Active End-Turn Cooling Nozzle for IPM Motor
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Solution Overview
Problem
Current interior permanent magnet (IPM) motors experience coolant maldistribution due to lack of control over coolant distribution, vehicle motion changes, and frame tilt, leading to undesirable hot spots.
Innovation Solution
A system and method for active end-turn cooling in IPM motors, involving a motor with a movable nozzle and cam system that adjusts coolant distribution based on vehicle speed, lateral acceleration, and road tilt angles to ensure even coolant delivery to the stator unit, using calculations to determine optimal nozzle positions for effective coolant distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coolant is distributed without control in current IPM motors, then the structure is simple, but coolant maldistribution occurs leading to hot spots
Solution Approach 1:
The nozzle is made movable rather than fixed, allowing it to dynamically adjust its position based on vehicle acceleration conditions. The cam mechanism enables the nozzle to move radially outward or inward relative to the stator windings, adapting the coolant distribution pattern to match the effects of lateral acceleration and maintain uniform cooling despite vehicle motion changes.
Solution Approach 2:
The system uses vehicle acceleration sensors to detect lateral acceleration conditions and feeds this information back to the cam mechanism. Based on the detected acceleration, the cam adjusts the nozzle position accordingly - moving the nozzle radially outward during high acceleration to compensate for coolant maldistribution caused by inertial forces.
2Reliability
If the nozzle is made movable to compensate for vehicle motion, then coolant distribution uniformity improves, but the device complexity increases
Solution Approach 1:
The cam mechanism serves as an intermediary between the vehicle acceleration sensor and the movable nozzle. Rather than directly controlling the nozzle with complex actuators, the cam translates acceleration signals into appropriate nozzle position adjustments, providing a mechanically simple yet effective means of adaptation to vehicle motion conditions.
Solution Approach 2:
The system automatically adjusts the nozzle position based on detected vehicle acceleration without requiring manual intervention or complex control algorithms. The cam mechanism self-adjusts the coolant distribution pattern in response to inertial forces, making the system adaptive and self-regulating.
3Temperature
If coolant distribution is adjusted for lateral acceleration, then hot spots are prevented, but the system requires additional sensors and control mechanisms
Solution Approach 1:
The patent replaces complex electronic control systems with a mechanically-based cam mechanism that responds to vehicle acceleration. Instead of using electronic actuators and complex control algorithms to adjust coolant distribution, the system uses the vehicle's own acceleration forces to drive the cam mechanism, which mechanically adjusts the nozzle position in response to inertial effects.
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 system ensures a more even and controlled coolant distribution to the stator unit, mitigating coolant maldistribution and hot spots by compensating for vehicle-induced movements, thereby enhancing motor performance and efficiency.
Implementation Method 1
The second open end extends from the at least one aperture and is positioned adjacently above the target area of the end turn portion for coolant distribution
Implementation Method 2
measuring vehicle speed, vehicle lateral acceleration, and road tilt angle of coolant due to road tilt of the vehicle
Implementation Method 3
calculating coolant angle, coolant acceleration angle based on the lateral acceleration and the road tilt angle
Data Source
AI summary
A system and method of active endturn cooling of an electric motor of a vehicle is provided. The method comprises providing a motor having a coolant nozzle and a cam, and measuring speed, lateral acceleration, and road tilt angle of coolant due to road tilt. The method further comprises calculating coolant angle and coolant acceleration angle based on the road tilt angle and the lateral acceleration if the speed is greater than zero. The method further comprises comparing the coolant angle with a critical angle. The method further comprises calculating a first control angle and a first coolant distance based on the road tilt angle and the lateral acceleration of the vehicle if the acceleration angle is greater than the critical angle. The method further comprises determining a cam position based on the first control angle. The method further comprises moving the cam to the position to move the nozzle and compensate for the lateral acceleration such that coolant drops within a target area of the motor.