Electric machine module cooling system and method

Abstract

Electrical machine module (10), comprising: a housing (12) at least partially defining a machine cavity (22); a coolant jacket at least partially defined by the housing (12); a plurality of coolant openings (68) disposed through portions of the housing (12) to fluidly connect the coolant jacket and the engine cavity (22), at least some of the plurality of coolant openings (68) having a valve seat (86) within the coolant jacket; and one or more solenoid assemblies (70) supported at least partially by the housing (12) and positioned substantially adjacent to at least a portion of the plurality of coolant openings (68), wherein the solenoid assemblies (70) comprise a plunger (74), a coil (76) arranged around a core, and a spring (78), wherein one end of the plunger (74) comprises a valve (85), and the valve (85) is designed and arranged to engage the valve seat (86) to substantially close the coolant opening (68) comprising the valve seat (86), the valve (85) being adapted to move through the coolant in the coolant jacket; and further comprising one or more temperature sensors connected to at least one of the electric machine (20) and the housing (12), the temperature sensors being in communication with at least one or more solenoid assemblies (70), at least some of the solenoid assemblies (70) being configured and arranged to be energized by flowing a current through the solenoid to enable coolant flow from the coolant jacket into the machine cavity (22) based at least in part on the temperature data obtained from the temperature sensors, by the plunger (74) of at least some of the solenoid assemblies (70) being configured and arranged to engage a portion of at least some of the plurality of coolant openings (68), and further comprising an electric machine (20) disposed at least partially within the machine cavity (22) and surrounded by the housing (12), the electric machine (20) being positioned such that the coolant jacket surrounds at least a portion of the electric machine (20), wherein the electric machine (20) has stator winding heads (54) and wherein at least some of the coolant openings (68) are arranged radially outwardly from at least a portion of the stator winding heads (54).

Description

BACKGROUND

[0001] Some conventional electrical machines include a stator assembly arranged around a rotor assembly. Some stator assemblies include multiple conductors positioned within a stator core. During operation of some electrical machines, current flows through at least some of the conductors. To prevent potential short-circuit incidents and / or ground faults, some conventional stator assembly designs require multiple layers of insulation between and beneath the conductors. In addition, during operation of some electrical machines, heat energy can be generated by both the stator assembly and the rotor assembly, as well as some other components of the electrical machine. The increase in heat energy generated by some elements of the electrical machine can lead to inefficient machine operation.

[0002] Document US 2 683 823 A describes an electrical machine module comprising a housing, a machine cavity, and a coolant jacket defined at least partially by the housing. A plurality of coolant openings connect the coolant jacket and the machine cavity. Furthermore, valves are provided that are designed and arranged to regulate the flow of at least a portion of a coolant from the coolant jacket into the machine cavity.

[0003] The document US 7 211 913 B2 describes controlled solenoid valves or solenoid assemblies for dosing and distributing coolant quantities in an electrical machine. SUMMARY

[0004] The invention provides an electric machine module comprising a housing that can define a machine cavity. A coolant jacket can be at least partially defined by the housing. A plurality of coolant openings are disposed through portions of the housing to fluidly connect the coolant jacket and the machine cavity. One or more solenoid assemblies are at least partially carried by the housing and positioned substantially adjacent to at least some of the coolant openings. The solenoid assemblies are configured to regulate a flow of coolant from the coolant jacket into the machine cavity.

[0005] The invention provides an electric machine module comprising a housing at least partially defining a machine cavity. A coolant jacket is at least partially defined by the housing. The electric machine has stator end windings that can be at least partially disposed within the machine cavity such that portions of the electric machine can be at least partially surrounded by the coolant jacket. A plurality of coolant openings are disposed in portions of the housing to fluidly connect the coolant jacket and the machine cavity. At least some of the coolant openings are positioned substantially adjacent the stator end windings. One or more solenoid assemblies, including a plunger, are at least partially carried by the housing and positioned substantially adjacent at least a portion of the plurality of coolant openings.The plunger of at least some of the solenoid assemblies is configured and arranged to engage a portion of at least some of the plurality of coolant openings. In some embodiments, an electronic control module may be in communication with at least a portion of the solenoid assemblies. DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional view of an electric machine module according to an embodiment of the invention. Fig. 2 is a perspective view of an electric machine module according to an embodiment of the invention. Fig. 3 is a perspective view of a stator assembly according to an embodiment of the invention. Fig. 4 is a front view of a stator lamination according to an embodiment of the invention. Fig. 5 is a perspective view of a conductor according to an embodiment of the invention. Fig. 6 is a side view of a stator assembly according to an embodiment of the invention illustrating a temperature differential. Fig. 7 is a partial cross-sectional view of a solenoid assembly according to an embodiment of the invention. Fig. Figure 8A is a partial cross-sectional view of a de-energized solenoid assembly according to one embodiment of the invention. Fig. Figure 8B is a partial cross-sectional view of an energized solenoid assembly according to one embodiment of the invention. DETAILED DESCRIPTION

[0006] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein is for the purpose of description and should not be considered limiting. The use of "comprising," "comprising," or "having," and variations thereof herein means to include the elements listed thereafter and equivalents thereof, as well as additional elements.Unless otherwise specified or limited, the terms "attached," "connected," "supported," and "coupled," and variations thereof, are used broadly and include both direct and indirect attachments, connections, supports, and couplings. Furthermore, "connected" and "coupled" are not limited to physical or mechanical connections or couplings.

