Stator core axial channel for temperature regulation of electric motor

Abstract

Aspects of the present disclosure relate to a stator core axial passage for temperature regulation of an electric motor. An electric motor includes a stator and a rotor. The stator includes a stator body having a plurality of stator coil slots and a plurality of stator coils respectively disposed within the plurality of stator coil slots, each stator coil slot being disposed on a radial inner side of the stator body facing the rotor. The stator also includes a base mechanically coupled to the stator body and configured to receive the fluid via the manifold and to dispense the fluid through a cavity formed between the base and the stator body. Each stator coil slot includes an opening forming a channel extending longitudinally across the stator body for dispensing fluid through the channel and thermally interacting with the plurality of stator coils and the stator body. Accordingly, the temperature of the electric motor can be adjusted.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 592,134, filed on October 20, 2023, entitled “STATOR CORE AXIAL CHANNELS FORTEMPERATURE REGULATION OF ELECTRIC MOTOR,” the disclosure of which is expressly incorporated herein by reference in its entirety. Background Art

[0003] The present disclosure relates generally to the automotive, manufacturing and industrial equipment fields. More specifically, the present disclosure relates to stator core axial passages for temperature regulation of electric motors. Summary of the invention

[0004] The present specification as a whole relates to an electric motor including a stator and a rotor. The stator includes a stator body, the stator body including a plurality of stator coil slots and a plurality of stator coils respectively arranged in the plurality of stator coil slots, each of the plurality of stator coil slots being arranged on the radial inner side of the stator body facing the rotor. The stator also includes a substrate, which is mechanically coupled to the stator body and is configured to receive a fluid via a manifold and distribute the fluid through a cavity formed between the substrate and the stator body. Each of the plurality of stator coil slots includes an opening forming a channel, which extends longitudinally across the stator body for distributing the fluid through the channel and thermally interacting with the plurality of stator coils and the stator body. Thus, the temperature of the electric motor can be adjusted.

[0005] According to one or more aspects of the present disclosure, a stator body includes a plurality of stator coil slots and a plurality of stator coils respectively arranged in the plurality of stator coil slots, each of the plurality of stator coil slots being arranged on the radial inner side of the stator body facing the rotor; and a base, which is mechanically connected to the stator body and is configured to receive a fluid via a manifold and distribute the fluid through a cavity formed between the base and the stator body, wherein each of the plurality of stator coil slots includes an opening forming a channel, which extends longitudinally across the stator body for distributing the fluid through the channel and thermally interacting with the plurality of stator coils and the stator body.

[0006] According to one or more aspects of the present disclosure, a vehicle includes a drive unit, which includes a stator and a rotor. The stator includes: a stator body, the stator body including a plurality of stator coil slots and a plurality of stator coils respectively arranged in the plurality of stator coil slots, each of the plurality of stator coil slots being arranged on the radial inner side of the stator body facing the rotor; and a base, the base being mechanically coupled to the stator body and configured to receive a fluid via a manifold and distribute the fluid through a cavity formed between the base and the stator body, wherein each of the plurality of stator coil slots includes an opening forming a channel, the channel extending longitudinally across the stator body for distributing the fluid through the channel and thermally interacting with the plurality of stator coils and the stator body. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Certain features of the subject technology are set forth in the appended claims. However, for purposes of explanation, several embodiments of the subject technology are set forth in the following figures.

[0008] Figure 1 A perspective cross-sectional view of an example electric motor is shown in accordance with one or more implementations of the subject technology.

[0009] Figure 2 One or more specific implementations of the subject technology are shown. Figure 1 A cross-sectional view of a portion of an electric motor.

[0010] Figure 3 A perspective view of an example stator is shown in accordance with one or more implementations of the subject technology.

[0011] Figure 4 A perspective rear-facing view of an example stator base panel is shown in accordance with one or more implementations of the subject technology.

[0012] Figure 5 One or more specific implementations of the subject technology are shown. Figure 3 A perspective cross-sectional view of a portion of a stator.

[0013] Figure 6 One or more specific implementations of the subject technology are shown. Figure 3 Front view of the stator.

[0014] Figure 7 A cross-sectional view of a portion of a stator coil slot having notched channels in accordance with one or more implementations of the subject technology is shown.

[0015] Figure 8 One or more specific implementations of the subject technology are shown. Figure 7 Another view of the portion of the stator coil slots having notched channels.

[0016] Fig. 9 A cross-sectional view of a portion of a stator coil slot having rounded corner channels in accordance with one or more implementations of the subject technology is shown.

[0017] Fig.10 One or more specific implementations of the subject technology are shown. Figure 3 A perspective cross-sectional view of a portion of a stator.

[0018] Fig.11 A cross-sectional view of a portion of a stator is shown in accordance with one or more implementations of the subject technology.

[0019] Fig.12 Exemplary embodiments of vehicles according to aspects of the present disclosure are shown. DETAILED DESCRIPTION

[0020] The specific embodiments set forth below are intended to be described as various configurations of the subject technology, and are not intended to represent the only configurations that can practice the subject technology. The accompanying drawings are incorporated herein and constitute a part of the specific embodiments. The specific embodiments include specific details in order to provide a thorough understanding of the subject technology. However, the subject technology is not limited to the specific details set forth herein, and one or more other specific implementations can be used to practice. In one or more specific implementations, well-known structures and components are shown in block diagram form to avoid confusion to the concepts of the subject technology.

[0021] Electric machines (including motors and generators) function in a wide variety of applications. Fundamental to their design and operation are several types of losses, each of which can significantly affect their performance. These losses range from thermal losses, resistive losses occurring in the winding conductors, to hysteresis, eddy currents, and excess losses in the motor core.

