Hybrid Module Stator Assembly Cooling and Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hybrid module stator assemblies face challenges in efficient cooling and structural integration with transmission cases, particularly in multi-speed planetary transmissions, where thermal management and secure fixation are critical but often inadequately addressed.
Innovation Solution
A stator assembly design incorporating a stator carrier with an inner cylindrical surface, a shrink-fitted stator segment, a water jacket fixed by circumferential welds, and a fluid port for cooling, along with a resolver stator extension and high voltage bus bar connections, which is securely attached to a transmission case using circumferential welds and rivets, enhancing thermal management and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a water jacket is added to the stator assembly for cooling, then thermal management is improved, but device complexity increases
Solution Approach 1:
The water jacket is integrated with the stator carrier to form a unified structure, combining the structural support function with the cooling function in a single component. This merging approach adds cooling capability while minimizing the increase in overall device complexity.
Solution Approach 2:
The stator carrier serves multiple functions: it provides structural support for the stator segment and simultaneously acts as a mounting structure for the water jacket, which performs cooling. This multi-functionality reduces the need for separate dedicated cooling components.
2Strength
If circumferential welds are used to fix the water jacket to the stator carrier, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
Welding replaces mechanical fastening methods (such as bolts or rivets) to join the water jacket to the stator carrier. This substitution provides superior structural integrity and sealing while eliminating the need for additional fastening components and assembly steps.
3Reliability
If a resolver stator extension with opening is added for high voltage connection, then electrical connectivity is improved, but device complexity increases
Solution Approach 1:
The high voltage connection feature is integrated into the resolver stator extension by incorporating an opening directly in the extension structure. This merging of electrical connection functionality into the existing structural component avoids adding separate connection hardware.
Solution Approach 2:
The resolver stator extension serves dual purposes: it provides structural support for the resolver stator and simultaneously incorporates the opening for high voltage bus bar connection. This multi-functionality reduces the need for separate electrical connection components.
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 proposed stator assembly effectively cools the hybrid module through fluid circulation and securely integrates with the transmission case, improving thermal performance and structural reliability, thus addressing the inefficiencies in existing designs.
Implementation Method 1
a fluid port fixed to the water jacket and arranged to guide a fluid into or out of the sealed chamber to cool the stator assembly
Implementation Method 2
The stator segment is installed in the inner cylindrical surface by shrink fitting
Data Source
AI summary
A stator assembly for a hybrid module includes a stator carrier, a stator segment, and a water jacket. The stator carrier has an inner cylindrical surface and the stator segment is installed in the inner cylindrical surface. The water jacket is fixed to the stator carrier to enclose a sealed chamber therebetween. The water jacket may be fixed to the stator carrier by a pair of circumferential welds at opposite ends of the sealed chamber. The stator assembly may include a fluid port fixed to the water jacket and arranged to guide a fluid into or out of the sealed chamber to cool the stator assembly.