Electric Machine Cooling via Rotor Hub Pump
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Solution Overview
Problem
Electric machines generate significant heat during operation, which can lead to reduced lifespan and reliability, and conventional cooling methods may not effectively manage this heat due to limitations in coolant circulation and distribution within the machine cavity.
Innovation Solution
An electric machine module with a coolant passage system within the rotor and a pump configuration that utilizes the rotor hub and output shaft to circulate coolant, enhancing heat dissipation through a network of channels and jackets within the machine cavity, including a coolant jacket surrounding the stator and apertures for coolant dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used with coolant circulation through inner walls or dispersion throughout the machine cavity, then heat removal is achieved, but cooling effectiveness is insufficient for high power output machines
Solution Approach 1:
The cooling system is segmented into multiple distinct pathways: a first coolant passage system within the rotor hub with inlet and outlet channels, and a second coolant passage system within the stator assembly. This segmentation allows independent optimization of cooling for each component, improving overall heat removal effectiveness for high power output machines.
Solution Approach 2:
The coolant passage systems are nested within the structural components themselves - the rotor hub and stator assembly - rather than being external additions. The inlet and outlet channels are integrated into the rotor hub structure, and cooling passages are embedded within the stator, maximizing cooling effectiveness while minimizing additional space requirements.
2Temperature
If external pumps are added to enhance coolant circulation, then cooling performance improves, but device complexity and production costs increase
Solution Approach 1:
The rotor hub is designed to function dual-purpose: as both a structural component and as a self-contained pump mechanism. The rotation of the rotor hub itself generates the coolant circulation through its integrated inlet and outlet channels, eliminating the need for separate external pumps and reducing device complexity while maintaining effective cooling.
Solution Approach 2:
The rotor hub serves multiple functions simultaneously: structural support for the rotor, mechanical drive element, and coolant circulation pump. This multi-functionality integrates the pumping action into the existing rotational mechanism, avoiding additional components and reducing overall system complexity.
3Temperature
If coolant passages are integrated within the rotor and stator, then heat dissipation from critical components improves, but manufacturing complexity increases
Solution Approach 1:
The coolant passages are merged with the rotor hub and stator assembly structures themselves rather than being separate components. The inlet and outlet channels are formed as integral parts of the rotor hub, and cooling passages are incorporated within the stator assembly, allowing heat dissipation from critical components while using conventional manufacturing techniques for integrated structures.
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 effectively manages heat dissipation by circulating coolant through the machine cavity, maintaining the electric machine's performance and longevity by transferring heat away from critical components, even when the machine is not in operation, and reduces the need for external pumps, thereby minimizing size and production costs.
Implementation Method 1
a considerable amount of heat energy can by generated by both the stator and the rotor... remove heat from the machine... circulating a coolant through portions of the machine cavity
Implementation Method 2
the movement of the electric machine can lead to coolant circulation by the pump... the pump can be coupled to the rotor hub and/or the output shaft, as the rotor hub, and the movement created by these components can drive operation of the pump
Data Source
AI summary
Embodiments of the invention provide an electric machine module including an electric machine. The electric machine includes a rotor and a stator assembly, and an output shaft having a longitudinal axis that is circumscribed by a portion of the rotor. The output shaft may comprise an output shaft channel and the rotor may include a rotor channel, and the rotor and the output shaft channels may be in fluid communication. The machine further includes a coolant jacket at least partially within a sleeve member that circumscribes at least a portion of the stator assembly, and at least one pump mounted generally concentrically with respect to the output shaft, that is in fluid communication with the coolant jacket. Some embodiments of the electric machine module include coupling to a fluid system that is configured and arranged to transport fluid, such as the coolant, throughout the fluid system.