[0022] Quantification of losses is important to the understanding and evaluation of electric machines. This quantification is usually expressed through an efficiency rating, which measures the motor's ability to convert electrical power into mechanical power. Efficiency is usually calculated using the following formula: Efficiency = Output Power / Input Power, or equivalently, as 1 minus the ratio of losses to input power. These losses manifest themselves in various forms, including dissipation of energy in the form of heat, sound, vibration, and other undesirable effects.

[0023] Heat or thermal losses within the motor are a particularly important aspect of these losses. They have a compounding effect, contributing to increased resistance within the system and therefore increasing the rate of losses. Furthermore, motors are constructed using materials that operate within certain temperature thresholds to prevent damage. Exceeding these thresholds may result in undesirable consequences, such as derating of the magnets or reduction in the electrical strength of the stator winding enamel.

[0024] Various techniques have been developed to mitigate heat losses within electric machines. Examples include the implementation of a water jacket that uses conduction and convection to extract heat directly from the stator core. Additionally, direct cooling methods employ convection-based mechanisms, such as oil mist, to remove heat from the stator core and windings.

[0025] The stator core (often referred to as the "stack") consists of a large mass of laminated electrical steel and serves as a thermal energy reservoir within the motor. Effective and direct cooling of the stator core offers the potential to significantly reduce the thermal energy retained within the motor, thus enhancing its overall performance and reliability.

[0026] This specification as a whole relates to a stator core in an electric motor, which is a component composed of a laminated iron core and copper windings. The coils of the stator can be operated to generate a rotating magnetic field. When the electric motor is operating, the electric motor generates heat due to the resistance of the windings and the core losses associated with the changes in magnetic flux. If the temperature of the stator core rises too high and is not effectively regulated, several problems may occur that adversely affect the life and / or performance of the electric motor. Therefore, the temperature of the electric motor can be regulated by distributing a fluid through a channel formed through and around the stator core as needed.

[0027] The present disclosure provides a solution to the problem of effective cooling within the stator core of an electric machine. In one or more specific embodiments, the stator core includes axial channels for directing a cooling fluid through a manifold, thereby enabling direct cooling of the stator core steel windings and copper windings. In one or more specific embodiments, the axial channels include channel geometry in the slots themselves to directly cool the copper conductors and core material. The channel configuration of these axial channels promotes effective cooling and balances the flux paths. Adjustable channel geometry features provide flexibility for specific cooling needs. The stator core also includes a sealed manifold that introduces cooling fluid into these channels and can also promote end turn cooling. The axial channel configuration and geometry promote uniform temperature distribution and effective flow management to obtain optimal thermal benefits without excessive power requirements.

[0028] In certain embodiments, the motors described herein may include features of a synchronous electric motor. However, it should be understood that one or more features of the present disclosure may be applied to one of a variety of motor types, including an induction motor (IM), a synchronous electric motor, an externally excited synchronous motor (EESM), a permanent magnet synchronous electric motor (PMSM), a line-start synchronous motor (LSSM), a line-start permanent magnet motor (LSPMM), etc.

[0029] refer to Figure 1 , the motor may include a stator and a rotor for providing a rotational output on a shaft. Figure 1 is a partial perspective view of a motor 100 having a stator 110 and a rotor 150 .

[0030] In some embodiments, such as Figure 1 As shown, the motor 100 may include a generally cylindrical rotor shaft 142 concentrically surrounded by a cylindrical rotor 150. As used herein, "cylindrical" and "annular" refer to a structure having a generally circular inner cross-sectional shape and a possibly generally circular outer cross-sectional shape, but the outer cross-sectional shape may vary to some extent, having flat or irregular areas. The rotor shaft 142 and the rotor 150 are configured to rotate concentrically in unison about a common central axis 144, potentially at a higher number of revolutions per minute (RPM). The rotor 150 may be made of electrical steel. The rotor shaft 142 may be made of steel and / or other possible metals or metal alloys.

[0031] The motor 100 may include a stator 110 including stator coils 120 configured to generate a rotating magnetic field. The rotating magnetic field may be generated by passing a multi-phase current through the stator coils 120. The stator coils 120 may form segments of windings distributed around the rotor 150. For example, Figure 1 As shown, the stator coil 120 may be formed into segments, each segment extending in a direction generally parallel to the central axis 144 of the rotor 150. The rotating magnetic field generated by the stator 110 may rotate around the central axis 144 of the rotor 150. Neither the stator 110 nor the stator coil 120 need to move to generate the rotating magnetic field. For example, the coil may be operated with alternating current, with different segments having currents of different directions and / or magnitudes at any given moment. When the current direction and / or magnitude of each segment of the stator coil 120 changes over time, the magnetic field generated in its vicinity may change accordingly. Therefore, the resulting magnetic field may be characterized as a standing wave magnetic field rotating around the central axis 144 (e.g., having an alternating magnetic field direction extending circumferentially around the central axis 144). The rotating magnetic field may further extend through the rotor 150, which may include permanent magnets 160 and rotor coils 170. The rotating magnetic field generated by the stator 110 may interact magnetically with such components of the rotor 150 to cause the rotor 150 to rotate around the central axis 144.

[0032] The end windings (e.g., crown end windings and / or welded end windings) of the stator coils 120 of the stator 110 may be a conductive material, such as copper or another suitable metal or material. The end windings of the stator coils 120 may protrude axially beyond the rotor 150 and / or concentrically surround the rotor 150. The end windings of the stator coils 120 are connected in parallel and / or in series with each other to form a set of windings having multi-phase terminals that are operably connected to a controller, such as a processing unit of an electronic system described elsewhere herein.

[0033] The rotor shaft 142 and / or the rotor 150 may rotate with a first bearing assembly 115 disposed at a first end of the rotor shaft 142 and a second bearing assembly 117 disposed at a second end of the rotor shaft 142. Thus, when the rotor 150 and / or the rotor shaft 142 responds to the rotating magnetic field generated by the stator 110, the rotor and / or the rotor shaft may rotate about the central axis 144. The rotor shaft 142 may provide a torque output accordingly. Such an output may be detected, for example, by a sensor of an electronic system described elsewhere herein.