[0007] The following discussion is presented to enable one skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the general principles herein may be applied to other embodiments and applications without departing from the embodiments of the invention. Accordingly, it is not intended that the embodiments of the invention be limited to the illustrated embodiments, but are to be given the broadest scope consistent with the principles and features disclosed herein. The following detailed description should be read with reference to the figures, in which like elements have like reference numerals throughout different figures.The figures, which are not necessarily to scale, illustrate selected embodiments and are not intended to limit the scope of the embodiments of the invention. Those skilled in the art will recognize that the examples provided herein have many useful alternatives that fall within the scope of the embodiments of the invention.

[0008] The Fig. 1 and Fig. 2 illustrate an electric machine module 10 according to an embodiment of the invention. The module 10 may include a housing 12 having a sleeve member 14, a first end cap 16, and a second end cap 18. An electric machine 20 may be housed within a machine cavity 22 defined at least partially by the sleeve member 14 and the end caps 16, 18. For example, the sleeve member 14 and the end caps 16, 18 may be connected via conventional fasteners (not shown) or another suitable connection method to enclose at least a portion of the electric machine 20 within the machine cavity 22. In some embodiments, the housing 12 may include a substantially cylindrical container 15 connected to an end cap 17, as shown in Fig. 2. Furthermore, in some embodiments, the housing 12 may include materials that may generally include thermally conductive properties, such as, but not limited to, aluminum or other metals, and materials that can generally withstand the operating temperatures of the electric machine. In some embodiments, the housing 12 may be manufactured using various methods, including casting, molding, extrusion, and other similar manufacturing processes.

[0009] In some embodiments, the housing 12 (i.e., the sleeve member 14 and the end caps 16, 18 and / or the reservoir 15 and the end cap 17) may be disposed within an additional support member (not shown). For example, the support member may include another housing (e.g., a transmission housing) in which the housing 12 may be disposed or to which the housing 12 may be connected. For example only, in some embodiments, a recess may be defined between the housing 12 and the support member. For example, as explained in more detail below, one or more coolant jackets may be defined between the housing 12 and the support member.

[0010] The electric machine 20 may include a rotor assembly 24, a stator assembly 26, and bearings 28 and may be arranged around a shaft 30. As shown in Fig. 1, the stator assembly 26 may substantially surround at least a portion of the rotor assembly 24. In some embodiments, the rotor assembly 24 may also include a rotor hub 32 or may have a "hubless" structure (not shown).

[0011] In some embodiments, the electric machine 20 may be operatively connected to the housing 12. For example, the electric machine 20 may be fitted within the housing 12. In some embodiments, the electric machine 20 may be fitted within the housing 12 using an interference fit, a shrink fit, or similar friction-based fits that may at least partially connect the machine 20 and the housing 12. For example, in some embodiments, the stator assembly 26 may be shrink-fitted into the module housing 12. Further, in some embodiments, the fit may at least partially secure the stator assembly 26, and consequently the electric machine 20, in axial, radial, and circumferential directions.In some embodiments, the fit between the stator assembly 26 and the housing 12 during operation of the electric machine 20 may serve, at least in part, to transfer torque from the stator assembly 26 to the housing 12. In some embodiments, the fit may result in a generally greater amount of torque being held by the module 10.

[0012] The electric machine 20 may be, without limitation, an electric motor, such as a hybrid electric motor, an electric generator, or a vehicle alternator. In some embodiments, the electric machine 20 may be a high-voltage hairpin (HVH) electric motor, an internal permanent magnet electric motor, or an induction motor for hybrid vehicle applications.

[0013] As in Fig. 3, in some embodiments, the stator assembly 26 may include a stator core 34 and a stator winding 36 disposed at least partially within a portion of the stator core 34. For example, in some embodiments, the stator core 34 may include a plurality of laminations 38. With reference to Fig. 4, the sheets 38 may, in some embodiments, have a plurality of substantially radially directed teeth 40. In some embodiments, as in Fig. 3, when at least a portion of the plurality of laminations 38 are substantially assembled, the teeth 40 may be substantially aligned to define a plurality of slots 42 configured and arranged to support at least a portion of the stator winding 36. As shown in Fig. 4, in some embodiments, the laminations 38 may include sixty teeth 40, and consequently, the stator core 28 may include sixty slots 42. In other embodiments, the laminations 38 may include more or fewer teeth 40, and accordingly, the stator core 34 may include more or fewer slots 42. Additionally, in some embodiments, the stator core 34 may have an inner periphery 41 and an outer periphery 43. For example, in some embodiments, the stator core 34 may have a substantially cylindrical configuration such that the inner and outer peripheries 41, 43 may have inner and outer diameters, respectively. However, in other embodiments, the stator core 34 may have other configurations (e.g., square, rectangular, elliptical, regular or irregular polygonal, etc.), and consequently, the inner and outer peripheries 41, 43 may have other dimensions.

