Fluid-Cooled Inductive Power Transmission for Electric Machines
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Solution Overview
Problem
Existing electric machines for vehicles face challenges in maintaining continuous operation and preventing wear due to the need for rotor voltage or current transmission, particularly in separately excited motors, where contact-based methods are prone to failure and non-contact methods require separate cooling systems, leading to inefficiencies and increased costs.
Innovation Solution
An electric machine design featuring a contactless inductive power transmission device with a fluid-cooled system that integrates a primary and secondary coil setup, where a fluid tube supplies coolant to both the rotor assembly and power transmission device, allowing for efficient cooling and lubrication, reducing the need for separate cooling systems and minimizing size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactless inductive power transmission is used for rotor voltage or current transmission, then reliability is improved by eliminating sliding contacts and wear, but device complexity increases due to the need for separate cooling systems for the power transmission device
Solution Approach 1:
The patent combines the cooling functions for both the rotor assembly and the power transmission device into a single integrated cooling system. A fluid tube with outlets is positioned to distribute coolant to both components simultaneously, eliminating the need for separate cooling systems and reducing overall device complexity while maintaining the reliability benefits of contactless power transmission
Solution Approach 2:
The cooling fluid system is designed to serve multiple functions: it cools the rotor assembly through traditional rotor outlets and simultaneously cools the power transmission device through strategically positioned outlets. This multi-functional cooling approach reduces the number of separate systems needed while effectively managing thermal loads from both components
2Temperature
If separate cooling systems are used for rotor assembly and power transmission device, then each component can be cooled effectively, but device complexity and cost increase
Solution Approach 1:
The patent merges multiple cooling functions into a single integrated cooling system. A unified fluid tube distributes coolant to both the rotor assembly and the power transmission device through strategically positioned outlets, achieving effective cooling of both components while eliminating the need for separate cooling systems and reducing overall complexity
3Weight of moving object
If a compact design is pursued to reduce size and weight, then vehicle integration is improved, but cooling efficiency may be compromised
Solution Approach 1:
The patent employs a nested cooling tube configuration where the fluid tube is positioned within or alongside existing structural components of the rotor assembly. This nesting approach allows the cooling system to occupy minimal space within the compact rotor structure, maintaining effective cooling capability while preserving the compact design and minimizing additional weight
Solution Approach 2:
The cooling outlets are strategically positioned in three-dimensional space to optimize cooling coverage. By distributing outlets at different locations and orientations, the system achieves comprehensive cooling of both the rotor assembly and power transmission device within a compact volume, maintaining cooling efficiency without increasing overall size
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 design enhances the efficiency and reliability of the electric machine by providing effective cooling for both the rotor assembly and power transmission device, reducing overheating risks, and simplifying the cooling system, thereby lowering costs and improving operational stability.
Implementation Method 1
the power transmission device contains a transmitter attached to the housing, and a transmitter attached to the rotor... rotor current, in particular an alternating current, is transmitted from the housing transmitter to the rotor transmitter
Implementation Method 2
a tube with which the rotor assembly is supplied with a fluid. The tube has at least one outlet inside the power transmission device, through which fluid flows through the power transmission device for cooling purposes
Implementation Method 3
fluid flows through the power transmission device for cooling purposes
Data Source
AI summary
An electric machine for a vehicle that has a housing, a rotor assembly which can rotate about a rotational axis in the housing, a contactless power transmission device for transmitting electricity to the rotor assembly, in which the power transmission device contains a housing transmitter and a rotor transmitter, wherein the housing transmitter contains a primary core and primary coil, and the rotor transmitter contains a secondary core and a secondary coil, wherein there is a fluid tube for supplying the rotor assembly with fluid that runs coaxially through the rotor assembly, in which the fluid tube has at least one fluid outlet inside the power transmission device, such that a fluid flow path runs through the power transmission device in order to cool the power transmission device.