Cooler Rib Layout for High-Capacity Motor Cooling
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Solution Overview
Problem
Existing coolers and rotating electric machines face challenges in achieving high cooling capacity while maintaining structural strength, particularly due to the difficulty in forming fine ribs within the coolant passage using traditional manufacturing methods like casting or forging.
Innovation Solution
The proposed solution involves a cooler design with a base material and protruding ribs, where the ribs are arranged in specific groups with varying distances between their base and protruding ends, enhancing coolant flow turbulence and heat dissipation without compromising structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods (casting or forging) are used to form ribs in the cooler, then structural strength is maintained, but the ability to form fine ribs with precise dimensions is insufficient
Solution Approach 1:
The cooler is divided into multiple separate components (first cooler component, second cooler component, third cooler component) that are manufactured using different methods. The first component with fine ribs is manufactured using additive manufacturing for high precision, while other components can use traditional casting or forging methods, thus resolving the contradiction between manufacturing precision and ease of manufacture.
2Productivity
If the number of ribs is increased to improve cooling capacity, then heat dissipation performance improves, but structural strength may be compromised
Solution Approach 1:
The cooler structure is segmented into multiple components where the first cooler component contains the fine ribs for heat dissipation while the second and third components provide structural support. This segmentation allows the ribbed component to be optimized for cooling capacity while other components maintain structural strength, resolving the contradiction between cooling capacity and structural strength.
Solution Approach 2:
The cooler assembly functions as a composite structure combining components made by different manufacturing methods (additive manufacturing for the ribbed component, casting or forging for other components). This composite approach enables the integration of fine ribs for high cooling capacity while maintaining overall structural strength through the combination of components.
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 effectively improves the cooling performance of the cooler while maintaining high structural strength, as the separate components allow for the use of additive manufacturing for fine ribs and traditional methods for strength-focused components.
Implementation Method 1
the plurality of ribs include a first rib group including a plurality of the ribs arranged in a second direction that intersects a first direction which is a direction from the first end portion of the base material toward the second end portion of the base material
Data Source
AI summary
A cooler includes a base material, and a plurality of ribs protruding from a main surface of the base material, a distance between a base end of a first rib and a base end of a second rib in a second direction is larger than a distance between a protruding end of the first rib and a protruding end of the second rib in the second direction, and a distance between the base end of the second rib and a base end of a third rib in the second direction is smaller than a distance between the protruding end of the second rib and a protruding end of the third rib in the second direction.