Motor Cooling Jacket Spray Structure for Stator Coil Overheating
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Solution Overview
Problem
The direct motor cooling system in eco-friendly vehicles experiences oil leakage between the cooling jacket and the end cover, leading to incomplete submersion of stator coil ends in oil, resulting in uneven cooling and potential overheating, which limits motor performance and safety.
Innovation Solution
The motor cooling device incorporates cooling jackets with a spray structure or dispersion-inducing structure at the upper portion of the oil fill space, ensuring that oil is evenly distributed to submerged and non-submerged portions of the stator coil, maintaining effective cooling even with oil leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If oil is supplied to cool the stator coil through the cooling channel and cooling jacket, then cooling performance is improved, but oil leakage occurs between the cooling jacket and end cover causing incomplete submersion of stator coil ends
Solution Approach 1:
A seal member is introduced as an intermediary component between the cooling jacket and end cover to prevent oil leakage. The seal member fills the gap caused by dimensional mismatches and maintains reliable sealing, ensuring complete submersion of stator coil ends in cooling oil without compromising cooling performance.
Solution Approach 2:
The patent anticipates potential oil leakage issues by designing a seal member that compensates for manufacturing tolerances and dimensional variations beforehand. The seal member acts as a cushioning element that prevents leakage before it can occur, ensuring reliable operation under various operating conditions.
2Temperature
If the cooling jacket is tightly fitted to ensure complete submersion of stator coil ends, then cooling efficiency is improved, but manufacturing precision requirements increase due to shape variations
Solution Approach 1:
Instead of requiring high precision throughout the entire cooling jacket, the patent applies a localized seal member only at the critical interface between the cooling jacket and end cover. This allows the cooling jacket to have standard manufacturing tolerances while still achieving complete submersion of stator coil ends through the localized sealing action.
Solution Approach 2:
The sealing function is segmented from the cooling jacket structure itself and implemented as a separate, dedicated seal member. This segmentation allows the cooling jacket to be manufactured with standard tolerances while the specialized seal member handles the precise sealing requirement, reducing overall manufacturing precision requirements.
3Device complexity
If oil leakage is allowed to occur, then device complexity is reduced, but stator coil ends are not fully submerged leading to overheating and damage
Solution Approach 1:
The seal member is designed as a simple, inexpensive component that can be easily replaced if needed. This disposable-like approach allows the use of a basic sealing element rather than a complex sealing mechanism, maintaining low device complexity while effectively preventing oil leakage and stator coil overheating.
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 ensures stable and efficient cooling of the stator coil, preventing overheating and damage, thereby maintaining motor efficiency and vehicle performance, and reducing the need for motor output limitations due to temperature concerns.
Implementation Method 1
the opposite end portions of the stator coil are submerged in the oil filling the cooling jackets, thereby directly cooling the stator coil
Implementation Method 2
allowing the oil whose temperature has been decreased through the heat exchange with the heat exchanger to pass through the oil supply hole in the motor housing and then through the cooling channel at the stator core
Implementation Method 3
performing heat exchange between oil pumped from the electric oil pump and the heat exchanger
Data Source
AI summary
An embodiment device for cooling a motor includes a motor housing including an oil supply hole, a stator core disposed within the motor housing and including a cooling channel in communication with the oil supply hole, a stator coil wound on the stator core, cooling jackets each having an inner side portion defining therein an oil fill space into which a corresponding one of opposite end portions of the stator coil is inserted, wherein the cooling jackets are tightly coupled to opposite side portions of the motor housing and opposite side portions of the stator core, respectively, and spray structures respectively disposed in upper portions of the oil fill spaces in the cooling jackets, each spray structure being configured to spray oil flowing into the spray structure from the cooling channel toward the corresponding one of the opposite end portions of the stator coil.