A flat wire motor winding cooling structure

Abstract

The application relates to a winding cooling structure of a vehicle flat wire motor, and relates to the technical field of motor cooling. The application is aimed at solving the winding cooling mode of the existing vehicle motor, the existence of air and insulating materials in the motor makes the winding difficult to dissipate heat, the temperature rise is high, and the service life of the winding and the insulating materials is reduced, thereby affecting the reliability of the motor operation. The winding cooling structure of the vehicle flat wire motor is characterized in that two layers of cooling flow channels are designed on the stator side, one layer is located on the casing and is mainly used for cooling the stator core, the casing is provided with a cooling liquid inlet and an outlet; the other layer is mainly used for cooling the end part of the flat wire winding, axial flow channels are drilled at the top and the bottom of the stator core, flow guide rings are arranged at the two ends of the axial flow channels, the casing is drilled with an inlet and an outlet, and the end part of the winding on the inner side of the flow guide ring is filled with heat-conducting insulating materials.

Description

Technical Field

[0001] This invention belongs to the field of motor cooling technology. Background Technology

[0002] As people pursue higher motor performance, motors are increasingly developing towards higher precision, higher power density, miniaturization, lighter weight, and mechatronics integration. This has led to a dramatic increase in internal heat generation and a severe shortage of effective heat dissipation space. A highly efficient cooling system is fundamental to suppressing motor temperature rise, improving operational stability, and extending motor lifespan. Regarding internal motor heat generation, winding temperature has always been a key concern. Excessive winding temperature can negatively impact motor performance, and in severe cases, damage insulation and cause motor malfunctions. Therefore, effective cooling of the heat-generating parts of the motor windings is crucial for ensuring stable and safe motor operation.

[0003] Currently, traditional motor winding cooling methods, such as air cooling and oil cooling, involve spraying non-magnetic and non-conductive cooling oil through oil channels in the motor housing or throwing it onto the stator winding ends via a rotating shaft, or adding fan blades to one end of the stator windings to cool the flat wire windings. Because the space at the winding ends is primarily air, the thermal resistance is relatively high, and the heat generated at the winding ends cannot be transferred to the outside of the motor in a timely manner. With the development of high power density motors, traditional cooling methods can no longer meet the cooling requirements of motors, especially for cooling the windings at the motor ends, where their shortcomings and deficiencies are becoming increasingly apparent. Summary of the Invention

[0004] This invention addresses the shortcomings of existing winding cooling methods for automotive flat-wire motors. The straight sections of the motor windings are embedded within the iron core and wrapped with insulating paper. Furthermore, the end windings primarily rely on air for heat transfer, resulting in high contact thermal resistance. This leads to difficulties in heat dissipation, high temperature rise, reduced lifespan of the windings and insulation materials, and compromised motor reliability. The invention provides a new winding cooling structure for automotive flat-wire motors.

[0005] A cooling structure for a flat wire motor winding for vehicles includes: a guide ring (1-1, 1-2), a thermally conductive insulating material (2-1, 2-2), a flat wire winding (3), a stator core (4), and a housing (5);

[0006] The flat wire winding (3) is embedded in the winding slot inside the stator core (4), the housing (5) is coaxially fixed on the outer surface of the stator core (4), and the guide rings (1-1, 1-2) are respectively connected to the two ends of the stator core (4).

[0007] The flow channels carved inside the housing (5), stator core (4), and guide rings (1-1, 1-2) form the coolant flow channels (6) and (7) on the stator side. The coolant flow channel (6) is a fluid flow area carved inside the housing (5) as shown in the coolant flow channel (6); the coolant flow channel (7) is a fluid flow area jointly formed by the coolant flow channels carved inside the housing (5), stator core (4), and guide rings (1-1, 1-2).

[0008] The guide rings (1-1, 1-2) have coolant flow channels cut into their interiors. The top and bottom of guide ring (1-1) have coolant inlets (1-3, 1-4), and the top and bottom of guide ring (1-2) have coolant inlets (1-5, 1-6). Coolant enters or exits the coolant flow channels inside the guide rings (1-1, 1-2) through the inlets (1-3, 1-4, 1-5, 1-6).

[0009] The thermally conductive insulating material (2-1, 2-2) is filled between the guide ring (1-1, 1-2) and the inner diameter surface of the stator core (4). The thermally conductive insulating material (2-1, 2-2) encapsulates the end areas of the flat wire winding (3) located at both ends of the stator core (4) and is in direct contact with the stator core (4) and the guide ring (1-1, 1-2).

