil is distributed to the first turn portion and the second turn portion.

[0042] Reference Figure 1-3The motor 12 further includes an oil tank 44 disposed on the housing 14 above the core 22. The oil tank 44 includes a reservoir 46 having an inner side 48 for containing coolant (or cooling oil or transmission oil) and an outer side 50 disposed above the core 22. The reservoir 46 has at least one hole 52, preferably a plurality of holes 52, formed through the reservoir on the turn portion 30 (the first turn portion 40 and the second turn portion) extending from the core 22. The hole 52 allows the coolant to be distributed to the stator unit 20 by gravity. Figure 3 As shown, each hole 52 is formed through the reservoir 46 at one of the first turn portion and the second turn portion extending from the core 22 .

[0043] like Figure 3 and Figure 4 As shown, the electric machine 12 also includes a movable nozzle or tube 54, preferably a plurality of movable nozzles 54, having a first open end 56 extending to a second open end 58. As shown, each first open end 56 is connected to one of the holes 52 so that each movable nozzle 54 is in fluid communication with the reservoir 46 for controlled gravity distribution of coolant to the stator unit 20. Each second open end 58 extends from the hole 52 to which the corresponding first open end 56 is connected and is positioned adjacent to the end turn portion 30 for coolant distribution. As shown, each second open end 58 is positioned adjacent to the first turn portion 40 or the second turn portion 42 so that cooling oil can be distributed to the corresponding end turn portion 30 of the stator unit 20 in a controlled manner by gravity.

[0044] As will be discussed in more detail below, the movable nozzle 54 is arranged to be movable over one of the first turn portion and the second turn portion to more evenly distribute cooling oil to the motor 12. The location of the hole 52 and the second open end 58 above the first turn portion and the second turn portion allows the cooling oil to be distributed thereon by gravity. During operation, movement of the second end distributes the cooling oil more evenly to the motor 12, as discussed in more detail below.

[0045] It should be understood that the movable nozzle 54 can be made of any suitable material, such as a polymeric material or a metallic material, without departing from the spirit or scope of the present invention. For example, if the nozzle 54 is constructed of a metallic material, the first open end 56 can be connected to the hole 52 by a flexible or pivotable joint, so that the second open end 58 is movable relative to the end turn portion 30. In addition, if the nozzle 54 is constructed of a polymeric material, the polymeric material can be any suitable plastic, so that the second open end 58 is movable relative to the end turn portion 30.

[0046] Further for this embodiment, Figure 3 and Figure 4A plurality of connectors are shown that are movably disposed in the housing 14. For example, a first connector 60 and a second connector 62 are movably disposed near the movable nozzle 54. In this embodiment, the connectors are movable rods, each of which is arranged to be movable around a rotation axis. As shown, the first connector 60 and the second connector 62 are movably rotated around the axis.

[0047] Reference Figure 3 and Figure 4 , the first connector 60 is disposed proximally above the first turn portion 40, and the second connector 62 is disposed proximally above the second turn portion. In this embodiment, a plurality of cams 64 are connected to each of the first connector 60 and the second connector 62. Each cam 64 has a first portion 66 extending to a second portion 68. As shown, the first portion 66 is connected to a corresponding connector, and the second portion 68 is slidably connected to one of the plurality of nozzles 54.

[0048] It should be understood that the second portion 68 may be slidably connected to one of the nozzles 54 by any suitable means without departing from the spirit or scope of the present invention. For example, the second portion 68 may be slidably connected to one of the nozzles 54 by a sliding mechanism (not shown) such that the second portion 68 slides along the length of the nozzle 54, thereby moving the second open end 58 when the corresponding connector is rotated about its axis. Thus, upon rotational movement of its respective connector, each cam 64 is arranged with the connector to move the second open end 58 of the nozzle 54 over the end turn portion 30 for distributing cooling oil from the oil groove 44 to the end turn portion 30.

[0049] It should be understood that the nozzle 54 and the cam 64 can be made of a metal material. In this embodiment, the second portion 68 of the cam 64 can be slidably connected to the nozzle 54 by a magnetic mechanism (not shown). The magnetic mechanism can slide the second portion 68 along the length of the nozzle 54, thereby moving the second open end 58 when the corresponding connector is rotated about its axis.

[0050] Figure 3 and Figure 4 Flows 70, 72 of cooling oil during vehicle operation resulting from implementation of the system 10 of the present disclosure are shown. When the vehicle experiences changes in motion or frame tilt, the flow of cooling oil 70, 72 distributed to the end turn portion 30 may be affected. Without implementation of the system 10, such changes in motion or frame tilt may result in uneven or non-uniform distribution of cooling oil to the end turn portion 30. In accordance with the present disclosure, the system 10 distributes coolant more evenly to the motor 12 by moving the connector and cam 64, thereby moving the nozzle 54 across the end turn portion 30. As shown in FIG. Figure 3 and Figure 4As shown, the coolant flows 70, 72 are affected by the implementation of the system 10. Thus, the system 10 compensates for potential maldistribution of cooling oil to the electric machine 12.