[0014] In some embodiments, the stator winding 36 may include a plurality of conductors 44. In some embodiments, the conductors 44 may have a substantially segmented configuration (e.g., a hairpin configuration), as shown in FIGS. Fig. 3 and Fig. 5. For example, in some embodiments, at least a portion of the conductors 44 may include a turn portion 46 and at least two leg portions 48. The turn portion 46 may be disposed between two leg portions 48 to connect the two leg portions 48, which may be substantially parallel. Furthermore, in some embodiments, the turn portion 46 may have a substantially "U-shaped" configuration, although in some embodiments, the turn portion 46 may have a V-shape, a wave shape, a curve shape, and other shapes. Additionally, in some embodiments, as shown in Fig. 5, at least a portion of the conductors 44 may have a substantially rectangular cross-section. In some embodiments, at least a portion of the conductors 44 may have other cross-sectional shapes, such as substantially circular, square, hemispherical, regular or irregular polygonal, etc. In some embodiments, the conductors 44 may have other configurations (e.g., substantially a non-segmented configuration). In some embodiments, as shown in Fig. 3, at least a portion of the conductors 44 may be substantially positioned within the slots 42. For example, in some embodiments, the stator core 34 may be configured such that the plurality of slots 42 are substantially axially disposed. The leg portions 48 may be inserted into the slots 42 such that at least some of the leg portions 48 may extend axially through the stator core 34. In some embodiments, the leg portions 48 may be inserted into adjacent slots 42. For example, the leg portions 48 of a conductor 44 may be disposed in slots spaced approximately one magnetic pole pitch apart (e.g., six slots, eight slots, etc.).In some embodiments, a plurality of conductors 44 may be disposed within the stator core 34 such that at least some of the turn portions 46 of the conductors 44 extend from the stator core 34 at a first axial end 50 of the stator core 34 and at least some of the leg portions 48 extend axially from the stator core 34 at a second axial end 52 of the stator core 34. In some embodiments, at least a portion of the portions of the conductors 44 that extend axially from the core 34 at the axial ends 50, 52 may include stator end turns 54.

[0015] In some embodiments, the conductors 44 may be generally made from a substantially rectilinear conductor 44 that may be formed and arranged in a shape substantially similar to the conductor in Fig. 5. For example, in some embodiments, a machine (not shown) may apply a force (e.g., bend, push, pull, or otherwise actuate) to at least a portion of a conductor 44 to substantially form the turn portion 46 and the two leg portions 48 of a single conductor 44.

[0016] In some embodiments, at least some of the leg portions 48 may include multiple regions. The leg portions 48 may include slot portions 56, angled portions 58, and connecting portions 60. As previously mentioned, in some embodiments, the leg portions 48 may be disposed within the slots 42 and may extend axially from the first end 50 to the second end 52. In some embodiments, after insertion, at least a portion of the leg portions 48 positioned within the slots 42 may include the slot portion 56. In some embodiments, the leg portions 48 may be substantially radially aligned in some or all of the slots 42, as shown in Fig. 3. In some embodiments, the leg portions 48 in some or all of the slots 42 may have other configurations.

[0017] In some embodiments, at least some of the stator end turns 54 extending from the stator core 34 at the second axial end 52 may include the angled portions 58 and the connecting portions 60. After inserting the conductors 44 into the stator core 34, in some embodiments, the leg portions 48 extending from the stator core 34 at the second axial end 52 may be subjected to a bending operation (not shown), which may result in the creation of the angled portions 58 and the connecting portions 60. For example, in some embodiments, the bending operation may provide the angled portions 58 at a more axially inward position and the connecting portions 60 at a more axially outward position, as shown in FIGS. Fig. 3 and Fig. 5. In some embodiments, after the bending process, the connecting portions 60 of at least a portion of the conductors 44 may be immediately adjacent to the connecting portions 60 of other conductors 44. Thus, the connecting portions 60 may be connected together to form one or more stator windings 36. In some embodiments, the connecting portions 60 may be joined by welding, brazing, soldering, fusing, gluing, or other joining methods. Additionally, in some embodiments, the angled portions 58 and the connecting portions 60 may extend from the first axial end 50 and may be configured and arranged in a manner similar to some previously mentioned embodiments.