[0010] The stator core (4) has two stator axial flow channels (4-3, 4-4) at the top and bottom. A coolant inlet (4-2) and a coolant outlet (4-1) are cut in the middle of the two stator axial flow channels (4-3, 4-4), which are connected to the coolant inlet (7-1) and coolant outlet (7-2) in the middle of the top and bottom of the casing (5), respectively.

[0011] The top and bottom of the housing (5) are respectively provided with coolant inlets (6-1, 6-2) and coolant outlets (6-3, 6-4) of coolant flow channels (6). At the same time, the top and bottom of the housing (5) are also provided with coolant inlets (7-1) and coolant outlets (7-2) of coolant flow channels (7) that penetrate the housing (5).

[0012] The coolant inlets (6-1, 6-2) and coolant outlets (6-3, 6-4) of the coolant flow channels (6) excavated at the top and bottom of the casing (5) are connected to the flow channels excavated inside the casing (5). The flow channels excavated inside the casing (5), together with the coolant inlets (6-1, 6-2) and coolant outlets (6-3, 6-4) excavated at the top and bottom, together form the coolant flow channels (6).

[0013] Axial flow channels (4-3, 4-4) are drilled at the top and bottom of the stator core (4). Simultaneously, circular holes (4-1, 4-2) are drilled perpendicular to the two axial flow channels (4-3, 4-4) in the middle section, respectively. These holes connect to the coolant inlets / outlets (7-1, 7-2) at the top and bottom of the housing (5). Furthermore, the two ends of the axial flow channels (4-3, 4-4) are sealed and connected to the guide ports (1-3, 1-4, 1-5, 1-6) at the top and bottom of the guide rings (1-1, 1-2). The interconnected coolant flow channels drilled within the housing (5), stator core (4), and guide rings (1-1, 1-2) together form the coolant flow channel (7).

[0014] Both the coolant flow channel (6) and the coolant flow channel (7) are used to fill the coolant.

[0015] The coolant flow channel (6) adopts a spatially symmetrical structure. The coolant inlets (6-1, 6-2) are located at the top of the coolant flow channel (6), and the coolant outlets (6-3, 6-4) are located at the bottom of the coolant flow channel (6). Under the action of gravity, the coolant flows from the inlet and exits from the outlet. The coolant flow channel (6) has two coolant inlets (6-1, 6-2) and two coolant outlets (6-1, 6-2). Compared with the traditional spiral cooling channel structure, this symmetrical structure makes the motor heat dissipation more uniform and efficient.

[0016] The purpose of the coolant flow channel (7) is mainly to cool the winding end. The cooling flow channel structure in the guide ring (1-1, 1-2) adopts a circumferential serpentine cooling structure. In this structure, the coolant enters the guide ring (1-1, 1-2) from the inlet and flows out from the bottom oil outlet under the action of gravity along the cooling flow channel in the guide ring (1-1, 1-2). This serpentine arrangement of the coolant flow channel in the guide ring (1-1, 1-2) prevents the problem of insufficient development of the coolant flow in the channel. After the flow rate stabilizes, the coolant can fill the entire channel well. At the same time, the serpentine circumferential structure increases the convective heat exchange area with the coolant and improves the heat dissipation efficiency.

[0017] Furthermore, the above-mentioned vehicle flat wire motor winding cooling structure also includes an external cooling device 1, which is used to cool the coolant in the coolant flow path (6) and the coolant flow path (7).

[0018] The outlet of the external cooling device 1 is connected to the coolant inlet (6-2, 6-2) of the coolant flow path (6) on the housing (5) and the coolant inlet (7-1) of the coolant flow channel (7). The inlet of the external cooling device 1 is connected to the coolant outlet (6-3, 6-4) of the coolant channel (6) and the coolant outlet (7-2) of the coolant flow path (7).

[0019] Furthermore, reliable sealing measures are taken at the flow guides (1-1, 1-2) in the cooling channel (7) and the flow guides (1-3, 1-4, 1-5, 1-6) at the interface between the flow guides (1-1, 1-2) and the flow guides (4) of the stator core to ensure that the coolant does not leak.

[0020] Furthermore, the coolant used in the coolant flow channels (6) and (30) is water or an aqueous solution of ethylene glycol, or it can be engine oil for cooling.

[0021] Furthermore, the aforementioned cooling and thermally conductive insulating materials (2-1, 2-2) are made of materials with high thermal conductivity and good insulation properties, such as thermally conductive resins and thermally conductive adhesives. The thermally conductive insulating material is filled into the gap between the motor end winding and the housing. This material is initially liquid-filled, then cured by heating and remains in a solid state, exhibiting excellent thermal conductivity and insulation properties.

