Electric Machine Cooling Jacket with Variable Radial Length
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Solution Overview
Problem
Electric machines generate heat during operation, which can impact their performance and lifespan, and existing cooling solutions often fail to effectively manage this heat due to inefficient coolant distribution around the stator end turns.
Innovation Solution
The electric machine module incorporates a housing with a coolant jacket that includes radial extensions and a thermal flange, allowing pressurized coolant to circulate closely around the stator end turns, enhancing heat transfer through a non-uniform radial length configuration and improved thermal communication between the stator assembly and the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional coolant jacket design is used, then the structure is simple, but the heat transfer efficiency is insufficient due to inadequate coolant distribution around the stator end turns
Solution Approach 1:
The coolant jacket is segmented into multiple regions with different radial lengths, creating distinct cooling zones. The first coolant jacket portion has a first radial length while the second coolant jacket portion has a second radial length that is greater than the first, allowing differentiated cooling strategies for different stator end turn regions.
Solution Approach 2:
Different portions of the coolant jacket are designed with different radial lengths to match the local heat generation characteristics. The extended radial length in the second portion provides enhanced cooling capacity where needed, while maintaining a compact design in regions with lower heat generation demands.
2Temperature
If the coolant jacket is positioned far from the stator end turns, then the structure is simpler to manufacture, but the thermal communication and cooling effectiveness are reduced
Solution Approach 1:
The coolant jacket is designed with variable radial length to dynamically adapt to the heat distribution pattern of the stator end turns. This allows the cooling system to maintain optimal thermal communication without requiring uniform proximity throughout, reducing manufacturing precision requirements while preserving cooling effectiveness.
Solution Approach 2:
The solution transitions from a uniform radial distance approach to a multi-dimensional radial length configuration. By varying the radial length in different angular positions, the design achieves superior thermal communication without requiring the coolant jacket to be uniformly close to all stator end turns, 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 design effectively increases heat energy transfer by minimizing the distance between the coolant and heat-generating components, leading to improved cooling efficiency and extended machine lifespan.
Implementation Method 1
enhancing heat transfer through a non-uniform radial length configuration and improved thermal communication between the stator assembly and the housing
Implementation Method 2
allowing pressurized coolant to circulate closely around the stator end turns, enhancing heat transfer
Data Source
AI summary
Embodiments of the invention provide an electric machine module. The module can include a housing that can define a machine cavity. The housing can include a sleeve member that can include a first axial sleeve member comprising a first flange, a second flange, and first recess at least partially defined between the first flange and the second flange. The sleeve member can also include a second axial sleeve member comprising a third flange, a fourth flange, and a second recess at least partially defined between the first flange and the second flange. The first axial sleeve member can be coupled to the second axial sleeve member to form the sleeve member and so that the first recess and the second recess form a coolant jacket. An electric machine can be positioned within the machine cavity so that it is substantially circumscribed by a portion of the coolant jacket.