[0018] In some embodiments, some components of the electric machine 20, such as, but not limited to, the rotor assembly 24, the stator assembly 26, and the stator end windings 54, may generate heat during operation of the electric machine 20. As indicated by the Fig. 6, different areas of the stator assembly 26 (e.g., different areas of the stator end windings 54) may operate at different temperatures under different conditions. Under some or all conditions (e.g., varying operating speeds, loads, and operating direction), different areas of the stator assembly 26 may operate at higher and lower temperatures. In addition, during operation of the module 10, some or all conditions, such as speed, load, and / or direction, may change, such that the operating temperatures in different areas may change as a result of the change in conditions. During operation of the module 10, the temperature in different areas of the stator end windings 54 may continuously change during operation of the module 10.

[0019] To provide optimized power density for the electric machine module 10, it may be desirable for the electric machine 20 to continuously operate at a high power level, which can be achieved through relatively careful and adequate cooling. In some conventional electric machine modules, cooling arrangements may be fixed throughout the lifetime of the module 10 (i.e., the cooling arrangement may be predetermined during the design phase of the module 10 and incorporated into the physical structure of the module 10). In some or all of these conventional modules, the cooling (e.g., coolant flows from a coolant jacket to the stator end windings 54) cannot be adjusted to accommodate thermal changes in the stator end windings.Consequently, thorough and adequate cooling cannot be consistently achieved because, under many conditions, some or all of the conventional module cooling arrangements are unable to provide cooling for the changing thermal patterns of the stator end windings 54. As explained below, some embodiments of the invention may include dynamic cooling arrangements to enable some electric machine modules 10 to operate at or near a continuous peak power level.

[0020] As in Fig. 1, in some embodiments, the housing 12 may include a coolant jacket 62. For example, in some embodiments, the sleeve member 14 may include an inner surface 64 and an outer surface 66, and the coolant jacket 62 may be positioned substantially between the surfaces 64, 66. As previously mentioned, in some embodiments, the reservoir 15 and the end cap 17 may be disposed within another housing, and a recess (not shown) may be defined between an outer periphery of the reservoir 15 and the other housing (not shown). In some embodiments, the recess may include the coolant jacket 62. In some embodiments, the coolant jacket 62 may substantially surround at least a portion of the electric machine 20.For example, the coolant jacket 62 may substantially surround at least a portion of the outer periphery 43 of the stator assembly 26, including the stator winding 36 extending at both the first end 50 and the second end 52 (i.e., the stator winding ends 54).

[0021] Further, in some embodiments, the coolant jacket 62 may contain a coolant including transmission oil, ethylene glycol, an ethylene glycol / water mixture, water, oil, engine oil, a mist, a gas, or another substance capable of absorbing heat energy generated by the electric machine module 10. The coolant jacket 62 may be in fluid communication with a coolant source (not shown) that may pressurize the coolant before or as it discharges into the coolant jacket 62, allowing the pressurized coolant to circulate through the coolant jacket 62.

[0022] Likewise, in some embodiments, the inner surface 64 and / or the container 15 may include coolant openings 68 such that the coolant jacket 62 may be in fluid communication with the machine cavity 22. In some embodiments, the coolant openings 68 may be positioned substantially adjacent the stator end windings 56. For example, in some embodiments, as the pressurized coolant circulates through the coolant jacket 62, at least a portion of the coolant may exit the coolant jacket 62 through the coolant openings 68 and enter the machine cavity 22. Likewise, in some embodiments, the coolant may contact the stator end windings 54, which may result in at least partial cooling depending at least in part on the operation of the machine 20.After exiting the coolant openings 68, at least a portion of the coolant may flow through portions of the machine cavity 22 and may contact various elements of the module 10, which in some embodiments may result in at least partial cooling of the module 10.

[0023] In some embodiments, at least a portion of the coolant may originate from and / or substantially adjacent to the rotor assembly 24.

[0024] For example, in addition to the heat-generating portions of the stator assembly 26, the rotor assembly 24 may also generate heat energy and require cooling for enhanced performance. In some embodiments, portions of the rotor assembly 24, such as the shaft 30 and / or the rotor hub 32, may include one or more channels (not shown) in fluid communication with the coolant source. Thus, in addition to or instead of the coolant entering the engine cavity 22 via the coolant jacket 62, at least a portion of the coolant may enter the engine cavity 22 via the rotor assembly 24 in a manner substantially similar to the coolant flow paths disclosed in U.S. Patent Application Serial No. 13 / 016,940, which is assigned to the same assignee as the present application and is incorporated herein by reference in its entirety.

[0025] In some embodiments, the electric machine module 10 may be configured to enable improved and / or optimized coolant distribution through at least some of the coolant openings 68. As shown in the Fig. 7 and Fig. 8, in some embodiments, the electric machine module 10 may include one or more valves 85 connected to one or more solenoid assemblies 70 disposed within, supported by, and / or connected to the housing 12 so as to be substantially adjacent to some or all of the coolant openings 68. For example, as explained below, some or all of the solenoid assemblies 70 may be configured and arranged to regulate at least a portion of the coolant flow from the coolant jacket 62 into the machine cavity 22. As shown in Fig. 7, in some embodiments, the solenoid assemblies 70 may be connected to a portion of the housing 12. For example, at least a portion of some of the solenoid assemblies 70 may be positioned at least partially between the inner surface 64 and the outer surface 66 and / or the reservoir 15 and the additional housing. As a result of this positioning, in some embodiments, at least a portion of some or all of the solenoid assemblies 70 may extend into the coolant jacket 62, which may result in the regulation of coolant flow from the coolant jacket 62 into the engine cavity 22.

