Motor Cooling Insert Geometry for Turbulent Channel Heat Exchange
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Solution Overview
Problem
Existing cooling assemblies for electrical machines in vehicles often fail to achieve an optimal cooling effect due to laminar flow in cooling channels, which is insufficient for efficient heat dissipation.
Innovation Solution
A cooling assembly with a two-part insertion part within the cooling channel that generates turbulence by using cruciform, T-shaped, and elongate depressions and elevations to convert laminar flow into turbulent flow, enhancing heat exchange through the creation of flow vortices and mixing within the cooling channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling passages are provided in a cast motor housing with cooling medium flowing through them, then the electrical machine can be cooled, but the cooling effect is insufficient due to laminar flow
Solution Approach 1:
The patent changes the flow regime parameter from laminar to turbulent flow by introducing insertion parts with specific geometric features (protrusions and recesses) into the cooling passages. This parameter change transforms the cooling medium's flow characteristics to enhance heat transfer efficiency between the motor housing and cooling medium.
Solution Approach 2:
The insertion parts act as intermediaries within the cooling passages, creating turbulence and improving the heat exchange interface between the cooling medium and the motor housing. These insertion parts mediate the interaction between the laminar flow and the housing surface to achieve more effective cooling.
2Ease of manufacture
If cooling channels are designed with simple geometry for easy manufacturing, then manufacturing is simplified, but turbulence cannot be generated effectively
Solution Approach 1:
The cooling channel system is segmented into base cooling passages and separate insertion parts. The insertion parts can be manufactured independently with complex geometries (protrusions and recesses) to generate turbulence, while the main cooling channel remains simple for easy manufacturing. This segmentation allows optimization of both manufacturing ease and heat exchange efficiency.
Solution Approach 2:
The insertion parts are nested within the cooling passages of the motor housing. These insertable components contain the turbulence-generating features and can be placed inside the existing cooling channels, combining the simplicity of the base structure with the functionality of complex internal geometries.
3Productivity
If the cooling assembly includes insertable components with complex geometries to generate turbulence, then heat exchange efficiency improves, but device complexity increases
Solution Approach 1:
The cooling assembly is divided into modular components: the motor housing with cooling passages and separate insertion parts. This segmentation allows the complex turbulence-generating features to be isolated in removable inserts rather than being integral to the entire housing, simplifying manufacturing and maintenance while achieving enhanced heat exchange.
Solution Approach 2:
The insertion parts introduce dynamic flow characteristics (turbulence) into the otherwise static and laminar cooling flow. The geometric features of the insertion parts create dynamic mixing and eddies that enhance heat transfer, transforming the static cooling system into one with active flow manipulation.
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 solution effectively converts laminar flow into turbulent flow, optimizing heat exchange and ensuring efficient cooling of electrical machines, thereby extending their operational lifespan and performance.
Implementation Method 1
an insert (20) with at least one insertion part (21) for generating turbulence (flow vortices) in the cooling medium within the cooling channel
Implementation Method 2
generating turbulence (flow vortices) in the cooling medium within the cooling channel
Implementation Method 3
The cooling medium can flow around the receiving region and in particular the electrical machine arranged in the receiving region of the cooling channel
Data Source
AI summary
The invention relates to a cooling assembly for a drive assembly, which comprises an electrical machine, for a vehicle, for cooling the electrical machine, the cooling assembly comprising a cooling channel, with an inlet and an outlet, for conducting a cooling medium, the cooling channel having a receiving region for receiving the electrical machine, the cooling assembly comprising an insert having at least one insertion part for generating turbulence in the cooling medium, the insert being arranged in a space surrounding the receiving region for the electrical machine within the cooling channel, and the insertion part having a two-part design. The invention also relates to an insert and a drive assembly having a cooling assembly of this kind and an electrical machine.