Electric Machine Cooling via Shroud Rotor Feed Path
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Solution Overview
Problem
Hybrid vehicle electric machines experience inefficiencies due to heat rejection, which affects their lifespan and operating efficiency, as existing cooling methods are not adequately effective in concentrating coolant near heat-generating components.
Innovation Solution
An electric machine module with a housing that includes a sleeve member, end caps with a shroud protruding into the machine cavity, and a coolant system that disperses coolant through apertures to concentrate it near stator end turns and redirect it towards the rotor using a variable-angled rotor feed path, enhancing heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used, then the electric machine can operate, but heat removal efficiency is insufficient and coolant is not concentrated near heat-generating components
Solution Approach 1:
The shroud structure creates a localized cooling zone by protruding into the machine cavity to form a stator cavity that concentrates coolant near the stator end turns, which are identified as heat-generating components. This localizes the cooling effect precisely where it is needed rather than distributing coolant uniformly throughout the machine.
Solution Approach 2:
The shroud acts as an intermediary structure between the coolant supply and the heat-generating stator end turns. It intercepts the coolant flow and redirects it to concentrate near the target components, serving as a mediator that improves heat transfer efficiency.
2Loss of energy
If a shroud structure is added to concentrate coolant, then cooling efficiency improves, but device complexity increases
Solution Approach 1:
The shroud is integrated as part of the end cap assembly, merging the cooling concentration function with the existing housing structure. This integration approach adds the necessary cooling functionality while minimizing the increase in overall device complexity by combining multiple functions into a single structural element.
3Quantity of substance
If coolant is dispersed through multiple apertures, then coolant distribution improves, but coolant concentration near specific components decreases
Solution Approach 1:
While coolant is dispersed through multiple apertures in the sleeve member for broad distribution, the shroud structure creates a localized concentration zone near the stator end turns. This achieves both widespread coolant availability and focused concentration at critical heat-generating areas.
Solution Approach 2:
The shroud serves as an intermediary that captures dispersed coolant from multiple apertures and redirects it to concentrate near the stator end turns, maintaining both distribution and concentration benefits.
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 configuration improves the cooling efficiency of electric machine components, extending their lifespan and enhancing operating performance by effectively concentrating coolant near heat-generating areas, thereby improving fuel economy and reducing emissions.
Implementation Method 1
the shroud, the sleeve member, and the at least one end cap can be positioned to define a stator cavity substantially surrounding the stator end turns in order to help concentrate a coolant within the stator cavity near the stator end turns
Implementation Method 2
Efficient removal of heat from the electric machine can improve the lifespan of the electric machine as well as improve the electric machine's operating efficiency
Data Source
AI summary
Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The electric machine module includes an electric machine and a housing enclosing the electric machine within a machine cavity. The housing can include at least one end cap positioned axially adjacent to the electric machine and including a shroud protruding into the machine cavity. The shroud can include a step with an angled rotor feed path.