[0034] The rotor coil 170 may form a winding segment 172 of its winding that extends within the rotor 150. For example, Figure 1 As shown, the rotor coil 170 may form winding segments 172, each of which extends in a direction generally parallel to the central axis 144 of the rotor 150. Additionally or alternatively, the winding segments 172 may extend longitudinally in a direction generally parallel to the segments of the stator coil 120. Each winding segment 172 may extend to or toward one or both of the longitudinal ends of the rotor 150. For example, a given winding segment 172 may extend longitudinally within the body of the rotor 150 and connect to another winding segment 172 on a circumferentially adjacent pole of the rotor 150. In this way, the winding segments 172 may form a winding that extends both parallel to the central axis 144 and through the central axis 144 to form one or more loops. One or more end windings 174 may be disposed at one or more ends of the rotor 150. Each of the end windings 174 of the rotor coil 170 can be operably connected to a controller, such as a processing unit of an electronic system described further herein. In some embodiments, the end windings 174 can be connected to a power source via one or more brushes (not shown) so that the rotor 150 and rotor coils 170 can rotate while the power source and / or control circuitry provides power (e.g., current) without rotation. Such brushes can also provide a substantially uniform current to the rotor coils 170 so that the resulting temporary magnetic field can be maintained as desired during rotation of the rotor 150. Thus, the end windings 174 can be connected (e.g., using brushes) in a manner that facilitates rotation and direct current (DC) through the rotor coils 170.

[0035] Reference now Figure 2 , the stator and rotor can interact to provide a rotational output. Figure 2 A portion of the motor 100 is shown, but it should be understood that the portion shown may be part of a pattern that is repeated circumferentially around the central axis to form a continuous cylindrical structure. The pattern may be repeated in any number of cycles, so that the illustrated example is not limited to the arrangement shown.

[0036] In some embodiments, such as Figure 2As shown, the stator 110 may include a stator body 112 and a stator coil 120. The stator coil 120 and / or its segments may be positioned in stator coil slots 126 formed in the stator body 112. In one or more specific implementations, the stator coil 120 and / or its segments may be referred to as conductors. The stator coil slots 126 may be arranged on the radially inner side of the stator body 112 facing the rotor 150. The stator coil slots 126 may guide the magnetic field generated by the stator coil 120 toward the rotor 150. The magnetic field may be shaped at least in part by the geometry of the stator body 112. The portion of the stator body 112 located between consecutive stator coil slots 126 on the radially inner side of the stator body 112 may be referred to as a core tooth 128 of the stator body 112.

[0037] In some embodiments, such as Figure 2 As further shown, the rotor 150 may include a rotor body 152. In some embodiments, the rotor coils 170 and / or segments thereof may be positioned within rotor coil slots 156 formed within the rotor body 152. The rotor coil slots 156 may form openings 158 at the radially outer side of the rotor body 152 facing the stator 110. For example, the rotor body 152 may define the openings 158 such that each opening 158 is radially disposed between a corresponding one of the plurality of coil slots 156 and the radially outermost side of the rotor 150. The openings 158 may guide the magnetic field generated by the rotor coils 170 toward the stator 110. The magnetic field may be shaped at least in part by the geometry of the rotor body 152.

[0038] As described herein, the stator coil 120 can be operated to generate a rotating magnetic field. For example, the stator coil 120 can be operated with an alternating current, and different segments thereof have currents of different directions and / or magnitudes at any given moment. When the direction and / or magnitude of the current of each segment of the stator coil 120 changes over time, the magnetic field generated in its vicinity can change accordingly. The rotating magnetic field generated by the stator 110 can interact magnetically with such components of the rotor 150 to rotate the rotor 150. The stator coil 120 of the stator 110 can be operated to generate a rotating magnetic field. For example, the stator coil 120 can be operated with a variable current, and different segments thereof have currents of different directions and / or magnitudes at any given moment. When the direction and / or magnitude of the current of each segment of the stator coil 120 changes over time, the magnetic field generated in its vicinity can change accordingly.

[0039] In one or more specific implementations, the motor 100 can be characterized as a three-phase alternating current (AC) motor, resulting in the inherent occurrence of eddy currents and stator core losses. These phenomena typically result in the generation of heat during motor operation. As a result, the stator 110 core and windings in the stator coils 120 experience an increase in temperature due to the flow of current. Effective cooling of these windings and the stator 110 core is important for reducing resistance and improving overall efficiency, as increased resistance can result in higher losses and risk of motor damage.

[0040] The central issue here revolves around the generation of heat within the motor 100, which requires the use of appropriate cooling measures. In one or more specific embodiments, the motor 100 is bolted to the housing. In one or more other specific embodiments, the motor 100 is shrink-fitted into the housing. The shrink-fit construction may involve heating the housing, placing the stack (e.g., the stator body 112) within the housing, and allowing the housing to cool, thereby enclosing the stator 110 core capsule within the housing. This shrink-fit construction may rely on friction to fix the position of the stator 110 and prevent rotation. In one or more other specific embodiments, this shrink-fit construction may include limited space to accommodate the installation of spray bars and other active cooling mechanisms used in electric motor designs.

[0041] In one or more implementations, the stator 110 core can be cooled around its outer diameter. In other drive units, oil is flowed through a rod positioned above the stator 110. A spray is then directed downward toward the end windings and sometimes toward the stator body 112. This enables an air cavity to be provided above in which items can be contained. In one or more implementations, this cooling technique can be performed using cutouts in the outer diameter by applying heat shrink.

