Electric Machine Cooling Channel Design
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Solution Overview
Problem
Existing cooling systems for electrical machines are complex and require intricate routing of heat mediums to effectively dissipate heat loss from multiple components, particularly in power applications, where both the stator and other components like end windings and power electronics need to be cooled.
Innovation Solution
A cooling channel is designed with a longitudinal section along the stator and an end face section that extends radially, allowing the heat medium to flow in the axial and radial directions respectively, enabling simple cooling of both the stator's peripheral surface and components like end windings and power electronics without additional fluid-technical measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate cooling channels are used to cool different components (stator, end windings, power electronics), then each component can be cooled effectively, but the cooling system becomes complex and requires additional fluid-technical components
Solution Approach 1:
The patent merges multiple cooling functions into a single integrated cooling channel that serves the stator, end windings, and power electronics simultaneously. The cooling channel is designed with a longitudinal section along the stator and end-face sections that extend radially to reach other components, eliminating the need for separate cooling systems for each component.
Solution Approach 2:
The single cooling channel is designed to perform multiple cooling functions throughout the electric machine. By extending the cooling channel radially at the end faces and providing thermal connections to various components, one cooling system universally serves multiple heat-generating components that would traditionally require separate cooling arrangements.
2Device complexity
If a single cooling channel is used to cool multiple components, then the design becomes compact and simple, but it may be difficult to effectively cool all components with different thermal requirements
Solution Approach 1:
The cooling channel transitions from a purely longitudinal arrangement to include radial extensions at the end faces. This dimensional change allows the single cooling channel to access and cool components located at different positions and orientations within the electric machine, maintaining cooling effectiveness while preserving design simplicity.
Solution Approach 2:
The cooling channel is segmented into different sections: a longitudinal section for cooling the stator and radially extending end-face sections for cooling other components. This segmentation within a unified system allows each section to be optimized for its specific cooling target while maintaining overall system simplicity.
3Reliability
If cooling channels are routed to access all heat-generating components, then comprehensive cooling is achieved, but the routing becomes intricate and requires additional fluidic components
Solution Approach 1:
Instead of routing separate cooling channels to each component, the patent combines all cooling functions into one continuous cooling channel structure. The longitudinal and radial sections are integrated into a single fluidic path, eliminating the need for distributors, junctions, or multiple separate channels, thereby simplifying manufacturing.
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 allows for a compact and straightforward heat dissipation design, effectively cooling all necessary components with a single cooling duct, reducing structural complexity and eliminating the need for additional cooling components like distributors.
Implementation Method 1
a cooling channel (60) located inside the housing (20), which has a longitudinal section (62, 64) and an end-face section (66), wherein the longitudinal section (62, 64) extends along a circumferential surface of the stator (30, 32) and the end-face section (66) extends along an end face of the stator (30, 32) or the electric machine (10)
Implementation Method 2
The longitudinal section, and thus the flow of the heat medium there, proceeds in the axial direction, while the end-face section, and thus the flow of the heat medium there, proceeds in the radial direction or at least in a direction perpendicular to the axial direction
Data Source
Figure 1
Figure 2
AI summary
An electric machine (10) comprising a housing (20), a stator (30, 32) and a rotor (40, 42) is described. The stator (30, 32) embraces the rotor (40, 42). The rotor (40, 42) includes a shaft (42). The electric machine (10) is equipped with power electronics (40) inside the housing (20). The electric machine (10) includes a cooling duct (62, 64, 66) that extends along a longitudinal section (62, 64) and a front section (66). The longitudinal section (62, 64) extends along a hollow cylinder, through the interior of which extends the axis of rotation (50) of the shaft (42). The front section (66) extends towards the shaft (42).