[0022] Furthermore, the aforementioned housing (5) and guide rings (1-1, 1-2) are made of metal.

[0023] The present invention discloses a cooling structure for a flat wire motor winding in an automotive application. The stator side employs a double-layer cooling channel: one layer for cooling the core and the straight sections of the winding, and the other layer primarily for cooling the winding ends. The entire structure utilizes forced liquid cooling to dissipate heat generated by the flat wire motor, particularly from the flat wire winding (3), significantly improving the motor's heat dissipation efficiency and further enhancing its performance. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the unfolded cooling structure for a flat wire motor winding of an vehicle according to the present invention;

[0025] Figure 2 A schematic diagram of the coolant flow channel (6) formed by the flow channels inside the casing;

[0026] Figure 3 A schematic diagram of the coolant flow channel (7) consisting of the flow channels in the casing, stator and guide ring;

[0027] Figure 4 A perspective view of the three-dimensional structure of the stator core;

[0028] Figure 5 A perspective view of the three-dimensional structure of the casing;

[0029] Figure 6 A perspective view of the three-dimensional structure of the flow guide ring;

[0030] Figure 7 An axial sectional view of a cooling structure for a flat wire motor winding of an vehicle as described in this invention before filling with thermally conductive silicone.

[0031] Figure 8 An axial cross-sectional view of the cooling structure for a flat wire motor winding of an automotive device as described in this invention after filling with thermally conductive silicone.

[0032] Guide ring (1-1, 1-2), guide port (1-3, 1-4, 1-5, 1-6), thermally conductive insulating material (2-1, 2-2), flat wire winding (3), stator core (4), coolant outlet (4-1), coolant inlet (4-2), stator axial flow channel (4-3, 4-4), housing (5), coolant flow channel (6), coolant inlet (6-1, 6-2), coolant outlet (6-3, 6-4), coolant flow channel (7), coolant outlet (7-1), coolant inlet (7-2). Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other.

[0034] Specific implementation method one: Refer to Figures 1 to 8 This embodiment describes a cooling structure for a flat wire motor winding, which includes: a guide ring (1-1, 1-2), a thermally conductive insulating material (2-1, 2-2), a flat wire winding (3), a stator core (4), and a housing (5).

[0035] The flat wire winding (3) is embedded in the winding slot inside the stator core (4), the housing (5) is coaxially fixed on the outer surface of the stator core (4), and the guide rings (1-1, 1-2) are respectively connected to the two ends of the stator core (4).

[0036] The flow channels carved inside the housing (5), stator core (4), and guide rings (1-1, 1-2) form the coolant flow channels (6) and (7) on the stator side. The coolant flow channel (6) is a fluid flow area carved inside the housing (5) as shown in the coolant flow channel (6); the coolant flow channel (7) is a fluid flow area jointly formed by the coolant flow channels carved inside the housing (5), stator core (4), and guide rings (1-1, 1-2).

[0037] The guide rings (1-1, 1-2) have coolant flow channels cut into their interiors. The top and bottom of guide ring (1-1) have coolant inlets (1-3, 1-4), and the top and bottom of guide ring (1-2) have coolant inlets (1-5, 1-6). Coolant enters or exits the coolant flow channels inside the guide rings (1-1, 1-2) through the inlets (1-3, 1-4, 1-5, 1-6).

[0038] The thermally conductive insulating material (2-1, 2-2) is filled between the guide ring (1-1, 1-2) and the inner diameter surface of the stator core (4). The thermally conductive insulating material (2-1, 2-2) encapsulates the winding end areas of the flat wire winding (3) located at both ends of the stator core (4) and is in direct contact with the stator core (4) and the guide ring (1-1, 1-2). The end of the flat wire winding is the portion of the flat wire winding that protrudes axially from the stator core (4) and is close to the guide ring (1-1, 1-2).

[0039] The stator core (4) has two stator axial flow channels (4-3, 4-4) at the top and bottom. A coolant inlet (4-2) and a coolant outlet (4-1) are cut in the middle of the two stator axial flow channels (4-3, 4-4), which are connected to the coolant inlet (7-1) and coolant outlet (7-2) in the middle of the top and bottom of the casing (5), respectively.

[0040] The top and bottom of the housing (5) are respectively provided with coolant inlets (6-1, 6-2) and coolant outlets (6-3, 6-4) of coolant flow channels (6). At the same time, the top and bottom of the housing (5) are also provided with coolant inlets (7-1) and coolant outlets (7-2) of coolant flow channels (7) that penetrate the housing (5).

