Electric Machine Temperature Sensor in Neutral Bridge
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Solution Overview
Problem
Current thermal management systems for electric machines in electrified vehicles face challenges in accurately measuring temperatures, particularly in high-power traction batteries and electric machines, where overheating can lead to system failure and reduced efficiency.
Innovation Solution
The integration of a temperature sensor with an insertion portion and sensing element into an electrical bridge or neutral bridge of the electric machine, featuring a planar body and mounting feature that secures the sensor in place, allowing for precise temperature measurement near the critical windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is integrated into the electrical bridge or neutral bridge, then temperature measurement precision is improved, but device complexity increases
Solution Approach 1:
The temperature sensor is integrated directly into the electrical bridge or neutral bridge structure, merging the sensing function with the existing electrical component. This combination allows the sensor to be positioned at critical locations near the windings without adding separate measurement devices, thereby improving temperature measurement precision while minimizing overall device complexity.
Solution Approach 2:
The insertion portion with sensing element acts as an intermediary component that bridges the gap between the electrical bridge structure and the thermal management system. This intermediary design enables precise temperature monitoring at critical locations without requiring direct integration of complex sensor assemblies into the windings themselves.
2Reliability
If the sensor is securely attached to the stator core, then temperature monitoring reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The mounting feature is pre-formed as an integral part of the electrical bridge or neutral bridge structure during manufacturing. This preliminary action ensures that the temperature sensor can be securely attached to the stator core through a simple insertion process, improving temperature monitoring reliability without significantly increasing manufacturing complexity. The pre-formed mounting feature eliminates the need for complex assembly operations.
Data Source
AI summary
An electric machine includes a stator having hairpin windings with at least first and second phases and a neutral bridge attached to the at least first and second phases. The neutral bridge defines a planar body and a mounting feature extending from an upper surface of the body and cooperating with the body to define an opening. A temperature sensor of the electric machine includes an insertion portion having a sensing element. The insertion portion is received in the opening.