Integrated Coolant Level Sensor for Electric Machine
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Solution Overview
Problem
Conventional electric machines face operational inefficiencies and potential component damage due to coolant interference with moving parts, leading to reduced performance and risk of breakdown, as existing coolant systems lack effective level sensing mechanisms to prevent coolant overflow or depletion.
Innovation Solution
An integrated coolant level sensor is positioned within the electric machine's housing to monitor coolant levels, providing feedback to a controller for adjusting coolant flow and preventing interference with moving components, thereby ensuring optimal operation and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant is introduced into the electric machine to cool internal components, then temperature control is improved, but coolant may overflow and interfere with moving components causing operational inefficiency and potential damage
Solution Approach 1:
The patent applies preliminary action by providing a coolant level sensor that proactively monitors coolant levels before overflow can occur. The sensor detects coolant levels in advance and provides feedback to the controller, allowing the system to adjust coolant flow or alert operators before coolant interferes with moving components, thus preventing operational inefficiency and damage.
Solution Approach 2:
The patent implements feedback through a coolant level sensing system that continuously monitors coolant levels and communicates with a controller. The controller receives level information and can adjust coolant flow rates or activate warnings, creating a closed-loop control system that maintains coolant levels within safe operating ranges and prevents overflow-related reliability issues.
2Device complexity
If coolant level is not monitored, then device complexity is reduced, but coolant overflow or depletion can occur causing harmful effects
Solution Approach 1:
The patent introduces an intermediary element - the coolant level sensor - that mediates between the coolant system and the controller. This sensor acts as a bridge, providing level information to the controller without requiring complex direct monitoring mechanisms, thus adding minimal complexity while effectively preventing harmful overflow or depletion conditions.
3Productivity
If higher power densities and speeds are achieved, then productivity is improved, but internal temperatures increase requiring more sophisticated coolant systems
Solution Approach 1:
The patent uses feedback control through the coolant level sensor and controller combination to manage thermal loads associated with high power density operation. The sensor provides real-time level data to the controller, which adjusts coolant flow to maintain appropriate cooling levels, enabling sustained high-performance operation without thermal damage.
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 integrated coolant level sensor enhances operational efficiency by maintaining proper coolant levels, preventing damage from overflow or depletion, and extending the electric machine's operational life by ensuring proper lubrication and heat transfer capabilities.
Implementation Method 1
a coolant level sensor arranged at the housing... sensing a level of coolant in a coolant collection area
Data Source
AI summary
A method of operating an electric machine includes flowing a coolant into an interior portion of a housing of the electric machine, and sensing a level of coolant in a coolant collection area within the interior portion with a coolant level sensor arranged at the housing.