[0026] In some embodiments, the solenoid assemblies 70 may include a core 72, a plunger 74, one or more coils 76, and a spring 78. For example, some or all of the solenoid assemblies 70 may include a conventional solenoid construction, and in some embodiments, some solenoid assemblies 70 may include a non-conventional solenoid construction. In some embodiments, the cores 72 may be connected to at least a portion of the housing 12. For example, the cores 72 may be disposed through and connected to at least a portion of the housing 12 and disposed around at least a portion of a perimeter of the housing 12 such that the solenoid assemblies 70 at least partially surround portions of the electric machine 20 (e.g., the stator assembly 26 including the stator end windings 54).Additionally, in some embodiments, the cores 72 may be positioned such that at least a portion of the solenoid assemblies 70 (e.g., the plunger 74) is substantially adjacent (e.g., radially outward) to at least some of the coolant openings 68, as shown in FIG. Fig. 7 is shown.

[0027] As previously mentioned, in some embodiments, some or all of the solenoid assemblies 70 may comprise a conventional solenoid structure, as shown in the Fig. 7 and Fig. 8. For example, the plunger 74 may be at least partially disposed within the core 72 and configured and arranged to move within the core 72. In some embodiments, the core 72 and / or the plunger 74 may comprise an iron-containing material, a steel-containing material, or any other material capable of operating in an electromagnetic function. In some embodiments, some or all of the solenoid assemblies 70 may have one or more alternative constructions. For example, to reduce power consumption, noise, the size occupied by the solenoid assembly 70, and the weight of the solenoid assembly 70, at least a portion of the plunger 74 may comprise a non-ferrous or steel-containing material, and the solenoid assembly 70 may be actuated (e.g., servo-actuated) by an iron- or steel-containing plunger.

[0028] In some embodiments, the plunger 74 may be configured and arranged to include multiple circumferences. As shown in Fig. 7, the plunger may, for example, have a first portion 80 and a second portion 82. In some embodiments, the first portion 80 may have a smaller circumference relative to the second portion 82. Consequently, when the solenoid assembly 70 is inactive, a gap 84 may be defined between the first portion 80 and an inner circumference of the core 72. Furthermore, in some embodiments, the spring 78 may be disposed around at least a portion of the first portion 80 of the plunger 74 and may contact the inner circumference of the core 72 to bias the plunger 74 when the solenoid assembly 70 is in an inactive state. When the solenoid assembly 70 is inactive, the plunger 74 may, in some embodiments, be arranged such that the valve 85 may be positioned immediately adjacent to one or more coolant ports 68, as in Fig. 7. For example, a first end of the plunger 74 may include the valve 85, which may be configured and arranged to close the coolant opening 68 so that no amount of coolant can enter the engine cavity 22 through the coolant openings 68 immediately adjacent the inactive solenoid assemblies 70. In some embodiments, some or all of the coolant openings 68 may include a valve seat 86, which may be configured and arranged to receive a portion of the valve 85 to substantially close the coolant openings 68 so that no amount of coolant can enter the engine cavity 22, as shown in the Fig. 8A and Fig. 8B is shown.

[0029] The coil 76, in some embodiments, may be at least partially disposed (e.g., wound) around an outer periphery of the core 72 and may be connected to one or more power sources. As a result of positioning the coil 76 around the outer periphery of the core 72, a magnetic field may be generated when a current flows through the coil 76. Additionally, the magnetic field generated by the current flowing through the coil 76 may cause the plunger 74 to move. The magnetic field may cause the plunger 74 to move to substantially or completely eliminate the gap 84 between the plunger 74 and the inner periphery of the core 72.

[0030] For example, the second portion 82 of the plunger 74 may move radially and / or axially (e.g., may be pulled by the magnetic field) to a substantially similar position to that in which the first portion 80 was located when the solenoid assembly 70 was inactive, which may result in at least partial compression of the spring 78. As long as current flows through the coil 76 and the solenoid assembly 70 has a magnetic field, the second portion 82 may, in some embodiments, remain in a substantially similar position (i.e., a position substantially similar to the position of the first portion 80 when the solenoid assembly 70 is inactive). Additionally, in some embodiments, at least some of the solenoid assemblies 70 may be configured and arranged such that the coolant openings 68 are generally unobstructed, and the solenoid assemblies 70, upon energization, may substantially or completely close the coolant openings 68.Accordingly, in some embodiments, the solenoid assemblies 70 may be configured and arranged to permit coolant flow upon activation of one or more of the assemblies 70. In some embodiments, at least a portion of the solenoid assemblies 70 may be configured and arranged to block coolant flow through the coolant openings 68 upon activation of one or more of the assemblies 70.

