Annular Cooling Cover for Vehicle Electric Machine End Windings
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Solution Overview
Problem
Existing electric machines in vehicles face challenges in compact thermal management due to limited space within transmissions, requiring innovative designs that minimize footprint while effectively cooling the stator and rotor windings.
Innovation Solution
The electric machine design incorporates annular covers with inner and outer walls defining annular cavities to receive end windings, with a radial distance between the walls minimized to match the radial length of the end face, and fluid channels connecting these cavities for efficient cooling, allowing for compact and effective thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional thermal management systems are used with larger cooling channels, then cooling efficiency is improved, but the footprint and space requirements increase
Solution Approach 1:
The patent transitions from traditional linear cooling channel designs to an annular (circular) cooling channel configuration. This dimensional change allows the cooling path to wrap around the end windings in a circular pattern, maximizing the cooling surface area within a compact radial space. The annular shape enables efficient heat dissipation without increasing the overall axial or radial footprint of the electric machine.
Solution Approach 2:
The cooling channels are nested within the annular cover structure, which itself is positioned around the end windings. This nested configuration allows the cooling system to be integrated within the existing structural envelope of the electric machine, eliminating the need for additional external cooling components and reducing the overall footprint.
2Temperature
If the gap between stator and rotor is increased to accommodate cooling components, then thermal management is improved, but the device complexity and space utilization worsen
Solution Approach 1:
The patent merges the cooling channel structure with the annular cover that houses the end windings. By integrating the cooling function into the existing cover structure rather than adding separate cooling components, the design eliminates additional parts and assembly steps, thereby reducing device complexity while maintaining effective thermal management.
Solution Approach 2:
The annular cover serves multiple functions: it houses the end windings, provides structural support, and incorporates the cooling channels. This multi-functional design eliminates the need for separate dedicated cooling components, reducing overall device complexity while achieving effective thermal management.
3Area of stationary object
If compact design is prioritized with minimal radial distance in annular covers, then space utilization is improved, but cooling effectiveness may be compromised
Solution Approach 1:
The annular cooling channel utilizes the circumferential dimension to create an extended cooling path within a compact radial space. By allowing the cooling fluid to flow in a circular path around the end windings, the system achieves high cooling effectiveness without requiring large radial distances, thus maintaining compact dimensions while ensuring adequate heat dissipation.
Solution Approach 2:
The patent optimizes the radial distance parameter of the annular cover to be less than or equal to the radial length of the end face. This parameter change allows the cooling channels to be positioned precisely within the available space, maximizing cooling surface area contact with the end windings while maintaining a compact overall design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances cooling efficiency by maintaining a compact footprint, preventing the need for increased gap between the stator and rotor, and effectively manages heat generated during operation, optimizing space utilization within vehicles.
Implementation Method 1
A first annular cover has an inner wall and an outer wall spaced apart to define a first annular cooling cavity configured to receive cooling fluid. A second annular cover has an inner wall and an outer wall spaced apart to define a second annular cooling cavity configured to receive cooling fluid.
Implementation Method 2
The channel opens into the cavity, and a radial distance between the inner and outer walls is less than or equal to a radial length of the end face... effectively manages heat generated during operation
Data Source
AI summary
A vehicle electric machine includes a stator having an end face and a yoke region defining a channel. End windings are adjacent to the end face. An annular cover has inner and outer walls defining an annular cavity configured to receive the end windings. The channel opens into the cavity, and a radial distance between the inner and outer walls is less than or equal to a radial length of the end face.