[0042] The subject technology provides a method to eliminate the spray bar and instead directly address the fundamental source of heat generation in the stator 110 core, thereby effectively regulating the temperature of the motor 100. Figure 3 As discussed, cooling of the motor 100 may be performed by the stator body 112 itself to maintain an optimal temperature in the motor 100. For example, a manifold-like structure is introduced into the stator 110 core, the primary purpose of which is to target the primary heat sources within the stator 110. Most of the heat may emanate from the bottom portion of the conductor, which may be free of steel or convenient cooling paths. To address this issue, stator coil slots 126 are incorporated so that the directed fluid flow can interact closely with the windings of the stator coils 120. This approach effectively addresses the heat generated within the stator 110 core due to the flux paths created by the stator coil 120 windings, and simultaneously cools the wires, thereby causing resistive losses due to the current flowing through the wires.

[0043] Figure 3A perspective view of an example stator according to one or more implementations of the subject technology is shown. Figure 3 In the present invention, the stator 110 includes a stator body 112 (also referred to herein as a "core"). The composition of the stator body 112 can be composed of several thin steel layers that are obtained from coils and processed through progressive dies. The manufacturing process can involve stamping out various features, including slots, outer diameters (OD), inner diameters (ID), and similar features. In one or more specific implementations, innovation focuses on the design of a mold that can incorporate additional features on top of the slots, which can be stamped directly into the steel sheet. In one or more specific implementations, steel sheets of various shapes and sizes are used in the manufacturing process.

[0044] Although the steel plates are typically a quarter millimeter thick, the entire core measures about 125 millimeters. The core assembly includes approximately 500 steel plates. In one or more specific implementations, the core bonding method includes a variety of techniques. For example, the bonding process may include gluing or welding, among other methods. In one or more specific implementations, the subject technology is not limited to a specific type of core bonding; it is applicable to any existing core bonding technology.

[0045] In one or more specific implementations, the stator 110 includes a substrate 330 located on one end of the stator body 112. The substrate 330 is a component that can be produced by injection molding using a material such as nylon, PPS, or similar materials. Once molded, the substrate 330 can then be coupled to a specific surface within the stator body 112. For example, the substrate 330 can be bonded to the stator body 112 by epoxy resin. In other examples, the substrate 330 can be coupled to the stator body 112 in an appropriate position by a clamping method (e.g., using fasteners, clamping the substrate 330 between the wire and the stator body 112, clamping the substrate 330 between the stator body 112 and the motor housing, etc.). In one or more other specific implementations, the substrate 330 can be formed of metal or include a metal material. In one or more other specific implementations, the substrate 330 can be formed as an integral part of the stator body 112. For example, a plurality of steel laminates having a specific cross-section can be stacked together to form the substrate 330. In one or more implementations, the base 330 can have a circular inner cross-sectional shape and a circular outer cross-sectional shape that is substantially aligned with the outer side surface of the stator body 112. In one or more other implementations, the stator 110 includes the base 330 located on two opposing ends of the stator body 112.

[0046] In one or more implementations, axial passages (e.g., axial passages 360) are incorporated into the stator body 112 to facilitate the cooling fluid being directed through the stator body 112 via the manifold 340. For example, the axial passages 360 (not visible) are indicated by dashed lines and are located where they will allow the cooling fluid to remove heat from the conductors and the teeth / core / steel of the stator body 112 via direct contact with these components. In one or more implementations, the inlet of the manifold 340 may have a radial configuration. In one or more other implementations, the inlet of the manifold 340 may have an axial configuration. As shown in FIG. Figure 3 As shown, the manifold 340 has a radially configured inlet. Figure 3 As shown, the base 330 includes a deformed portion on the rear surface of the base 330, so that when the base 330 is coupled to the stator body 112, the base 330 can form an internal cavity (e.g., cavity 350) between the rear surface of the base 330 and the outer side surface of the stator body 112. This configuration allows direct cooling of the stator 110 core steel and the copper windings located within the stator coil slots 126.

[0047] In one or more specific implementations, the size of the stator body 112 can be minimized in order to optimize the electromagnetic design. This approach involves reducing the steel content, thereby creating more space for the flux path. Although this reduction in the size of the stator body 112 can affect the torque output of the entire system, it increases effective heat dissipation. In this regard, heat removal exceeds heat generation, thereby improving overall performance.

[0048] The distribution of thermal energy and peak temperature management within the electric motor is controlled by the distribution of oil flowing through the axial passages of the stator 110 core. This configuration can promote substantially uniform temperature gradients within the motor 100 and help control the size and location of hot spots. In addition, the cooling architecture of the motor 100 can accommodate the necessary fluid flow without adversely affecting lubrication and cooling system limitations.

[0049] Figure 4 A perspective rear view of an example stator base panel according to one or more implementations of the subject technology is shown. Figure 4 In the embodiment, the substrate 330 may be disposed on the substrate 330 facing the rotor (eg, Figure 2 The rotor 150 of the embodiment of the present invention forms an opening 434 on the radially inner side thereof, and when the base 330 is coupled to the stator body 112, the opening is aligned with the stator core (eg, Figure 3 The slot opening of the stator body 112 (e.g., Figure 2 The stator coil slots 126 are aligned. Figure 4As shown, the base 330 includes an alignment pin 432 that protrudes outward from the rear surface of the base 330 and is arranged at a designated position on the rear surface of the base 330. The alignment pin 432 may be a molded feature that may be produced by injection molding using a material similar to that of the base 330. The alignment pin 432 may be used to position the base 330 on the outer side surface of the stator body 112, such as Figure 3 as shown, and ensures the retention of the substrate 330.