[0031] Furthermore, in some embodiments, the valve 85 may disengage from the valve seat 86 as a result of the movement of the plunger 74 to allow coolant to flow into the machine cavity 22, which may result in cooling of the stator end windings 54 and / or other elements of the electric machine module 10, as shown in Fig. 8B. Conversely, when current either substantially or completely ceases to flow through coil 76, the magnetic field may weaken and / or dissipate, which may cause second portion 82 to return to its original position. For example, plunger 74 may return to its original position because the force of the magnetic field holding second portion 82 in position may weaken to a point where the biasing force of spring 78 may overcome the magnetic field and move plunger 74 back to its original position to form gap 84 between first portion 80 and the inner periphery of core 72. As a result, valve 85 may engage valve seat 86 to substantially close one or more coolant ports 68 to prevent quantities of coolant from entering machine cavity 22, as shown in Fig. 8A is shown.

[0032] In some embodiments, some or all of the solenoid assemblies 70 may be activated and / or deactivated to coordinate cooling of the electric machine module 10. In some embodiments, one or more sensors (e.g., temperature sensors) (not shown) may be connected to portions of the electric machine module 10. For example, in some embodiments, multiple temperature sensors may be connected to the inner surface 64 and / or portions of the stator assembly 26, such as the stator end windings 54 and / or the stator core 34. The temperature sensors may be arranged around part or all of the circumference of the stator end windings 54 at regular and / or irregular intervals at the first axial end 50 and / or the second axial end 52 of the stator core 34.In some embodiments, the temperature sensors may be arranged at other locations so that the operating temperatures of the stator assembly 26 and other parts of the module 10 can be detected by the sensors. In some embodiments, the positioning of some or all of the temperature sensors may be determined at least in part by temperature ranges associated with various machine speeds, loads, and / or directions. In some embodiments, the module 10 may include any other devices configured and arranged to measure the temperature of the electric machine module 10.

[0033] In some embodiments, some or all of the sensors may be in communication with some or all of the solenoid assemblies 70 and / or an electronic control module 88 (e.g., wired and / or wireless connection), as shown in Fig. 7. For example, some or all of the solenoid assemblies 70 may be activated upon receiving an input from at least a portion of the sensors. In other embodiments, some or all of the sensors may transmit temperature data to the electronic control module 88. For example, in some embodiments, the electric machine module 10 may be installed in a vehicle, and the temperature sensors may be in communication with the vehicle's electronic control module 88. In other embodiments, the electric machine module 10 may include one or more electronic control modules 88. Regardless of the positioning, the electronic control module 88 may be in communication with some or all of the solenoid assemblies 70 and may be configured and arranged to activate and / or deactivate the solenoid assemblies 70 based at least in part on the temperature data received from the sensors.

[0034] In some embodiments, the electronic control module 88 may include one or more programs configured to optimize the cooling of the electric machine module 10. For example, the electronic control module 88 may control the flow of current to the coils 76 of at least some of the solenoid assemblies 70. As a result of controlling the flow of current, the electronic control module 88 may also control the flow of coolant through the valve seat 86 and at least a portion of the coolant openings 68. Upon receiving temperature data from one or more sensors indicating that the temperature in one or more areas of the stator end windings 54 is above a predetermined threshold, the electronic control module 88 may enable current flow to the coils 76 of some or all of the solenoid assemblies 70 that are substantially adjacent to the locations where the temperature sensor detects an excessive temperature condition.When the electronic control module 88 receives data from some or all of the temperature sensors and some of the sensors that are substantially adjacent to a "twelve o'clock" and a "nine o'clock" position of the stator assembly, as shown in . Fig. 6, for example, transmit data indicating that those portions of the stator end windings 54 are operating above a predetermined threshold, the electronic control module 88 may enable current flow to at least a portion of the solenoid assemblies 70 substantially adjacent the "twelve o'clock" and "nine o'clock" positions. The coolant may exit the coolant jacket 62 (i.e., as the valve 85 at least partially disengages from the valve seat 86 to allow coolant drainage from the coolant jacket 62) and contact the stator end windings 54, at least some of which are operating at temperatures at or above the predetermined threshold.

