Liquid Cooled Stator Terminal Block for Electric Machines
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Solution Overview
Problem
In electric machines, axial space constraints often lead to reduced machine size, which compromises performance, and existing terminal blocks struggle to efficiently manage heat generated by high voltage leads, risking premature component failure due to excessive heat buildup.
Innovation Solution
A liquid-cooled stator terminal block design featuring a non-electrically conductive member with a fluid cavity that guides a cooling fluid along electrically conductive members to absorb heat, maintaining a compact form factor while preventing environmental and foreign object contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the machine size is reduced to meet axial space constraints, then the overall length and space occupancy are reduced, but the machine performance deteriorates due to insufficient cooling capacity and heat management
Solution Approach 1:
The fluid cavity is nested within the terminal block structure, allowing the cooling system to be integrated into the existing component rather than adding external cooling apparatus. This enables heat management functionality to be incorporated without increasing overall machine volume, thus resolving the contradiction between compact size and effective cooling capacity
Solution Approach 2:
The terminal block combines multiple functions: electrical connection, environmental protection, and thermal management. By merging the cooling function into the terminal block structure itself, the design achieves efficient heat removal without requiring separate cooling components that would increase machine size
2Device complexity
If conventional terminal blocks are used without integrated cooling, then the structure is simpler, but heat generated by electrical flow causes premature component failure
Solution Approach 1:
The cooling function is merged with the terminal block structure by incorporating a fluid cavity directly into the terminal block body. This integration allows heat management to be performed by the same component that provides electrical connection and protection, eliminating the need for separate cooling systems while improving reliability
Solution Approach 2:
The terminal block is designed as a multi-functional component that simultaneously provides electrical connection, environmental protection, and thermal management. The fluid cavity integrated into the terminal block enables cooling without adding separate dedicated cooling components, achieving multi-functionality with minimal additional complexity
3Object-affected harmful factors
If additional protective covers, cavities, and seals are added to protect connections, then protection from environmental conditions and foreign objects is improved, but the device complexity and space requirements increase
Solution Approach 1:
The terminal block integrates multiple protective functions into a single component structure. The terminal block itself provides shielding from environmental conditions and foreign object contact, while the fluid cavity is incorporated within this same structure. This merging eliminates the need for separate protective covers, cavities, and seals that would otherwise be required
Solution Approach 2:
The terminal block is designed as a universal component that simultaneously provides electrical connection, environmental protection, and thermal management. By consolidating these functions into one multi-functional component, the design reduces the total number of parts while maintaining comprehensive protection capabilities
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
Effectively cools high voltage leads, reducing the risk of premature component failure and maintaining motor performance by channeling heat away from the terminal block, while protecting connections from environmental and accidental contact.
Implementation Method 1
The fluid cavity guides a fluid along a portion of the at least one electrically conductive member to absorb heat
Implementation Method 2
A fluid circuit passes, at least in part, through the housing. The fluid circuit includes an inlet portion and an outlet portion
Data Source
AI summary
An electric machine including a housing having an outer surface and an inner surface that defines an interior portion. The housing includes a connection zone. A fluid circuit passes, at least in part, through the housing. The fluid circuit includes an inlet portion and an outlet portion. A stator assembly is arranged within the interior portion of the housing. The stator assembly includes at least one connector lead, and a terminal block extending through the housing. The terminal block includes a non-electrically conductive member that is sealed against the housing. The non-electrically conductive member includes a fluid cavity. At least one electrically conductive member is covered, at least in part, by the non-electrically conductive member. The fluid cavity guides a fluid along a portion of the at least one electrically conductive member to absorb heat.