[0050] The base 330 includes an input port of the manifold 340 located on the front surface of the base 330 for the entry of the cooling fluid and an output port of the manifold 340 located on the rear surface of the base 330 for the exit of the cooling fluid (e.g., Figure 4 112) to distribute cooling fluid through the axial passages of the stator body 112. The base 330 includes a deformed portion located on the rear surface of the base 330 so that when the base 330 is fastened to the stator body 112, the base 330 can form a cavity 350 between the rear surface of the base 330 and the outer side surface of the stator body 112. In this regard, the base 330 facilitates the controlled extraction and transfer of cooling fluid from the metal to a predetermined location. This ability facilitates routing the cooling fluid through a designated passage and then directing it through the axial passages of the stator body 112. For example, the axial passages are located in a position that will allow the cooling fluid to remove heat from the conductors and the teeth / core / steel of the stator body 112 via direct contact with these components.

[0051] Figure 5 One or more specific implementations of the subject technology are shown. Figure 3 4. The stator body 112 may include fastening locations 536 for fastening, clamping, and / or bonding the substrate 330 to the stator body 112. For example, the substrate 330 may be bonded to the stator body 112 at the fastening locations 536 by epoxy. In other examples, the substrate 330 may be coupled to the stator body 112 at an appropriate position at the fastening locations 536 by a clamping method (e.g., using fasteners, clamping the substrate 330 between a wire and the stator body 112, clamping the substrate 330 between the stator body 112 and a motor housing, etc.). The fastening locations 536 may be disposed circumferentially around an outer radial diameter of the substrate 330 and between the openings 434 around an inner radial diameter of the substrate 330. In one or more specific implementations, the fastening locations 536 may be disposed at a radially inner side of the substrate 330 and at a radially outer side of the substrate 330.

[0052] Figure 6 One or more specific implementations of the subject technology are shown. Figure 312. To introduce cooling fluid or oil into the axial channels formed along the longitudinal axis of the stator coil slots 126, the base 330 includes a sealed manifold (e.g., manifold 340) to direct the fluid from a source and supply it to the axial channels adjacent to the stator coil slots 126 for temperature regulation of the stator body 112 and the motor 100. In addition, the manifold 340 can be equipped with strategically positioned and sized orifices 638 to enable the cooling fluid to be sprayed onto the end turns in opposite directions, thereby creating an overall cooling solution covering the stator coil slots 126, the stator body 112, and the end turns at both ends of the motor 100.

[0053] In one or more specific implementations, the stator 110 includes stator coil slots 126 (eg, a subset of the stator coil slots 620) arranged on a portion of the stator body 112 facing the rotor (eg, Figure 2 The stator body 112 is radially inwardly disposed on the rotor 150 of the stator body 112. Each of these stator coil slots 126 may include a channel geometry that is an extension of the stator coil slot 126 itself. This structural configuration allows for distribution (e.g., pumping) of cooling fluid or oil through the stator body 112, thereby providing a direct cooling mechanism that effectively addresses the primary heat sources, including the copper conductors and the core material itself.

[0054] In one or more specific implementations, the base 330 includes an orifice 638 through which the cooling fluid flows out and contacts the outer surface of the stator coil 120. The orifice 638 can be used as an output hole so that the fluid can flow out through the orifice 638 through a process driven primarily by pressure. The cooling fluid can be directed to spray onto the windings of the stator coil 120, thereby promoting the cooling process at one end, which then continues to cool the windings at the other end. In one or more specific implementations, the channel positioning is also used to direct the pressurized cooling fluid to be sprayed on the other end turns at the end opposite to the orifice 638, thereby further removing heat from this portion of the motor 100 as well.

[0055] The orifice 638 may include a specific geometry that allows it to protrude slightly from the front surface of the substrate 330. The orifice 638 may be sized according to desired parameters, including frequency and flow rate. To control the cooling rate, a pump may be used for adjustment. Increasing the RPM of the pump increases the flow rate, thus increasing the pressure, which allows the cooling rate to be varied. However, cooling may be limited to a specific temperature range.

[0056] In one or more specific implementations, the apertures 638 may be arranged radially around the inner side of the base 330 and may be located between the openings 434. The base 330 may include any number of apertures 638, and the number of apertures 638 may vary according to the specific implementation that suits the specific cooling requirements without departing from the scope of the present disclosure. In one or more specific implementations, the base 330 includes apertures 638 located between consecutive openings 434. In one or more other specific implementations, the base 330 includes apertures 638 located between non-continuous openings 434.

[0057] In one or more other specific implementations, the stator body 112 includes an oriented transition between the stator coil slots 126. For example, the stator body 112 may include an arrangement of the stator coil slots 126 in an alternating pattern, with an even-odd slot arrangement at one end and a different configuration at the opposite end. In this regard, the stator body 112 may include a mechanism located at the center of the stator body 112 to facilitate such a transition. The mechanism may guide movement from one stator coil slot 126 to another stator coil slot, thereby ensuring a symmetrical distribution of heat generation. Therefore, each stator coil slot 126 is considered for integration of these transitions, and the size of the transition elements can be adjusted as needed.

[0058] Figure 7 A cross-sectional view of a portion of a stator coil slot having a notched channel according to one or more implementations of the subject technology is shown. A subset of the stator coil slots 620 includes a stator coil 120 having a stator coil slot 126. In one or more implementations, the stator coil slot 126 includes a notch 728 that establishes an alternate path for fluid. The path traverses the internal channel, exiting from the channel to promote cooling on both the outer and inner surfaces of the stator body 112.

[0059] The stator coil slot 126 may include a plurality of openings formed around its periphery. The notch 728 may include various arrangements relative to the stator coil slot 126 for use as an axial passage, whether located on the top edge of the stator coil slot 126 (see Figure 7 ) or on the side of the stator coil slot 126 (see Fig. 9 ).like Figure 7 As shown, notches 728 are formed on the top edges of the stator coil slots 126 .

