Electric Machine Cooling with Slinger Mechanism and Segmented Jackets
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Solution Overview
Problem
The performance and durability of electric machines are compromised by high temperatures, which can lead to increased internal resistance and risk of demagnetization in interior permanent magnet machines, and polymer-based insulation systems suffer from cumulative damage, necessitating effective heat extraction methods to extend machine lifespan.
Innovation Solution
The electric machine module incorporates a housing with coolant jackets and end cap configurations, including semi-sealed and semi-open chambers, to enhance cooling efficiency, utilizing pressurized coolants that circulate through the system to absorb and transfer heat energy effectively, with a slinger mechanism to recycle coolant and increase contact time and velocity on stator end turns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If high dielectric strength coolant (oil) is used for cooling, then thermal efficiency and cost-effectiveness are improved, but incompatibility with some applications and potential harm to components occurs
Solution Approach 1:
The cooling system is divided into separate zones: an oil-cooled region for the stator windings (using high dielectric strength coolant for thermal efficiency) and a water-cooled region for power electronics (using compatible coolant). This segmentation allows each component to receive appropriate cooling without incompatibility issues
Solution Approach 2:
A barrier layer or seal structure is introduced between the oil coolant and power electronics components to prevent direct contact. This intermediary allows the oil cooling system to maintain thermal efficiency while preventing harmful effects on incompatible components
2Loss of energy
If coolant velocity and contact time on stator end turns are increased, then cooling efficiency is improved, but device complexity increases due to slinger mechanism
Solution Approach 1:
The slinger mechanism is driven by the rotation of the stator end turns themselves, utilizing the existing motion of the component to be cooled. This self-service approach increases coolant velocity and contact time without requiring an independent power source or complex external drive mechanism
Solution Approach 2:
The cooling function is merged with the existing rotational motion of the stator end turns. The slinger mechanism combines the cooling delivery function with the operational motion of the machine, eliminating the need for separate cooling pumps or motors and reducing overall device complexity
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 significantly enhances cooling efficiency, prolongs the lifespan of electric machine components by effectively managing heat, reducing the risk of demagnetization and extending the machine's operational life while maintaining cost-effectiveness.
Implementation Method 1
utilizing pressurized coolants that circulate through the system to absorb and transfer heat energy effectively
Implementation Method 2
pressurized coolants that circulate through the system to absorb and transfer heat energy effectively
Implementation Method 3
with a slinger mechanism to recycle coolant and increase contact time and velocity on stator end turns
Data Source
AI summary
Some embodiments of the invention provide an electric machine module comprising a housing including a sleeve member and at least one end cap. In some embodiments, the sleeve member can include a first coolant jacket and a second coolant jacket. Also, in some embodiments, the end cap can include an end cap coolant jacket. Also, some embodiments provide an electric machine including stator end turns, housing at least partially enclosing the electric machine, and an end cap coolant jacket positioned substantially axially outward relative to at least one of the stator end turns.