BSG Motor Cooling Structure With Parallel Water Jackets
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Solution Overview
Problem
Existing liquid-cooled BSG motors face challenges with low heat dissipation efficiency, thick and heavy housing walls, difficulty in manufacturing, and incompatibility with low-pressure water circuits due to series-connected water circuits.
Innovation Solution
A cooling structure featuring parallel water passages with an outer and inner water jacket, spirally arranged first cooling water passage, U-shaped second cooling water passage, and transfer passages for simultaneous cooling of the stator, rotor, and inverter, along with a split-type housing design for efficient heat dissipation and manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If series-connected water passages are integrated into the motor housing, then the volume of the motor is reduced and production cost is saved, but the inner and outer walls of the housing become thick, making the housing heavy and difficult to manufacture
Solution Approach 1:
The water passages are segmented into separate components (water inlet pipe, motor housing water passages, inverter housing water passages, drain pipe) rather than integrating them all into a single thick housing structure. This allows each component to be manufactured independently with thinner walls, reducing overall manufacturing difficulty while maintaining compact volume.
Solution Approach 2:
The water passages are nested within separate housing structures (motor housing and inverter housing) rather than requiring a single thick-walled integrated housing. The inner water passage is positioned within the inverter housing that is mounted on the motor housing, creating a nested arrangement that reduces wall thickness requirements.
2Volume of moving object
If series-connected water passages are integrated into the motor housing, then the volume of the motor is reduced, but the housing becomes heavy
Solution Approach 1:
The housing structure is segmented into separate components (motor housing and inverter housing) with thin walls, avoiding the need for a single thick-walled integrated housing. This segmentation reduces the total material required while maintaining structural integrity and compact volume.
3Device complexity
If series-connected water passages with large flow resistance are manufactured, then the housing structure is simplified, but heat dissipation efficiency becomes low
Solution Approach 1:
The water cooling system is segmented into separate passages for the motor and inverter, each optimized for its specific cooling needs. The motor housing water passages and inverter housing water passages are designed independently, allowing for optimized flow paths that reduce overall flow resistance while maintaining structural simplicity.
Solution Approach 2:
The water inlet pipe and drain pipe act as intermediaries that connect the separate water passages without requiring complex integrated structures. This intermediary approach allows for simple, efficient water flow paths that minimize flow resistance while keeping the housing structure straightforward.
4Reliability
If series-connected water circuits are used, then the motor and inverter are cooled sequentially, but the requirement for pressure of the complete vehicle water circuit becomes high
Solution Approach 1:
The cooling system is segmented into parallel water circuits for the motor and inverter rather than a single series circuit. This segmentation allows each component to be cooled independently with lower pressure requirements, while maintaining reliable cooling for both components simultaneously.
5Device complexity
If series-connected water passages are used, then the structure is simplified, but heat dissipation efficiency becomes low
Solution Approach 1:
The water passages are segmented into separate, optimized circuits for the motor and inverter rather than a single series passage. Each passage is designed independently to minimize flow resistance and maximize heat dissipation efficiency, while the overall structure remains relatively simple and easy to manufacture.
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 achieves high heat dissipation efficiency and compatibility with low-pressure water circuits, reducing manufacturing complexity and weight, while maintaining balanced water flow and efficient cooling.
Implementation Method 1
a first cooling water passage disposed on the inner water jacket, and a water outlet and a water inlet of the first cooling water passage both disposed on the outer water jacket, and in communication with a cooling water circuit of the liquid-cooled motor for BSG
Implementation Method 2
cooling water enters into the first cooling water passage and the first transfer water passage synchronously from the transfer water inlet, and enters into the second cooling water passage through the first transfer water passage, thereby realizing simultaneous cooling and heat dissipation
Data Source
AI summary
The liquid-cooled motor for BSG includes a motor housing, which has a cooling structure. A cooling structure includes: an outer water jacket; an inner water jacket fitted into the outer water jacket; a first cooling water passage disposed on the inner water jacket; a second cooling water passage disposed on an inverter; a first transfer water passage and a second transfer water passage both disposed on the outer water jacket and a rear end cover. Cooling water enters into the first cooling water passage and the first transfer water passage synchronously from a transfer water inlet, and enters into the second cooling water passage through the first transfer water passage, thereby realizing simultaneous cooling and heat dissipation of a stator, a rotor and the inverter of the liquid-cooled motor for BSG, respectively.