[0060] The notches 728 formed on the top edges of the stator coil slots 126 may include a channel geometry that facilitates providing sufficient cooling fluid flow to remove more heat than is generated without adversely affecting the radial and tangential flux paths within the stator body 112. The notches 728 may take a variety of shapes, such as triangular or circular. Figure 7 As shown, the recess 728 has a rectangular shape.

[0061] Adjustment of channel size, location, and frequency can be achieved by modifying the lamination geometry, allowing flexibility in cooling strategy. This modification enables selection of different cooling channel configurations based on specific cooling requirements and the electromagnetic (EM) design of the motor 100.

[0062] Figure 8 One or more specific implementations of the subject technology are shown. Figure 7 Another view of the portion of the stator coil slot having a notched channel. The notch 728 formed on the top edge of the stator coil slot 126 can be defined by dimensions: width (W1) and height (H). In one or more specific implementations, the height H of the notch 728 is minimized while increasing the width W1 of the notch 728, thereby facilitating optimal design considerations. In one or more specific implementations, the width W1 of the notch 728 is less than the width W2 of the stator coil slot 126 that accommodates the stator coil 120.

[0063] Fig. 9 A cross-sectional view of a portion of a stator coil slot 126 having a rounded corner channel according to one or more implementations of the subject technology is shown. In one or more implementations, the stator coil slot 126 includes a notch 928. In one or more implementations, the stator coil slot 126 includes a single notch 928. In one or more other implementations, the stator coil slot 126 includes a pair of notches 928. Fig. 9 As shown, the stator coil slot 126 includes a pair of notches 928 formed on the corner top edges of the stator coil slot 126. Fig. 9 As shown, each notch in the pair of notches 928 has a circular shape.

[0064] Fig.10 One or more specific implementations of the subject technology are shown. Figure 3 A perspective cross-sectional view of a portion of a stator. Figure 3 As conceptually shown in FIG. 1002 , a fluid (e.g., cooling fluid or oil) enters the manifold 340 from a source. The substrate 330 is separated from at least a portion of the outer surface steel plate of the stator body 112 to create a cavity (e.g., Figure 3 The embodiment of the present invention is a cavity 350 of the base 330, wherein the fluid is distributed internally around the annulus formed by the cavity 350. At 1004, the flow of the fluid occurs within the annulus, which is effectively sealed around the radial edge of the base 330, thereby directing the fluid downward and routing it around the annulus, as shown by the dashed arrow line. The size of the annulus can be adjusted to accommodate specific flow rate and pressure requirements.

[0065] At 1006, the fluid distributed around the annulus can exit the base 330 through the orifices 638 to cool the end turns of the stator coil 120. At 1008, the fluid can enter the axial channel (represented as the notch 728 formed around the stator coil slots 126) to directly cool the stacked steel plates of the stator body 112 and the windings of the stator coil 120. For example, the axial channel is located where it will allow the cooling fluid to remove heat from the conductors and the teeth / core / steel of the stator body 112 via direct contact with these components. In order to provide a comprehensive understanding of this construction, the windings of the stator coil 120 appear in this context. These windings are separated from the cooling fluid and the stator coil 120 by a barrier. The barrier can be positioned as close as possible to promote cooling of the windings.

[0066] The base 330 includes a continuous passageway within a cavity 350 of the base 330. In this regard, the fluid enters via the manifold 340 at one end of the base 330, traverses a path (e.g., a labyrinthine path) within the cavity 350 of the base 330, and exits the base 330 at the other end of the stator body 112 via an axial passage and / or via an orifice 638. The fluid may be hotter upon exiting, resulting in reduced cooling efficiency. However, the subject technology directs the fluid outward, effectively utilizing any remaining thermal capacity to absorb heat from heat sources located within the stator body 112.

[0067] Fig.11 A cross-sectional view of a portion of a stator according to one or more implementations of the subject technology is shown. At 1110, fluid enters the axial channel 1130 via the manifold 340 and enters a region having a liner that defines a fluid path relative to the stator coils 120. In one or more implementations, the thickness of the liner is substantially small, falling in the range of hundreds of microns. For example, the liner may measure approximately 0.2 millimeters or 200 microns. Notably, the liner may exhibit effective heat conduction properties, enabling direct cooling through it.

[0068] At 1120, the fluid exits the axial channel 1130 at the opposite end of the stator body 112 for additional cooling of the end turns of the stator coil 120. This process involves the fluid collecting heat from the heat source and returning to the system via a sump and heat exchanger. Therefore, it minimizes the need for large amounts of circulation of the fluid, as the goal is to significantly heat the fluid by directly managing the heat source.

[0069] According to some embodiments, for example Fig.12 As shown, an example implementation of a movable device takes the form of a vehicle 1200. In some embodiments, the vehicle 1200 is a sport utility vehicle. Fig.12In the illustrated embodiment, the vehicle 1200 is a truck. In general, the vehicle 1200 may take the form of any motor vehicle, including a motor vehicle having an internal combustion engine and / or one or more electric motors. In this regard, other specific implementations of the vehicle 1200 may include a land vehicle, such as, by way of non-limiting example, a car (e.g., a sedan, a hatchback), a minivan, a motorcycle, an electric scooter, or a commercial truck. Further, by way of non-limiting example, other specific implementations of the vehicle 1200 may include a sea or air transport vehicle, an airplane, a helicopter, a submarine, a ship, or a drone.