[0041] The coolant inlets (6-1, 6-2) and coolant outlets (6-3, 6-4) of the coolant flow channels (6) excavated at the top and bottom of the casing (5) are connected to the flow channels excavated inside the casing (5). The flow channels excavated inside the casing (5), together with the coolant inlets (6-1, 6-2) and coolant outlets (6-3, 6-4) excavated at the top and bottom, together form the coolant flow channels (6).

[0042] Axial flow channels (4-3, 4-4) are drilled at the top and bottom of the stator core (4). Simultaneously, circular holes (4-1, 4-2) are drilled perpendicular to the two axial flow channels (4-3, 4-4) in the middle section, respectively. These holes connect to the coolant inlets / outlets (7-1, 7-2) at the top and bottom of the housing (5). Furthermore, the two ends of the axial flow channels (4-3, 4-4) are sealed and connected to the guide ports (1-3, 1-4, 1-5, 1-6) at the top and bottom of the guide rings (1-1, 1-2). The interconnected coolant flow channels drilled within the housing (5), stator core (4), and guide rings (1-1, 1-2) together form the coolant flow channel (7).

[0043] Both the coolant flow channel (6) and the coolant flow channel (7) are used to fill the coolant.

[0044] In practical application, this embodiment also requires an external cooling device 1, which is used to cool the coolant in the coolant flow path (6) and the coolant flow path (7). The outlet of the external cooling device 1 is connected to the coolant inlet (6-2, 6-2) of the coolant flow path (6) on the housing (5) and the coolant inlet (7-1) of the coolant flow path (7). The inlet of the external cooling device 1 is connected to the coolant outlet (6-3, 6-4) of the coolant channel (6) and the coolant outlet (7-2) of the coolant flow path (7), thus forming a forced liquid cooling structure. The coolant used in the forced liquid cooling structure can be water, ethylene glycol aqueous solution, or cooling oil, etc., with non-magnetic and non-conductive cooling oil being preferred.

[0045] In practical applications, this implementation method uses stator-side cooling. The working principle is as follows:

[0046] The stator-side cooling process is as follows: Coolant at a lower temperature enters from the top coolant inlets (6-1), (6-2), and (7-1) at the bottom of the casing (5). Part of the coolant enters the coolant flow channel (6) through the coolant inlets (6-1) and (6-2), carrying away heat from the stator core (4) and the straight section of the flat wire winding (3) that has been conducted to the casing (5). Then, the coolant, now heated, enters the external cooling device from the coolant outlets (6-3) and (6-4) of the coolant flow channel (6). Another part of the coolant... The coolant enters the coolant channel (7) through the inlet (7-1). The coolant circulates in the coolant channel (7) and carries away the heat generated by the flat wire windings (3) at both ends of the stator core (4) and conducted to the guide rings (1-1, 1-2) through the thermally conductive insulating materials (2-1, 2-2). The coolant, which absorbs heat and its temperature rises, enters the external cooling device from the coolant outlet (7-2) of the coolant channel (7). The cooled coolant then enters the coolant channel (6) and the coolant channel (7) again through the coolant inlets (6-1), (6-2) and (7-1).

[0047] In practical applications, to facilitate the installation of the guide ring (1-1, 1-2), the stator core (4) and the housing (5) are assembled before the guide ring (1-1, 1-2) is assembled. Then, the end faces of the stator axial flow channels (4-3, 4-4) at the top and bottom of the stator core (4) are interference-fitted with the guide ports (1-3, 1-4, 1-5, 1-6) of the guide ring (1-1, 1-2), and effective sealing measures are taken. To prevent coolant from seeping out at the interface; secondly, in order to fully wrap the flat wire winding end with thermally conductive insulating material and make close contact with the inner surface of the guide ring, thermally conductive insulating material is filled after the guide ring (1-1, 1-2) is installed. In order to prevent the liquefied thermally conductive insulating material (2-1, 2-2) from seeping into the air gap of the stator core during the filling process, the air gap should be isolated during filling, and the inner surface of the thermally conductive insulating material (2-1, 2-2) should be aligned with the inner surface of the stator core (4).

[0048] While the invention has been described herein with reference to specific embodiments, it should be understood that these embodiments are merely examples of the principles and applications of the invention. Therefore, it should be understood that many modifications can be made to the exemplary embodiments, and other arrangements can be designed without departing from the spirit and scope of the invention as defined by the appended claims. It should be understood that different dependent claims and features described herein can be combined in ways different from those described in the original claims. It is also understood that features described in conjunction with individual embodiments can be used in other described embodiments.

