Electric Machine Cooling via Directed Coolant Apertures
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Solution Overview
Problem
Electric machines experience inefficient operations due to insufficient heat dissipation at the stator end turns, primarily because air convection is inadequate for transferring heat energy to the stator core and housing, leading to significant copper losses.
Innovation Solution
The electric machine module incorporates a coolant jacket within the housing with strategically positioned coolant apertures that direct varying volumes of coolant to different impingement locations on the stator end turns, enhancing heat transfer by minimizing the distance between the coolant and the heat-producing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air convection is used for heat dissipation, then the structure is simple, but the heat transfer efficiency is insufficient
Solution Approach 1:
The patent introduces a coolant jacket with coolant apertures that direct liquid coolant onto the stator end turns. This hydraulic cooling system replaces inadequate air convection with efficient liquid coolant flow, achieving superior heat transfer from the stator end turns while maintaining operational simplicity.
2Device complexity
If uniform coolant distribution is provided, then the system is simple, but thermal imbalances at different impingement locations cannot be addressed
Solution Approach 1:
The patent configures coolant apertures with varying orientations and positions to direct coolant to different impingement locations on the stator end turns. This creates locally optimized coolant distribution that addresses thermal imbalances at specific locations, with each aperture tailored to its target region's cooling needs.
Solution Approach 2:
The coolant apertures are arranged asymmetrically with different orientations relative to the stator end turns. This asymmetric configuration enables differentiated coolant delivery to various impingement locations, effectively managing thermal gradients and hot spots that would be impossible with uniform symmetric distribution.
3Ease of manufacture
If coolant apertures are positioned far from stator end turns, then manufacturing is easier, but heat transfer efficiency decreases
Solution Approach 1:
The coolant apertures are strategically positioned and oriented during manufacturing to direct coolant flow precisely onto the stator end turns before the system operates. This preliminary configuration ensures optimal heat transfer pathways are established in advance, maximizing cooling efficiency from the start of operation.
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 configuration optimizes coolant distribution, reducing thermal imbalances and improving heat energy transfer, leading to more efficient operation and extended lifespan of the electric machine by effectively managing heat dissipation.
Implementation Method 1
a coolant jacket can be at least partially positioned within the housing... a plurality of coolant apertures can be disposed through at least a portion of the housing to fluidly connect the coolant jacket and the machine cavity... direct varying volumes of coolant to different impingement locations on the stator end turns
Data Source
AI summary
Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, a coolant jacket can be at least partially positioned within the housing. In some embodiments, a plurality of coolant apertures can be disposed through at least a portion of the housing to fluidly connect the coolant jacket and the machine cavity. The coolant apertures can include a first group configured and arranged to direct a first volume from the coolant jacket. The coolant apertures can include a second group configured and arranged to direct a second volume from the coolant jacket. In some embodiments, the first volume can be greater than the second volume.