[0051] Reference Figure 1 and Figure 3-4 The system 10 further includes an actuator 80, a controller 82, a sensor 84, and a power source 86. The actuator 80 is in communication with the connector. That is, the actuator 80 is arranged to move the first connector 60 and the second connector 62 and the cam 64. The movement of the connector and the cam 64 thereby moves the second open end 58 of the nozzle 54 onto the end turn portion 30.

[0052] In addition, the sensor 84 is configured to sense one of a change in motion or a tilt of the vehicle frame. When one of the change in motion or the tilt of the frame is sensed, the sensor 84 is arranged to send a signal 88 related to the change in motion or the tilt of the frame to the controller 82. It should be understood that the sensor 84 can be disposed at any suitable location of the vehicle (e.g., near the front wheels, the steering wheel, the center of the vehicle) to sense a change in motion or a tilt of the frame of the vehicle without departing from the spirit or scope of the present disclosure.

[0053] The controller 82 is in communication with the actuator 80 and is configured to control the actuator 80 for optimal distribution of the cooling oil upon receiving a signal 88 from the sensor 84 . In the present embodiment, the power supply 86 is configured to supply power to the actuator 80 , the controller 82 , and the sensor 84 .

[0054] The description of the present disclosure is merely exemplary in nature, and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations should not be regarded as departing from the spirit and scope of the present disclosure.

Claims

1. A built-in permanent magnet motor with controllable coolant distribution, the motor comprising: Motor housing; a rotating shaft connected to a rotor rotatably disposed in the housing; a stator unit disposed in the housing and comprising an electrically conductive winding arranged around the rotor, the winding having a straight portion extending radially to an end turn portion; an oil tank disposed on the housing above the stator unit, the oil tank comprising a reservoir having an inner side for accommodating cooling oil and an outer side arranged above the end turn portion, the reservoir having at least one hole formed through the reservoir on the end turn portion extending from the straight portion; a movable nozzle having a first open end extending to a second open end, the first open end connected to the at least one aperture so that the movable nozzle and the reservoir are in fluid communication, the second open end extending from the at least one aperture and positioned adjacently above the end turn portion for coolant dispensing; a connector movably disposed in the housing near the movable nozzle; and a cam having a first portion extending to a second portion, the first portion being connected to the connector, the second portion being in contact with the nozzle; Wherein when the connector moves, the cam is arranged together with the connector to move the second open end of the nozzle onto the end turn portion to distribute cooling oil from the oil groove to the end turn portion.

2. The electric machine of claim 1, wherein the stator comprises an iron core, the conductive winding is radially disposed in the iron core and extends radially from the iron core, the iron core is disposed around the straight portion of the winding, and the end turn portion extends radially from the iron core.

3. The electric machine of claim 2, wherein the straight portion has a first radial side extending to a second radial side, the end turn portion has a first turn portion extending radially from the first radial side, and a second turn portion extending radially from the second radial side, the core is arranged around the straight portion of the winding, and the first turn portion and the second turn portion extend radially from the core.

4. The motor of claim 3, wherein the at least one hole is a plurality of holes, each of which is formed through the reservoir at one of the first turn portion and the second turn portion extending from the core.

5. The electric machine as claimed in claim 4, wherein the movable nozzle is a plurality of movable nozzles, each hole is connected to a movable nozzle, so that the reservoir and each movable nozzle are fluidically connected, and each second open end extends from the reservoir and is positioned adjacent to and above one of the first turn portion and the second turn portion for coolant distribution.

6. The motor of claim 5, wherein the connector is a plurality of connectors movably disposed in the housing near the plurality of movable nozzles, the plurality of connectors comprising a plurality of cams, each cam having a first portion extending to a second portion, the first portion being connected to the connector, the second portion being in contact with one of the plurality of nozzles, Wherein when each of the connectors moves, each cam is arranged to move one of the second open ends of one of the nozzles to one of the first turn portion and the second turn portion to distribute cooling oil from the oil groove.

7. The electric machine of claim 1, wherein the movable nozzle is comprised of a polymeric material.

8. The motor of claim 7, wherein the second portion of the cam is in sliding contact with the nozzle via a connecting track.

9. The motor of claim 1, wherein the movable nozzle is made of a metal material.

10. The motor of claim 9, wherein the cam is made of metal, and the second portion of the cam is in sliding magnetic contact with the nozzle via a connecting magnet.

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