Integrated Electric Motor Cooling Layout for Heat and Vibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric motor designs in vehicles suffer from high weight, volume, low power density, and vibration risks due to separate inverter and motor units connected by long cables, leading to electrical losses and misaligned gravity centers.
Innovation Solution
An integrated electric motor design with a rotor, stator, and power modules, featuring dual coolant channels for efficient cooling and compact integration, reducing weight and volume while aligning gravity centers to minimize vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the inverter and motor parts are independent units connected by long cables, then the structure is simple and easy to maintain, but the weight and volume increase, leading to low power density
Solution Approach 1:
The patent combines the inverter and motor parts into a single integrated unit, eliminating the need for separate independent units connected by cables. This merging reduces overall weight and volume while improving power density, as the inverter is now housed within the motor assembly rather than being a separate component.
2Loss of energy
If the inverter is placed on top of the motor parts, then the electrical losses are reduced and maintenance is easier, but the overall volume remains high and gravity centers are misaligned causing vibration
Solution Approach 1:
The inverter is nested within the motor assembly, with the power module section housed inside the motor housing. This nesting approach reduces the overall volume compared to placing the inverter on top of the motor, while maintaining short electrical connections that minimize electrical losses.
Solution Approach 2:
The patent redistributes components within the motor assembly along different spatial dimensions. The power module section is positioned at a second side of the motor housing, and coolant channels are arranged to flow alongside the power module section, optimizing the use of available space and aligning gravity centers to reduce vibration.
3Weight of moving object
If the inverter and motor parts are integrated into a single unit, then the weight and volume are reduced, but the heat dissipation challenge increases
Solution Approach 1:
The patent introduces a coolant as an intermediary substance to manage heat dissipation. Coolant channels are provided within the motor housing, allowing coolant to flow alongside the power module section and remove heat generated during operation, effectively solving the heat dissipation challenge of the integrated design.
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 integrated design enhances heat dissipation, reduces electrical losses, and increases vehicle range by improving power density and stability, with modular components for easy maintenance.
Implementation Method 1
a first channel arranged in between the stator and a first side of the power module section for conveying a coolant in between the stator and the first side of the power module section, and a second channel arranged at a second side of the power module section for conveying a coolant alongside the second side of the power module section
Data Source
AI summary
In an aspect, the disclosure relates to an electric motor a rotor; a stator; a power module section having one or more power modules of an inverter; a first channel arranged in between the stator and a first side of the power module section for conveying a coolant in between the stator and the first side of the power module section; and a second channel arranged at a second side of the power module section for conveying a coolant alongside the second side of the power module section; wherein the first side is located opposite of the second side.