[0035] In some embodiments, current may flow to the selected solenoid assemblies 70 for a predetermined time to allow a predetermined amount of coolant to exit the coolant jacket 62. In other embodiments, current may flow to the selected solenoid assemblies 70 until temperature sensors adjacent to the activated solenoid assemblies 70 transmit temperature data to the electronic control module 88 indicating that the temperature of the stator end windings 54 has returned to an acceptable temperature range. Additionally, in some embodiments, current may continuously flow through the coils 76 of the activated solenoid assemblies 70. In other embodiments, the current may be controlled via pulse width modulation such that the plunger 74 closes and opens the coolant ports 68 to control the flow of coolant from the coolant jacket 62 into the machine cavity 22.For example, if current were designed to flow to the solenoid assemblies 70 at a 25% duty cycle, approximately one-quarter the amount of coolant would flow through the coolant ports 68 compared to a solenoid assembly 70 operating at a 100% duty cycle (i.e., in a continuously energized state). Additionally, in some embodiments, the housing 12 may include one or more coolant ports 68 that function without a solenoid assembly 70, allowing coolant to flow substantially continuously from the coolant jacket 62 into the machine cavity 22. Accordingly, some areas of the module 10 may experience substantially continuous changes in coolant flow from the coolant jacket 62 depending on the sensed temperature (e.g., solenoid assemblies 70 that are activated and deactivated as a result of temperature increases and decreases at the stator end windings 54).

[0036] In some embodiments, the electronic control module 88 may have alternative control capabilities. Instead of communicating with some or all of the temperature sensors, in some embodiments the electronic control module may be preprogrammed with temperature data so that the control module 88 can activate some or all of the solenoid assemblies 70 at predetermined times. For example, temperature data indicative of the temperature of different portions of the stator end windings 54 operating under different conditions (e.g., load, direction, and speed) may be collected during assembly and / or design of the electric machine module 10. As a result, during operation of the electric machine module 10, the electronic control module may estimate the operating state of the module 10 (e.g., load magnitude, direction of the machine 20, speed of the machine 20, etc.).) and can compare the operating condition with the pre-programmed temperature data to determine which solenoid assemblies 70 should be energized to cool the stator end windings 54 that are likely to exceed a desired temperature based at least in part on the operating condition.

[0037] In some embodiments, some or all of the solenoid assemblies 70 may include a passive temperature control system (not shown) in addition to or instead of the electronic control module 88 and / or the temperature sensors. For example, some or all of the solenoid assemblies 70 may include a conventional thermal sensor or other passively operating temperature sensing device such that when the thermal sensor detects thermal output from the electric machine module 10 that exceeds the predetermined threshold, the conventional thermal sensor may activate some or all of the solenoid assemblies 70. Additionally, in some embodiments, a thermal sensor may be in communication with each of the solenoid assemblies 70, each solenoid assembly 70 may be in communication with a thermal sensor, and some solenoid assemblies 70 may be in communication with one or more thermal sensors.

[0038] Some embodiments of the invention provide improvements relative to some conventional cooling arrangements. As previously mentioned, some conventional cooling arrangements can be substantially fixed at the design stages of the module 10 because only coolant openings 68 can be accommodated in the housing 12 to allow coolant flow. Consequently, at least some conventional cooling arrangements fail to provide cooling performance that is adaptable to changes in the conditions of the module 10, such as load, direction, and speed. Some embodiments of the invention allow for optimization of the coolant flow so that coolant is provided to areas of the module 10 operating at higher temperatures.The solenoid assemblies 70 can enable optimized coolant flow so that thorough and adequate cooling can occur, allowing the electric machine module 10 to operate at or near peak performance levels for an extended period of time. Furthermore, by being able to optimize cooling based on temperature, electric machine modules 10 can be used in any number of configurations and applications. For example, electric machine modules 10 can be installed in any number of applications, and the optimized cooling configuration including the solenoid assemblies 70 can be used to provide coolant regardless of the module 10's positioning or use due to its temperature-based cooling.

[0039] In some embodiments, the coolant flow controlled by the solenoid assemblies 70 may at least partially influence the cooling of the rotor assembly 24. As previously mentioned, in some embodiments, an amount of coolant may enter the machine cavity 22 after flowing through portions of the rotor assembly 24 and the shaft 30, in addition to coolant flowing from the coolant jacket 62. As a result of coolant flowing through portions of the rotor assembly 24, at least a portion of the torque generated by the rotor assembly 24 rotating during operation of the electric machine 20 may be lost. Some embodiments of the invention may enable cooling of the rotor assembly 24 and minimize the torque loss resulting from the coolant flow through the rotor assembly 24.For example, in some embodiments, the coolant jacket 62 and the rotor assembly 24 and shaft 30 may be connected to one or more of the same coolant sources. In some embodiments, some or all of the solenoid assemblies 70 may be energized so that coolant may flow through some or all of the coolant ports 68. Consequently, at least a portion of the coolant that would normally flow through the shaft 30 and the rotor assembly 24 may be redirected through the open coolant ports 68, resulting in minimized torque losses due to the reduced coolant flow through the rotor assembly 24.In addition, although the rotor assembly 24 has a lower coolant flow relative to when coolant is not flowing through some of the coolant openings 68, at least a portion of the rotor assembly 24 may still be cooled due to the increased coolant flow through the coolant openings 68, resulting in larger amounts of coolant entering the machine cavity 22.

