Electric Machine Power Module Cooling for Compact Motor Housings
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Solution Overview
Problem
Effective cooling of power electronic systems in electric machines, particularly in motor vehicles, is challenging due to limited installation space, which can lead to overheating and damage.
Innovation Solution
A modular electric machine design with a separately housed power electronic module that includes a cooling plate and conductor board, allowing for independent cooling of the power electronic system and stator windings using separate cooling circuits and coolants, enabling efficient heat dissipation and easy replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the power electronic system is integrated into the housing with the stator and rotor, then the machine structure is compact, but the cooling of the power electronic system becomes problematic due to limited installation space
Solution Approach 1:
The power electronic system is segmented from the main machine housing and integrated into a separate power electronic module. This module can be inserted into or removed from the housing, providing dedicated space for the power electronics while maintaining overall compactness. The segmentation allows independent cooling solutions for the power electronic components without compromising the compact integration of the entire drive system.
2Temperature
If a cooling device is added to dissipate waste heat from the power electronic system, then the temperature control is improved, but the device complexity increases
Solution Approach 1:
The cooling device for the power electronic system is merged with the existing cooling system of the electric machine. The power electronic module includes cooling elements that can be integrated with the stator cooling passages, allowing a single cooling circuit to serve both the power electronics and the stator windings. This merging approach improves temperature control while minimizing the increase in system complexity by utilizing existing cooling infrastructure.
3Ease of repair
If the power electronic system is formed as a separate module, then the ease of repair is improved by allowing easy replacement, but the device complexity increases due to additional modular components
Solution Approach 1:
The power electronic system is segmented into a separate, self-contained module that can be easily inserted into or removed from the housing. This modular design enables straightforward replacement of the power electronic components during repair or maintenance without disassembling the entire machine. The segmentation creates a standardized interface between the module and housing, simplifying the replacement process despite the added modular complexity.
4Temperature
If separate cooling circuits are used for the power electronic system and stator, then the temperature control precision is improved, but the device complexity increases
Solution Approach 1:
The cooling system is designed with dynamic control capabilities that allow the cooling circuits for the power electronic system and stator to be operated independently when needed, providing precise temperature control for each component. The system can switch between coupled and decoupled cooling modes based on operational requirements, optimizing temperature management while minimizing the complexity increase from having separate cooling circuits.
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 dissipates waste heat from both the power electronic system and stator windings, ensuring reliable operation and easy maintenance by allowing independent adjustment of cooling capacities and using different temperature levels for sensitive electronic components.
Implementation Method 1
the power electronic module comprises a cooling plate for cooling the power electronic system
Implementation Method 2
waste heat generated by the power electronic system can be dissipated
Implementation Method 3
the field coils generate a magnetic field, typically a magnetic dipole field
Implementation Method 4
With magnetic interaction between the magnetic (stator) field generated by the stator and the magnetic (rotor) field generated by the rotor, the rotor can be set into rotary motion
Implementation Method 5
A magnetic field is also generated by the rotor in that permanent magnets or—similar to the stator—magnetic field coils are provided on the same
Data Source
AI summary
An electric machine, in particular for a motor vehicle, is provided. The machine includes a housing, which is designed open and partially surrounds a housing interior. The machine, furthermore, includes a rotor, which is arranged rotationally adjustably relative to the housing in the housing interior. The machine additionally includes a stator, which is arranged fixed in place relative to the housing in the housing interior and includes multiple magnetic field coils with electrically energizable stator windings. For electrically energizing the stator windings the field coils are electrically connectable or connected to a power electronic system. The power electronic system includes a cooling plate for cooling the power electronic system and is formed by a power electronic module that is formed separately from the housing and can be inserted into the housing interior.