Cooling Plate Layout for Electric Motor Coil Heat Dissipation
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Solution Overview
Problem
Existing electric motor systems face challenges with thermal management due to high switching losses and conduction losses, particularly at higher power ratings, which limit their power handling capacity and efficiency, and are also cumbersome in design and manufacturing, with bulky switching devices and labor-intensive coil winding processes.
Innovation Solution
The electric motor design allows independent control of each coil subset, increasing the number of turns and inductance, enabling the use of smaller switching devices for reduced heat dissipation and cost, with smaller components housed within the motor and a common control device for coordinated operation, and includes a braking arrangement and traction control system for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of coils in each coil set is increased to improve power handling capacity, then the power rating is improved, but the switching losses and conduction losses increase
Solution Approach 1:
Each coil set is divided into multiple coil sub-sets (e.g., four sub-sets per coil set), allowing independent control of each sub-set. This segmentation enables the motor to handle higher power ratings while using smaller switching devices for each sub-set, thereby reducing switching losses and conduction losses compared to controlling all coils in a set through a single switching device.
2Power
If larger switching devices are used to handle higher power ratings, then the power handling capacity is improved, but the switching losses increase and switching speed decreases
Solution Approach 1:
The switching control is segmented into multiple independent switching devices, each controlling a coil sub-set. This allows the use of smaller switching devices with lower switching losses and faster switching speeds, while collectively handling high power ratings through the combined capacity of multiple sub-sets.
3Stability of the object's composition
If coils in each coil set are connected in series to balance currents, then the current balance is improved, but the inductance decreases and switching speed must be reduced
Solution Approach 1:
Instead of connecting all coils in a set in series, each coil sub-set is independently controlled with its own switching device. This segmentation maintains current balance through independent control while preserving high inductance values in each sub-set, enabling faster switching speeds without compromising current balance.
4Power
If the motor size is increased to handle higher power ratings, then the power capacity is improved, but the thermal management becomes more difficult
Solution Approach 1:
The motor is divided into multiple coil sub-sets with independent control, allowing higher power capacity without proportionally increasing motor size. The segmented architecture improves thermal management by distributing heat generation across multiple smaller, independently controllable units, enabling better heat dissipation and thermal control.
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 enhances control precision, reduces switching losses, and allows for faster switching speeds, improving thermal management, manufacturing efficiency, and providing a compact, reliable, and responsive motor system with enhanced traction and braking capabilities.
Implementation Method 1
a first cooling plate (310) to which said first and second coil subsets (14, 16) are directly attached, a second cooling plate (320) to which said third and fourth coil subsets (18, 20) are directly attached
Implementation Method 2
a cooling channel disposed immediately adjacent the plurality of coils through which a coolant fluid may circulate
Data Source
Figure 1~2
Figure 3
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AI summary
An electric motor of the type comprising a plurality of coils circumferentially mounted around a stator on teeth and a plurality of magnets mounted on a rotor is provided with the motor including a cooling plate. The cooling plate has channels that are arranged to cool the coils on three sides with a first channel provided on a first side of the coils and located on a first side of the teeth, a second channel provided on a second side of the coils and located on a second side of the teeth, and a third channel provided on a third side of the teeth that is adjacent to the first and second sides of the teeth.