E-Machine Nozzle Cooling for Stator End Windings
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Solution Overview
Problem
Conventional cooling systems for e-machines are inefficient and limit the performance of e-machines due to excessive thermal conditions, which can be addressed by providing an improved cooling system that efficiently circulates cooling fluid to the stator.
Innovation Solution
The e-machine incorporates a housing with nozzles spaced circumferentially about the axis of rotation, directing cooling fluid radially toward the stator end windings to provide a collective spray profile that covers a majority of the stator's circumference, ensuring effective and efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling systems are used for the stator, then the e-machine can operate, but the cooling effectiveness is limited and thermal conditions become excessive
Solution Approach 1:
The cooling system is segmented into multiple nozzles distributed circumferentially around the stator, with each nozzle independently directing coolant to specific zones. This segmentation allows targeted cooling of different stator regions, improving overall thermal management effectiveness compared to conventional single-point or limited-zone cooling systems.
Solution Approach 2:
Different nozzles are positioned and angled to provide localized cooling quality matching the thermal load distribution of the stator. The circumferential arrangement ensures that each stator zone receives appropriate cooling intensity, addressing local thermal conditions rather than applying uniform cooling throughout.
2Manufacturing precision
If the nozzle arrangement is fixed to the housing, then positioning is stable, but manufacturing and assembly complexity increases
Solution Approach 1:
The nozzle arrangement is designed with removable and reconfigurable mounting features that allow the nozzles to be dynamically positioned and adjusted during assembly and maintenance. This dynamic approach enables precise positioning without permanent fixed connections, simplifying manufacturing and assembly processes while maintaining positioning accuracy.
Solution Approach 2:
The nozzles are pre-positioned and pre-adjusted as modular units before final installation in the housing. This preliminary action allows for precise positioning to be achieved during assembly rather than requiring complex precision manufacturing of fixed mounting structures, reducing overall manufacturing 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
The solution effectively reduces misting, evaporation, and deposit formation, providing high atomization and fluid flow to maintain high efficiency and compact design while allowing efficient manufacturing.
Implementation Method 1
the plurality of nozzles is configured for atomizing a cooling fluid and spraying the cooling fluid in a collective spray profile
Data Source
AI summary
An e-machine includes a housing and a rotating group supported for rotation about an axis of rotation within the housing. The e-machine includes a stator with a plurality of end windings. The e-machine further includes a plurality of nozzles that is removably supported by the housing and spaced apart in a circumferential direction about the axis of rotation. The plurality of nozzles is directed generally radially toward the axis of rotation and toward the plurality of end windings for spraying a cooling fluid on respective ones of the plurality of end windings.