[0040] It will be understood by those skilled in the art that, although the invention has been described above in connection with certain embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications, and variations from the embodiments, examples, and uses are intended as encompassed by the claims appended hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated herein by reference. Various features and advantages of the invention are set forth in the following claims. Reference numbers 10 Module 12 module housings 12 housings 13 Serial number 14 Sleeve element 15 containers 16 first end cap 18 second end cap 20 machines 22 Machine cavity 24 Rotor assembly 26 Stator assembly 28 Stator core 30 wave 32 Rotor hub 34 core 36 Stator winding 38 sheets 40 teeth 41, 43 outer circumference 41 inner circumference 42 slots 44 ladders 46 Turning section 48 leg section 50 first end 52 second end 54 stator winding heads 56 slot section 58 angular section 60 connecting section 64 inner surface 66 exterior area 68 Coolant opening 70 Solenoid assembly 74 plungers 76 coil 78 spring 80 first area 82 second area 84 gap 85 valve 86 valve seat 88 electronic control module

Claims

[1] Electrical machine module (10), comprising: a housing (12) at least partially defining a machine cavity (22); a coolant jacket at least partially defined by the housing (12); a plurality of coolant openings (68) disposed through portions of the housing (12) to fluidly connect the coolant jacket and the engine cavity (22), at least some of the plurality of coolant openings (68) having a valve seat (86) within the coolant jacket; and one or more solenoid assemblies (70) supported at least partially by the housing (12) and positioned substantially adjacent to at least a portion of the plurality of coolant openings (68), wherein the solenoid assemblies (70) comprise a plunger (74), a coil (76) arranged around a core, and a spring (78), wherein one end of the plunger (74) comprises a valve (85), and the valve (85) is designed and arranged to engage the valve seat (86) to substantially close the coolant opening (68) comprising the valve seat (86), the valve (85) being adapted to move through the coolant in the coolant jacket; and further comprising one or more temperature sensors connected to at least one of the electric machine (20) and the housing (12), the temperature sensors being in communication with at least one or more solenoid assemblies (70), at least some of the solenoid assemblies (70) being designed and arranged to be energized by flowing a current through the solenoid to enable coolant flow from the coolant jacket into the machine cavity (22) based at least in part on the temperature data obtained from the temperature sensors, by the plunger (74) of at least some of the solenoid assemblies (70) being designed and arranged to engage a portion of at least some of the plurality of coolant openings (68), and further comprising an electric machine (20) disposed at least partially within the machine cavity (22) and surrounded by the housing (12), the electric machine (20) being positioned such that the coolant jacket surrounds at least a portion of the electric machine (20), wherein the electric machine (20) has stator winding heads (54) and wherein at least some of the coolant openings (68) are arranged radially outwardly from at least a portion of the stator winding heads (54). [2] The electric machine module (10) of claim 1, wherein the housing (12) includes a sleeve member (14) connected to at least one end cap (16, 18), and wherein the sleeve member (14) includes an inner surface (64) and an outer surface (66), and the coolant jacket is at least partially disposed between the inner surface (64) and the outer surface (66). [3] The electric machine module (10) of claim 1, wherein the housing (12) includes a reservoir (15) connected to at least one end cap (16, 18), and wherein at least a portion of the reservoir (15) defines at least a portion of the coolant jacket. [4] A method for assembling an electrical machine module (10), the method comprising: Providing a housing (12) at least partially defining a machine cavity (22) and a coolant jacket, the coolant jacket being configured to receive a coolant; Positioning an electrical machine (20) at least partially into the machine cavity (22) such that at least a portion of the electrical machine (20) is substantially surrounded by the coolant jacket; and further comprising one or more temperature sensors connected at least to the electrical machine (20) and the housing (12), Arranging a plurality of coolant openings (68) radially outwardly and adjacent to a stator winding head (54) through portions of the housing (12) to fluidly connect the coolant jacket and the machine cavity (22), wherein at least some of the plurality of coolant openings (68) have a valve seat (86) disposed within the coolant jacket, wherein at least a portion of the plurality of coolant openings (68) are substantially adjacent to the stator winding head (54); and Positioning one or more solenoid assemblies (70) substantially adjacent to at least a portion of the plurality of coolant openings (68), the solenoid assemblies (70) comprising a plunger (74), a coil (76) disposed around a core (34), and a spring (78), and wherein the solenoid assemblies (70) are configured and arranged to regulate the flow of at least a portion of a coolant from the coolant jacket into the engine cavity (22) based at least in part on the temperature data obtained from the temperature sensors by the plunger (74) of at least some of the solenoid assemblies (70) being configured and arranged to engage a portion of at least some of the plurality of coolant openings (68) while moving through the coolant in the coolant jacket. [5] The method of claim 4 and further comprising providing an electronic control module (88) in communication with at least some of the solenoid assemblies (70). [6] The method of claim 5 and further comprising connecting one or more temperature sensors to at least one of the electric machine (20) and the housing (12).

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