[0070] As shown, the vehicle 1200 includes a battery pack 1202. The battery pack 1202 may be coupled (e.g., electrically coupled) to one or more power systems of the vehicle 1200 to provide power to the one or more power systems. The battery pack 1202 may include one or more battery modules ( Fig.12 1202), each of the one or more battery modules carries a number of battery cells. In some embodiments, the battery pack 1202 does not include any battery modules and is in the form of a cell-to-pack configuration. In addition, the battery cells of the battery pack 1202 may include rechargeable battery cells, and therefore, the battery pack 1202 may be referred to as a rechargeable battery pack. In this regard, the vehicle 1200 may include a port 1204 (e.g., a charging port) that is designed to receive a cable connector (e.g., a charging port) for providing power (e.g., AC power). Fig.12 1202), which is converted to DC power to charge the battery pack 1202. The port 1204 can be accessed by removable cover 1206. As a non-limiting example, the vehicle 1200 may include a chassis 1208 for supporting the battery pack 1202 and various other components of the vehicle 1200 ( Fig.12 not shown), such as suspension and differential.

[0071] The battery pack 1202 may be coupled to a drive unit 1210a and a drive unit 1210b. The drive units 1210a and 1210b may include, for example, a motor, an inverter, a gearbox, and a differential. The drive unit 1210a is typically located at the front of the vehicle 1200, while the drive unit 1210b is typically located at the rear of the vehicle 1200. Therefore, the drive unit 1210a and the drive unit 1210b may be referred to as a front drive unit and a rear drive unit, respectively. Although two drive units (e.g., drive units 1210a and 1210b) are shown, the vehicle 1200 may include additional drive units. In some embodiments, each of the drive units 1210a and 1210b is an internal combustion engine. In Fig.12 In the illustrated embodiment, each of the drive units 1210a and 1210b is an electric motor (e.g., Figure 11200). In this regard, drive unit 1210a and drive unit 1210b can use energy (e.g., electrical energy) stored in battery pack 1202 for propulsion so as to drive (e.g., rotationally drive) wheel 1212a and wheel 1212b, respectively. Wheels 1212a and 1212b each represent additional front and rear wheels of vehicle 1200, respectively. By driving wheels 1212a and 1212b, vehicle 1200 can move in various directions. In one or more specific implementations, each of drive units 1210a and 1210b includes a motor 100 having a stator 110, including axial channels formed in the stator coil slots and base for distributing a cooling fluid in and around the stator body 112 and the stator coil slots 126, thereby temperature regulating the motor 100.

[0072] Additionally, the vehicle 1200 may also include a vehicle management system 1214 that is configured to provide torque commands to the drive units 1210a and 1210b. The drive units 1210a and 1210b may operate according to torque shaping logic provided by the vehicle management system 1214. In this regard, the drive units 1210a and 1210b may generate torque outputs that are provided to the wheels 1212a and 1212b, respectively, based on the torque shaping logic, which determines the speed at which the vehicle 1200 is traveling.

[0073] Unless otherwise specified, an element mentioned in the singular is not intended to represent one and only one, but one or more. For example, "a" module may refer to one or more modules. In the absence of further constraints, an element beginning with "a", "an", "the" or "said" does not exclude the presence of other identical elements.

[0074] Headings and subheadings, if any, are used for convenience only and do not limit the present disclosure. The word exemplary is used to mean serving as an example or illustration. To the extent that the terms "including" or "having" and the like are used, such terms are intended to be inclusive in a manner similar to the term "comprising" as understood when "comprising" is used as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0075] Phrases such as an aspect, this aspect, another aspect, some aspects, one or more aspects, a specific implementation, this specific implementation, another specific implementation, some specific implementations, one or more specific implementations, an embodiment, this embodiment, another embodiment, some embodiments, one or more embodiments, a construction, this construction, another construction, some constructions, one or more constructions, subject technology, this disclosure, the present disclosure, other variations thereof, etc. are for convenience and do not imply that the disclosures associated with such phrases are necessary for the subject technology, or that such disclosures are applicable to all constructions of the subject technology. The disclosures associated with such phrases may be applicable to all constructions or one or more constructions. The disclosures associated with such phrases may provide one or more examples. Phrases such as an aspect or some aspects may refer to one or more aspects, and vice versa, and this is similarly applicable to other aforementioned phrases.

[0076] The phrase "at least one" preceding a list of items, with the terms "and" or "or" used to separate any of those items, modifies the list as a whole, rather than as each constituent item of the list. The phrase "at least one" does not require selection of at least one item; rather, the phrase allows for a meaning that includes at least one of any of those items, and / or at least one of any combination of those items, and / or at least one of each of those items. As an example, each of the phrases "at least one of A, B, and C" or "at least one of A, B, or C" means only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

[0077] It should be understood that the specific order or level of the disclosed steps, operations or processes is an illustration of an exemplary method. Unless otherwise clearly stated, it should be understood that the specific order or level of steps, operations or processes can be performed in different orders. Some of the steps, operations or processes can be performed simultaneously. The attached method claims (if any) present the elements of various steps, operations or processes in a sample order, and are not meant to be limited to the specific order or level presented. These can be performed serially, linearly, in parallel or in different orders. It should be understood that the instructions, operations and systems described can usually be integrated together in a single software / hardware product or encapsulated in multiple software / hardware products.

[0078] Terms such as top, bottom, front, back, side, horizontal, vertical, etc. refer to an arbitrary reference frame, not the ordinary gravitational reference frame. Thus, such terms may extend upward, downward, diagonally, or horizontally in a gravitational reference frame.

[0079] The present disclosure is provided to enable any person skilled in the art to practice the various aspects described herein. In some instances, well-known structures and components are shown in block diagram form to avoid confusion with the various concepts of the subject technology. The present disclosure provides various examples of the subject technology, and the subject technology is not limited to these examples. Those skilled in the art will readily appreciate various modifications to these aspects, and the principles described herein may be applied to other aspects.

