Bladed Balancing Disc for Stator End Winding Cooling

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Stator end windings in electric motors of electric vehicles are prone to overheating due to high temperatures, leading to reduced efficiency and potential failure.

Innovation Solution

A bladed balancing disc is integrated with the rotor shaft, featuring blades that force a coolant and gas radially outward to cool the stator end windings, enhancing heat removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional balancing discs are used to hold rotor laminations, then the rotor structure is stable, but the stator end windings overheat and motor efficiency decreases

Engineering Contradiction:
Improverotor structure stabilityVSAvoidstator end winding temperature
Core Design Contradiction:
ReliabilityVSTemperature

Solution Approach 1:

The patent combines the balancing disc function with the cooling function by integrating coolant flow passages directly into the balancing disc structure. The balancing disc now serves dual purposes: maintaining rotor lamination stability and providing thermal management for stator end windings through internal coolant channels that draw heat away from the windings.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The balancing disc acts as an intermediary component between the rotor shaft and the stator end windings. By positioning the balancing disc radially outward from the rotor and incorporating coolant passages, it mediates heat transfer from the stator end windings to the coolant flowing through the disc, thereby protecting the windings from overheating while maintaining structural stability.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Temperature

If cooling is added to reduce stator end winding temperature, then motor efficiency improves, but device complexity increases

Engineering Contradiction:
Improvestator end winding temperatureVSAvoidcooling system complexity
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the cooling system with the existing balancing disc component, eliminating the need for separate cooling mechanisms. The coolant passages are integrated directly into the balancing disc structure, allowing the same component to perform both structural support and thermal management functions, thereby reducing overall system complexity despite adding cooling capability.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The balancing disc is transformed into a multi-functional component that simultaneously provides mechanical support for rotor laminations and thermal management for stator end windings. By incorporating coolant flow passages into the balancing disc, the component achieves universality, performing both structural and thermal functions within a single element, thus avoiding the need for additional separate cooling devices.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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

The solution effectively reduces stator end winding temperatures, improving motor efficiency and preventing failure by combining liquid coolant and gas convection cooling.

Implementation Method 1

During rotation of the rotor shaft the bladed balancing disc forces a first fluid and a second fluid in a radial direction away from the axis of the rotor shaft and onto the stator end windings

Methodology Applied
Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

The solution effectively reduces stator end winding temperatures, improving motor efficiency and preventing failure by combining liquid coolant and gas convection cooling

Methodology Applied
Scientific EffectConvection cooling: Convection

Implementation Method 3

The solution effectively reduces stator end winding temperatures, improving motor efficiency and preventing failure by combining liquid coolant and gas convection cooling

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12451758B2Bladed balancing disc
Publication Date: 2025.10.21 SCHAEFFLER TECHNOLOGIES AG & CO KG
  • US12451758B2 patent drawing
  • US12451758B2 patent drawing
  • US12451758B2 patent drawing

AI summary

A bladed balancing disc for an electric motor is disclosed. The bladed balancing disc includes a first disc, a second disc, a plurality of blades, and at least one disc aperture. The first disc includes a first flange extending from the first disc in an axial direction relative to a central axis of the first disc, and the second disc is axially offset from the first disc in an extension direction of the first flange. Each of the plurality of blades extend between the first disc and the second disc. The at least one disc aperture extends through the first flange, fluidly coupling a volume radially inward of the first flange to a volume radially outward of the first flange.