Claims

1. A cooling structure for a flat wire motor winding in an automotive application, comprising a first guide ring (1-1), a second guide ring (1-2), thermally conductive and insulating materials (2-1, 2-2), a flat wire winding (3), a stator core (4), and a housing (5), characterized in that, include: The stator core (4) has two stator axial flow channels (4-3, 4-4) at the top and bottom. A first coolant inlet (4-2) and a first coolant outlet (4-1) are cut in the middle of the two stator axial flow channels (4-3, 4-4). The first coolant inlet (4-2) and the first coolant outlet (4-1) are connected to the second coolant inlet (7-2) and the second coolant outlet (7-1) in the middle of the top and bottom of the casing (5), respectively. The top and bottom of the housing (5) are respectively provided with the third and fourth coolant inlets (6-1, 6-2) and the third and fourth coolant outlets (6-3, 6-4) of the coolant flow channel (6). At the same time, the top and bottom of the housing (5) are also provided with the second coolant inlet (7-2) and the second coolant outlet (7-1) of the coolant flow channel (7) that penetrates the housing (5). The first guide ring (1-1) and the second guide ring (1-2) have coolant channels cut inside. The top and bottom of the first guide ring (1-1) are designed with a first guide port (1-5) and a second guide port (1-6) for coolant. The top and bottom of the second guide ring (1-2) are designed with a third guide port (1-3) and a fourth guide port (1-4) for coolant. Coolant enters or flows out of the coolant channels inside the first guide ring (1-1) and the second guide ring (1-2) through the first guide port (1-5), the second guide port (1-6), the third guide port (1-3) and the fourth guide port (1-4).

2. The cooling structure for automotive flat wire motor windings according to claim 1, characterized in that, The stator side cooling channel adopts a double-layer cooling method; one layer of coolant channel (6) is mainly used to cool the motor stator core (4) and the straight section of the flat wire winding (3) located in the slot on the stator core (4); the other layer of coolant channel (7) is mainly used to cool the ends of the flat wire winding (3) located at both ends of the stator core (4), and the ends of the flat wire winding (3) are filled with thermally conductive insulating material (2-1, 2-2).

3. The cooling structure for automotive flat wire motor windings according to claim 2, characterized in that, Stator axial flow channels (4-3, 4-4) are drilled at the top and bottom of the stator core (4). Simultaneously, a first coolant inlet (4-2) and a first coolant outlet (4-1) are drilled perpendicularly to the stator axial flow channels (4-3, 4-4) at the middle of the two stator axial flow channels (4-3, 4-4). These are connected to the second coolant inlet (7-2) and the second coolant outlet (7-1) at the middle of the top and bottom of the casing (5), respectively. Furthermore, the stator shaft... The flow channels (4-3, 4-4) are connected to the first flow port (1-5), second flow port (1-6), third flow port (1-3) and fourth flow port (1-4) at the top and bottom of the first flow guide ring (1-1) and the second flow guide ring (1-2) through sealing treatment at both ends; the interconnected coolant flow channels carved in the casing (5), stator core (4), first flow guide ring (1-1) and second flow guide ring (1-2) together form the coolant flow channel (7).

4. The cooling structure for automotive flat wire motor windings according to claim 2, characterized in that, The third and fourth coolant inlets (6-1, 6-2) and the third and fourth coolant outlets (6-3, 6-4) of the coolant flow channels (6) excavated at the top and bottom of the housing (5) are connected to the flow channels excavated inside the housing (5). The flow channels excavated inside the housing (5) together with the third and fourth coolant inlets (6-1, 6-2) and the third and fourth coolant outlets (6-3, 6-4) excavated at the top and bottom of the housing (5) form the coolant flow channels (6).

5. The cooling structure for automotive flat wire motor windings according to claim 2, characterized in that, The thermally conductive insulating material (2-1, 2-2) that is filled in the gap between the end windings of the flat wire windings (3) at both ends of the motor stator core (4) and the housing (5) is in direct contact with the inner walls of the first guide ring (1-1) and the second guide ring (1-2) with cooling channels cut out inside.

6. The cooling structure for automotive flat wire motor windings according to claim 1, characterized in that, The heat generated at the end of the flat wire winding (3) of the motor is mainly conducted to the area of ​​the first guide ring (1-1) and the second guide ring (1-2) through the thermally conductive insulating material (2-1, 2-2). The heat generated at the end of the winding is discharged in time by the coolant filling the coolant channels dug in the first guide ring (1-1) and the second guide ring (1-2) through the coolant flow channel (7).

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