Direct Cooling Stator Core for Electric Vehicle Motors
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Solution Overview
Problem
Existing cooling methods for electric vehicle driving motors, such as air-cooling and water-cooling, face limitations in cooling performance due to indirect cooling structures, which can lead to heat-related damage and performance degradation, especially under high output conditions.
Innovation Solution
A direct-cooling driving motor design featuring a stator core with core recesses and a cooling fluid supply member, like an insert ring, that allows cooling fluid to directly cool the stator core and coil, enhancing heat transfer efficiency and temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air-cooling method with heat sink is used, then cooling structure is simple, but cooling performance is degraded due to indirect cooling
Solution Approach 1:
The patent introduces a cooling fluid as an intermediary medium to transfer heat from the motor components. The cooling fluid circulates through channels in the stator core and rotor, directly contacting the heat-generating components and efficiently removing heat, thereby resolving the contradiction between structural simplicity and cooling performance.
Solution Approach 2:
The patent employs a liquid cooling system where cooling fluid flows through hydraulic channels formed in the stator core and rotor. This hydraulic cooling approach provides superior heat transfer compared to air cooling, achieving high cooling performance while maintaining reasonable structural complexity.
2Temperature
If water-cooling method with cooling channels is used, then cooling performance is improved, but contact thermal resistance between components degrades efficiency
Solution Approach 1:
The patent integrates cooling channels directly within the stator core and rotor structures, nesting the cooling system inside the motor components. This nested design ensures direct thermal contact between the cooling fluid and the heat-generating parts, minimizing contact thermal resistance and maximizing cooling efficiency.
Solution Approach 2:
The patent applies cooling channels specifically at the locations where heat is generated most intensely - within the stator core and rotor. This localized cooling approach targets the critical heat-generating regions, reducing thermal resistance at the most problematic interfaces and improving overall cooling efficiency.
3Temperature
If direct oil spray cooling is used, then cooling efficiency is improved, but structural constraints and limited cooling area reduce effectiveness
Solution Approach 1:
The patent divides the cooling system into multiple segmented channels distributed throughout the stator core and rotor. This segmentation allows the cooling fluid to access multiple heat-generating regions simultaneously, overcoming the limited cooling area of spray methods while avoiding the complexity of extensive spray piping.
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 direct-cooling method improves cooling performance, prevents heat-related damage, increases motor durability, and enhances fuel efficiency by allowing longer EV driving distances and reducing engine startup frequency.
Implementation Method 1
when cooling fluid is flowing through the core recesses, the cooling fluid flowing through the core recesses directly cools the stator core
Implementation Method 2
the cooling fluid flowing through the core recesses directly cools the stator core and the coil
Data Source
AI summary
A direct-cooling stator core assembly having cooling channels so as to directly cool a stator core and a wound coil, and a driving motor for a vehicle including the same, are provided. The direct-cooling stator core assembly includes a stator core having an outer surface and a plurality of core recesses formed in the outer surface in a longitudinal direction. The direct-cooling stator core assembly further includes a cooling fluid supply member configured to supply cooling fluid to the core recesses in the stator core. In the direct-cooling stator core assembly, when cooling fluid is flowing through the core recesses, the cooling fluid flowing through the core recesses directly cools the stator core.