Electric Machine Radial Air Cooling for Tight Axial Mounting
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Solution Overview
Problem
Existing air cooling systems for electric machines are inefficient, particularly in tight axial configurations, as they often obstruct airflow due to axial air intakes and outlets, leading to overheating and reduced efficiency and lifespan.
Innovation Solution
The design incorporates a radial air intake and outlet system within the housing, featuring an air passage with channels that direct ambient airflow through a heat sink, allowing for efficient cooling and mounting in close proximity to adjacent structures without obstructing airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If air intake and outlet are positioned on axial ends of the machine, then cooling function is provided, but the machine cannot be mounted in tight axial configurations due to obstruction
Solution Approach 1:
The patent transitions the air intake and outlet from axial positioning (along the rotation axis) to radial positioning (perpendicular to the rotation axis). This dimensional change allows the machine to be mounted in tight axial configurations while maintaining unobstructed airflow paths, as the air passages now extend radially through the housing rather than axially.
2Reliability
If air passages are configured for axial airflow, then cooling is achieved, but airflow is obstructed in tight mounting configurations
Solution Approach 1:
The air passages are reconfigured to extend in the radial direction rather than the axial direction. This allows the machine to adapt to various mounting configurations including tight axial spaces, while the radial airflow paths remain unobstructed. The housing includes radially extending air passages that guide airflow from radial intakes through the motor assembly to radial outlets.
3Adaptability or versatility
If radial air passages are implemented, then mounting in tight axial configurations is enabled, but air passage design complexity increases
Solution Approach 1:
The housing structure is designed to integrate the air passages directly into its walls, merging the structural function of the housing with the flow guidance function of the passages. The housing walls themselves form the air passages that extend radially, eliminating the need for separate complex passage structures and simplifying manufacturing while maintaining adaptability.
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 prevents overheating by facilitating efficient airflow through the electric machine, extending its operational life and enabling mounting in tight axial configurations without obstructing airflow.
Implementation Method 1
a heat sink positioned at least partially within the air passage and thermally connected to the electronics assembly
Implementation Method 2
directs the airflow along the heat sink
Data Source
AI summary
An electric machine includes a housing having an air intake, an air outlet, and defining an air passage therein. The air passage includes a first channel extending from the air intake in a radial direction and a second channel extending in the radial direction to the outlet. The electric machine further includes a motor assembly positioned within the housing that includes a shaft that rotates about a rotational axis that is generally perpendicular to the radial direction. The electric machine further includes an electronics assembly within the housing interior and a heat sink positioned at least partially within the air passage and thermally connected to the electronics assembly. Operation of the motor assembly draws an ambient airflow into the air passage in the radial direction through the air intake, directs the airflow along the heat sink, and exhausts the airflow through the air outlet in the radial direction.