Cooling Crescent Channel Layout for Variable Hybrid E-Motor Stators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current cooling systems for hybrid modules, particularly those in electric motor vehicles, face challenges in accommodating e-motor stators of varying sizes and ensuring effective cooling while maintaining serviceability and structural integrity.
Innovation Solution
A cooling crescent design comprising two half sections with radially and axially extending orifices and adjustable tabs for secure attachment to the hybrid module housing, forming a hydraulic channel for efficient fluid flow and cooling, and allowing for adjustable tab heights to accommodate different stator sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed cooling system design is used, then manufacturing simplicity is maintained, but adaptability to different stator sizes is reduced
Solution Approach 1:
The cooling system incorporates adjustable tabs that can be positioned at different heights to accommodate various stator sizes. This dynamic adjustment capability allows the same cooling system design to adapt to different stator dimensions without requiring complete redesign, thereby improving adaptability while controlling complexity through a standardized adjustable mechanism.
Solution Approach 2:
The cooling system is divided into modular components including multiple tabs that can be independently adjusted. This segmentation allows each tab to be positioned separately to match specific stator requirements, providing flexibility in adapting to different stator sizes while maintaining overall system coherence.
2Temperature
If cooling fluid flow is increased to improve cooling efficiency, then temperature control improves, but pressure losses increase
Solution Approach 1:
The cooling system employs multiple outlet orifices distributed circumferentially around the cooling crescent, creating localized cooling zones that directly target the stator windings. This distributed approach ensures efficient heat removal from critical areas without requiring excessive overall flow rates, thereby controlling pressure losses while maintaining effective temperature control.
3Ease of operation
If tabs are made fixed for structural stability, then structural integrity is maintained, but serviceability and adjustability are reduced
Solution Approach 1:
The tabs are designed with adjustable height capability while maintaining structural integrity when installed. The adjustment mechanism allows for different configurations during installation to match various stator sizes, yet once positioned, the tabs provide stable structural support. This dynamic design enables both serviceability through adjustment and structural strength when properly installed.
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 design enhances cooling efficiency by directing fluid towards e-motor stator windings and supports various stator sizes through adjustable tabs, improving serviceability and structural stability.
Implementation Method 1
forming a hydraulic channel for efficient fluid flow and cooling
Implementation Method 2
directing fluid towards e-motor stator windings
Data Source
AI summary
A cooling crescent for a hybrid module includes a first half section and a second half section. The first half section has a radially outer inlet orifice and a plurality of circumferentially disposed radially inner outlet orifices. The second half section is sealed to the first half section to form a narrow channel hydraulically connected to the radially outer inlet orifice, and a circumferentially extending channel hydraulically connected to the narrow channel and the plurality of circumferentially disposed radially inner outlet orifices. In some example embodiments, the first half section or the second half section comprises a plurality of axially extending tabs with respective orifices for fixing the cooling crescent to a housing of the hybrid module. In an embodiment, the plurality of axially extending tabs are configured to be adjustable to vary a respective height of the tabs to accommodate for e-motor stators of varying sizes.