[0080] All structural and functional equivalents of the various aspects of the elements described throughout this disclosure are known or will become known to those of ordinary skill in the art, and these equivalents are expressly incorporated herein by reference and are intended to be included in the claims. In addition, nothing disclosed herein is intended to serve the public, regardless of whether such disclosure is explicitly stated in the claims. Any claim element should not be interpreted under the provisions of 35 U.S.C. § 112 (f) unless the element is explicitly stated using the phrase "means for..." or, in the case of a method claim, the phrase "step for..." is used to state the element.

[0081] Those skilled in the art will appreciate that the various illustrative frames, modules, elements, parts, methods and algorithms described herein can be implemented as hardware, electronic hardware, computer software or a combination thereof. In order to illustrate this interchangeability of hardware and software, various illustrative frames, modules, elements, parts, methods and algorithms have been generally described above in terms of their functionality. Whether this functionality is implemented as hardware or software depends on the specific application and the design constraints imposed on the entire system. Those skilled in the art can implement the described functionality in different ways for each specific application. Various parts and frames can be arranged differently (e.g., arranged in different orders or divided in different ways), all of which do not depart from the scope of this subject technology.

[0082] The names, figure descriptions, abstracts, and drawings are hereby incorporated into this disclosure and are provided as illustrative examples of the disclosure rather than as limiting descriptions. This document is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that for the purpose of simplifying the present disclosure, the description provides illustrative examples and various features are grouped together in various specific implementations. The method of the present disclosure should not be interpreted as reflecting an intention that the claimed subject matter requires more features than those expressly stated in each claim. On the contrary, as reflected in the claims, the inventive subject matter lies in less than all the features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim independently serving as a separately claimed subject matter.

[0083] The claims are not intended to be limited to the aspects described herein, but should be accorded the full scope consistent with the language of the claims and encompassing all legal equivalents. Nevertheless, none of the claims is intended to encompass subject matter that fails to satisfy the requirements of applicable patent law, nor should it be interpreted in such a manner.

Claims

1. A stator for an electric motor, the stator comprising: a stator body, the stator body comprising a plurality of stator coil slots and a plurality of stator coils respectively disposed in the plurality of stator coil slots, each of the plurality of stator coil slots being arranged on a radially inner side of the stator body facing the rotor; and a substrate mechanically coupled to the stator body and configured to receive a fluid via a manifold and distribute the fluid through a cavity formed between the substrate and the stator body, Each of the plurality of stator coil slots includes an opening forming a channel extending longitudinally across the stator body for distributing the fluid therethrough. 2 . The stator of claim 1 , wherein the base includes an orifice configured to output the fluid from the cavity based on a pressure within the cavity. 3 . The stator of claim 1 , wherein the base is coupled to the stator body at one or more locations at a radially inner side of the base and at a radially outer side of the base.

4. The stator of claim 1 , wherein the base includes a plurality of openings located at a radially inner side of the base facing the rotor, the plurality of openings being aligned with the plurality of stator coil slots of the stator body based at least in part on the base being mechanically coupled to the stator body. 5 . The stator of claim 1 , wherein the opening comprises a channel geometry having a first width, the first width being less than a second width of a corresponding stator coil slot.

6. The stator of claim 5, wherein the channel geometry of the opening comprises a rectangular shape.

7. The stator of claim 5, wherein the passage geometry of the opening comprises a circular shape.

8. A motor, comprising: Rotor; and A stator, the stator comprising: a stator body, the stator body comprising a plurality of stator coil slots and a plurality of stator coils respectively disposed in the plurality of stator coil slots, each of the plurality of stator coil slots being arranged on a radially inner side of the stator body facing the rotor; and a substrate mechanically coupled to the stator body and configured to receive a fluid via a manifold and distribute the fluid through a cavity formed between the substrate and the stator body, Each of the plurality of stator coil slots includes an opening forming a channel extending longitudinally across the stator body for distributing the fluid therethrough.

9. The motor of claim 8, wherein the base includes an orifice configured to output the fluid from the cavity based on a pressure within the cavity. 10 . The motor of claim 8 , wherein the base is coupled to the stator body at one or more locations at a radially inner side of the base and at a radially outer side of the base.

11. The motor of claim 8, wherein the base includes a plurality of openings located at a radially inner side of the base facing the rotor, the plurality of openings being aligned with the plurality of stator coil slots of the stator body based at least in part on the base being mechanically coupled to the stator body. 12 . The motor of claim 8 , wherein the opening comprises a channel geometry having a first width that is less than a second width of a corresponding stator coil slot.

13. The motor of claim 12, wherein the passage geometry of the opening comprises a rectangular shape.

14. The motor of claim 12, wherein the passage geometry of the opening comprises a circular shape.

15. A carrier, comprising: a drive unit, the drive unit comprising a stator and a rotor, The stator comprises: a stator body including a plurality of stator coil slots and a plurality of stator coils respectively disposed in the plurality of stator coil slots, each of the plurality of stator coil slots being arranged on a radially inner side of the stator body facing the rotor; and a substrate mechanically coupled to the stator body and configured to receive a fluid via a manifold and distribute the fluid through a cavity formed between the substrate and the stator body, Each of the plurality of stator coil slots includes an opening forming a channel extending longitudinally across the stator body for distributing the fluid therethrough.

16. The carrier of claim 15, wherein the base includes an orifice configured to output the fluid from the cavity based on a pressure within the cavity.

17. The carrier of claim 15, wherein the base is coupled to the stator body at one or more locations radially inward of the base and radially outward of the base.

18. The vehicle of claim 15, wherein the substrate includes a plurality of openings located at a radially inner side of the substrate facing the rotor, the plurality of openings being aligned with the plurality of stator coil slots of the stator body based at least in part on the substrate being mechanically coupled to the stator body.

19. The carrier of claim 15, wherein the opening comprises a channel geometry having a first width, the first width being less than a second width of a corresponding stator coil slot.

20. The carrier of claim 19, wherein the channel geometry of the opening comprises a rectangular shape or a circular shape.

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