Electric Machine Internal Cooling With Direct Airflow Pathways
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Solution Overview
Problem
Current cooling systems for electric machines in electric vehicles are complex, costly, and unsustainable, involving multiple circulation systems, heat exchangers, and heavy components that do not align with sustainability objectives.
Innovation Solution
A direct internal cooling system for electric machines that uses a housing with ducts and coolant pathways for direct thermal communication, an external cooling means comprising a fan and water injector module to deliver a cooling airflow or aerosol directly to internal components, and a control system to regulate temperature based on sensor data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional liquid cooling systems with multiple circulation systems, heat exchangers, pipes, and tubes are used, then effective heat dissipation is achieved, but device complexity, weight, and production costs increase significantly
Solution Approach 1:
The patent extracts and eliminates unnecessary intermediate components (heat exchangers, multiple circulation systems, complex piping) from the traditional cooling system, retaining only the essential cooling function through direct internal coolant pathways that contact heat-generating components directly
Solution Approach 2:
The patent merges the cooling function directly into the motor structure by integrating coolant pathways within the stator and rotor assemblies, combining the cooling system with the motor housing and internal components to eliminate separate cooling subsystems
2Temperature
If traditional liquid cooling systems with heat exchangers and multiple circulation systems are implemented, then thermal management is effective, but weight increases due to heavy components
Solution Approach 1:
The patent removes heavy components such as heat exchangers, large radiators, and complex pumping systems, replacing them with lightweight internal coolant channels that utilize the existing motor structure for heat dissipation
Solution Approach 2:
The patent employs a simplified hydraulic cooling approach using direct internal coolant flow through the motor components, eliminating the need for heavy liquid-to-liquid heat exchangers and complex circulation infrastructure
3Temperature
If traditional cooling systems with multiple circulation systems and heat exchangers are used, then heat dissipation is effective, but production costs increase
Solution Approach 1:
The patent eliminates expensive components such as heat exchangers, multiple pumps, and complex piping systems, reducing the bill of materials and assembly requirements while maintaining effective cooling through direct internal pathways
Solution Approach 2:
The patent combines the cooling function with the motor manufacturing process by integrating coolant channels directly into the stator and rotor assemblies during motor production, eliminating the need for separate cooling system assembly and reducing overall production costs
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 solution reduces weight and production costs, improves thermal management, prevents overheating, and enhances the sustainability of electric machines by eliminating the need for pipes and heat exchangers, ensuring efficient and reliable operation within safe temperature ranges.
Implementation Method 1
The one or more coolant pathways are configured to be in direct thermal communication with one or more internal parts of the EM
Implementation Method 2
delivering a coolant comprising a cooling airflow to the one or more coolant pathways
Implementation Method 3
delivering a coolant comprising a cooling airflow or aerosol
Data Source
Figure 1a
Figure 1b~1c
Figure 2~3
AI summary
The present disclosure relates to methods, systems, an electric machine (EM), a vehicle and a computer-readable storage medium and a computer program product. The EM comprises a housing and a stator unit and a rotor unit arranged therein and supported by the housing. The direct internal cooling system for the EM comprises an external cooling means configured for regulating an operational temperature of the one or more internal parts of the EM. The external cooling means is arranged separately from the EM and proximal to the housing of the EM, and is further configured for delivering a coolant comprising a cooling airflow to the EM and thereby regulating the operational temperature of the one or more internal parts of the EM.