Extruded Cooling Jacket for Electric Motor with Multi-Directional Flow
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Solution Overview
Problem
Traditional motor cooling jackets made from cast components are costly, inflexible, and limited in cooling capability, requiring unique castings for each motor configuration and involving costly end cap modifications for fluid flow redirection.
Innovation Solution
An extruded cooling jacket with discrete passages that allow multi-directional fluid flow without the need for end cap modifications, formed from a single-piece or multiple extruded sections that can be easily cut to size, providing a cost-effective and flexible cooling solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece cast cooling jacket with cast-in-place cooling tubes is used, then the cooling jacket provides structural integrity and cooling function, but the manufacturing cost is high and lead time is long due to costly cast tooling
Solution Approach 1:
The cooling jacket is divided into a body portion and separate end caps that can be manufactured independently through casting, then assembled together. This segmentation allows each component to be optimized for its specific function while reducing overall manufacturing complexity and cost.
Solution Approach 2:
The cooling passages are formed by combining the body portion with the end caps, creating integrated fluid flow paths without requiring complex cast-in-place cooling tubes. The merging of these components achieves the cooling function while simplifying the manufacturing process.
2Adaptability or versatility
If cast tooling is used for each different motor configuration, then the cooling jacket can be customized for specific motor designs, but the manufacturing flexibility is reduced and each configuration requires unique tooling
Solution Approach 1:
The end caps are designed as universal components that can be used across multiple motor configurations. By standardizing the end cap design and using them in combination with different body portions, the system achieves adaptability to various motor designs without requiring unique tooling for each configuration.
Solution Approach 2:
The cooling passages are pre-formed in the body portion and end caps through separate casting processes, allowing these components to be manufactured independently and then assembled. This preliminary formation of cooling passages eliminates the need for complex post-casting modifications and enables greater manufacturing flexibility.
3Reliability
If end caps are enclosed with fluid channels to redirect fluid flow, then the cooling jacket can provide complete fluid circulation, but the manufacturing cost increases due to additional forming or machining operations
Solution Approach 1:
The fluid circulation system is segmented into the body portion and end caps, with cooling passages extending into the end caps. This segmentation allows the end caps to be manufactured with integrated cooling passages through simple casting, eliminating the need for costly additional forming or machining operations while maintaining complete fluid circulation.
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 extruded cooling jacket design enhances cooling efficiency and flexibility, reducing costs by eliminating the need for costly cast tooling and end cap machining, while accommodating various motor configurations with a single extrusion process.
Implementation Method 1
a plurality of discrete cooling passages that cooperate to cool the motor
Data Source
AI summary
A cooling jacket for a motor includes an extruded jacket body having an outer peripheral surface, an inner peripheral surface, and a plurality of discrete cooling passages located between the inner and outer peripheral surfaces that provide multi-directional fluid flow. A fluid inlet is provided to direct cooling fluid into the jacket body and a fluid outlet to direct heated fluid away from the jacket body.