L-Shaped Sheet Metal Cooling Jacket for Electric Machine Thermal Management
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Solution Overview
Problem
Existing electric machines face challenges in minimizing size while maximizing heat rejection to enhance performance and efficiency, as excessive heat generation can lead to damage and reduced performance due to inadequate cooling methods.
Innovation Solution
The electric machine design incorporates a pair of aligned sheet metal housing sections with a cooling channel at the axial end, where power electronics components are positioned to facilitate heat transfer to the coolant flowing through the channel, utilizing thermal interface materials and biasing members to improve thermal conductivity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used, then the electric machine can operate, but heat rejection is insufficient leading to excessive heat generation
Solution Approach 1:
The cooling system transitions from traditional radial or axial cooling to a three-dimensional cooling architecture where cooling channels are integrated at multiple locations including the axial end of the housing. This multi-dimensional cooling approach increases the total heat transfer surface area and improves heat rejection efficiency by accessing heat sources from different spatial directions.
Solution Approach 2:
The cooling channels are merged with the housing structure itself, integrating the cooling function directly into the mechanical support structure. The housing sections are designed with internal cooling passages that combine structural support and thermal management functions, eliminating the need for separate cooling components and improving heat transfer efficiency.
2Volume of moving object
If the electric machine size is reduced, then power density increases, but heat dissipation capacity decreases
Solution Approach 1:
The cooling channels are nested within the housing structure, with coolant passages routed through the housing walls and internal cavities. This nesting approach allows the cooling system to occupy the same spatial envelope as the mechanical structure, maintaining compact machine dimensions while providing sufficient cooling capacity through optimized heat transfer pathways.
Solution Approach 2:
The cooling system implements location-specific thermal management with dedicated cooling channels positioned at high heat generation zones such as the axial end where power electronics are mounted. The cooling architecture provides enhanced heat transfer capacity at critical locations rather than uniform cooling, optimizing heat dissipation within limited space.
3Adaptability or versatility
If power electronics components are added to increase functionality, then control capability improves, but heat generation increases
Solution Approach 1:
Thermal interface materials are introduced as intermediaries between the power electronics components and the cooling channels. These interface materials improve thermal contact and heat transfer efficiency, acting as a mediator that bridges the heat source (power electronics) and heat sink (coolant channels) while minimizing thermal resistance.
Solution Approach 2:
The cooling system is segmented into multiple independent cooling zones, with dedicated cooling channels for different components including power electronics at the axial end. This segmentation allows targeted cooling of high-heat-generation components without affecting other areas, enabling effective thermal management of complex multi-component systems.
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 effectively reduces thermal resistance, allowing for increased heat dissipation and improved operational efficiency, enabling the electric machine to operate at higher performance levels with reduced size and increased reliability.
Implementation Method 1
heat from the electronics components is transferred to the cooling channel
Implementation Method 2
coolant flow path that includes a power electronics cooling channel formed at the axial end between the housing sections
Data Source
AI summary
An electric machine includes a pair of substantially aligned sheet metal housing sections each including a substantially “L” shaped portion, at least one cooling channel being formed at an axial end between the two sections, and a plurality of power electronics components engaged with at least one of the housing sections adjacent the axial end cooling channel. An embodiment includes a stator, a pair of housing sections enclosing the stator, power electronics components positioned at an axial end of the electric machine for controlling operation of the electric machine, and a coolant flow path that includes a power electronics cooling channel formed at the axial end between the housing sections. A method includes forming an axial end cooling channel between two sheet metal housing sections, and positioning power electronics components at the axial end along the cooling channel, whereby heat from the electronics components is transferred to the cooling channel.