Integrated Housing Coolant Jacket for Electric Machine Stator
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Solution Overview
Problem
Conventional oil-cooled electric machine modules have inefficiencies in coolant distribution and cooling effectiveness due to the radial gap between the steel canister and cast aluminum housing, leading to suboptimal heat dissipation from stator end turns.
Innovation Solution
The electric machine module incorporates a housing with coupled members forming a coolant jacket around the stator, featuring circumferential and axial flow paths with apertures to enhance coolant circulation and distribution, eliminating the need for a separate canister and improving cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a radial gap is created between the steel canister and cast aluminum housing to form an oil jacket, then coolant circulation is enabled, but cooling effectiveness to stator end turns is reduced
Solution Approach 1:
The patent merges the steel canister and cast aluminum housing into a single integrated housing structure. The housing includes both the coolant jacket region and the stator mounting structure as unified components, eliminating the need for a separate canister and improving coolant distribution to stator end turns through integrated aperture placement.
Solution Approach 2:
The patent adds axial flow paths in addition to the traditional radial coolant flow. By creating aperture patterns that enable both radial and axial coolant movement, the system enhances cooling effectiveness to stator end turns from multiple dimensional directions simultaneously.
2Strength
If a separate steel canister is used to mount the electric machine, then structural support is provided, but cooling system complexity increases
Solution Approach 1:
The patent combines the previously separate steel canister and cast aluminum housing into a single integrated housing structure. This unified housing provides both the structural support function and the coolant jacket function, reducing the number of components while maintaining structural integrity.
Solution Approach 2:
The integrated housing performs multiple functions simultaneously: it provides structural support for the electric machine, contains the coolant jacket for cooling, and incorporates aperture patterns for coolant distribution. This multi-functional design eliminates the need for separate dedicated components.
3Temperature
If coolant flows circumferentially around the oil jacket and exits through holes in the steel canister, then coolant circulation is achieved, but uniform coolant distribution to stator end turns is insufficient
Solution Approach 1:
The patent introduces axial flow paths complementing the traditional radial coolant flow. The aperture patterns are designed to enable coolant movement in both radial and axial directions, creating a three-dimensional coolant distribution network that achieves more uniform heat dissipation across stator end turns.
Solution Approach 2:
The patent implements location-specific aperture patterns within the housing structure. Different regions of the housing have optimized aperture configurations tailored to the local cooling requirements of various stator end turn areas, ensuring uniform coolant distribution across all critical heat-generating zones.
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 cooling efficiency by ensuring uniform coolant distribution to stator end turns and other components, increasing the performance and lifespan of the electric machine while reducing the complexity of the cooling system.
Implementation Method 1
introducing a coolant into the coolant inlet, circulating the coolant through the coolant passageway and into the coolant jacket
Implementation Method 2
circulating the coolant through the coolant passageway and into the coolant jacket, and forcing at least a portion of the coolant through the plurality of apertures into the machine cavity
Data Source
AI summary
Embodiments of the invention provide an electric machine module comprising an electric machine with a stator and housing at least partially circumscribing the electric machine. The housing includes at least two housing members coupled together and substantially securing the electric machine within the housing. The electric machine module also includes a coolant jacket at least partially defined by an outer diameter of the stator and an inner diameter portion of the housing.