Electro-mechanical Drive Unit Fastener Fluid Cooling
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Solution Overview
Problem
Hybrid vehicle powertrains face inefficiencies in torque and speed management due to direct dependence on engine and electric motor speeds and torques, which affects vehicle performance across various driving conditions.
Innovation Solution
An electro-mechanical drive-unit with a gearing arrangement, a pump for circulating pressurized fluid, and an electric motor, where the fluid is used for cooling and lubrication of the motor windings, and a fastener system to direct the fluid for effective cooling and lubrication, enhancing the drive-unit's efficiency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the electric motor components operate at high power levels, then the vehicle propulsion capability is improved, but the heat generation in the motor windings increases reducing efficiency and reliability
Solution Approach 1:
The patent employs a hydraulic fluid circulation system where a pump delivers pressurized fluid through channels to cooling surfaces in thermal contact with the motor windings. This hydraulic cooling system efficiently removes heat generated during high-power operation, allowing the motor to maintain high power output without excessive temperature rise that would reduce efficiency and reliability.
2Reliability
If the motor housing is tightly sealed to protect internal components, then the reliability is improved, but the heat dissipation capability deteriorates
Solution Approach 1:
The patent introduces a thermal intermediary system consisting of cooling surfaces and circulating fluid that acts as a heat transfer medium between the motor windings and the external environment. This intermediary cooling system allows the motor housing to remain sealed for protection while efficiently conducting heat away from internal components through the fluid circulation pathway.
3Temperature
If additional cooling systems are added to the motor, then the temperature control is improved, but the device complexity increases
Solution Approach 1:
The patent merges the cooling function with the existing motor housing structure by integrating cooling surfaces directly into the housing and using the housing itself as part of the thermal management system. The pump and fluid channels are incorporated into the existing motor assembly, combining multiple functions (structural support, thermal management, and component mounting) into a unified system that reduces overall complexity compared to separate cooling subsystems.
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 allows for independent control of torque and speed contributions from the engine and electric motors, improving vehicle efficiency and performance across all speed ranges by maintaining optimal operating conditions for the electric motor components.
Implementation Method 1
The passage discharges the pressurized fluid from under the fastener head onto the wire windings for cooling of the windings
Implementation Method 2
The passage discharges the pressurized fluid from under the fastener head onto the wire windings for cooling of the windings and lubrication of other components
Data Source
AI summary
An electro-mechanical drive-unit includes an input member, an output member, a drive-unit housing, and a gearing arrangement operatively connected to each of the output and input members. The drive-unit also includes a pump for circulating pressurized fluid and an electric motor. The electric motor includes a rotor connected to the gearing arrangement, a stator fixed relative to the drive-unit housing and having wire windings, and a motor housing configured to retain the rotor and the stator. The drive-unit also includes a fluid cavity between the drive-unit housing and the motor housing configured to receive the pressurized fluid. The drive-unit housing defines a passage in fluid communication with the fluid cavity. The drive-unit also includes a fastener having a head and a shank. The fastener is secured within the passage to facilitate discharging the fluid from under the fastener head onto the wire windings for cooling and/or lubrication thereof.