Sealed Motor Heat Exchanger for Thermal Runaway
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Solution Overview
Problem
Existing closed electric motors used in rail transport vehicles face thermal runaway due to insufficient heat dissipation, particularly in operating regimes where heat generated by the conversion of electrical energy into mechanical energy is not effectively transferred to the liquid cooling system, leading to complex and non-modular thermal coupling solutions that are difficult to install and require special arrangements.
Innovation Solution
A closed electric motor design featuring a heat exchanger with a simple, reliable thermal coupling mechanism that includes a heat exchanger made from a good heat-conducting material, such as aluminum, integrated with the motor's casing and liquid cooling system, allowing for efficient heat transfer through a gaseous volume and easy installation without requiring specific motor arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermal coupling device is installed to improve heat transfer from the engine interior compartment to the liquid cooling system, then heat dissipation efficiency is improved, but device complexity increases and installation becomes difficult
Solution Approach 1:
The heat exchanger is nested within the interior compartment of the motor, utilizing the available space efficiently. The heat exchanger core is positioned inside the compartment while its cooling fins extend outward, nesting multiple functional elements within the motor structure without increasing overall footprint.
Solution Approach 2:
The heat exchanger acts as an intermediary component between the motor's interior compartment and the liquid cooling system. It mediates heat transfer from the hot interior compartment air to the cooling liquid flowing through its channels, enabling efficient thermal coupling without direct contact between the cooling system and motor components.
2Temperature
If a thermal coupling device is installed to improve heat transfer, then heat dissipation efficiency is improved, but ease of installation deteriorates as it cannot be added during motor life
Solution Approach 1:
The heat exchanger is designed as a separate, modular component that can be independently installed. The heat exchanger core and fin assembly are segmented from the motor housing, allowing it to be added as a distinct unit during maintenance or upgrades without requiring motor disassembly or special arrangements.
Solution Approach 2:
The heat exchanger is pre-assembled with its cooling fins and core structure before installation into the motor. This preliminary preparation allows for quick installation during motor maintenance without requiring complex on-site assembly procedures or special motor configurations.
3Device complexity
If conventional heat dissipation through casing conduction is used, then device simplicity is maintained, but heat dissipation efficiency becomes insufficient leading to thermal runaway
Solution Approach 1:
The heat exchanger utilizes liquid cooling hydraulics to improve heat dissipation. Cooling liquid flows through channels in the heat exchanger core, carrying heat away from the motor interior compartment much more efficiently than air conduction through the casing, preventing thermal runaway while maintaining relative simplicity.
Solution Approach 2:
The heat exchanger changes the thermal parameters of the cooling system by introducing a liquid cooling medium with high heat capacity and thermal conductivity. This parameter change enables significantly higher heat transfer rates compared to the original air conduction system, solving the insufficient heat dissipation problem.
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 reduces the interior compartment temperature by approximately 10°C, providing a simpler and more reliable thermal management system that can be easily integrated during the motor's life cycle, addressing the inefficiencies of previous solutions.
Implementation Method 1
heat transfer from the engine interior compartment to the liquid cooling system
Implementation Method 2
heat transfer through a gaseous volume
Implementation Method 3
liquid cooling means for liquid cooling of the interior compartment of the motor
Implementation Method 4
means for converting the electrical energy received by the motor into mechanical energy
Implementation Method 5
heat generated by the operation of the engine... by Joule effect
Data Source
Figure 1
Figure 2
AI summary
This engine comprises a frame (12) delimiting an internal compartment (14) defining an internal gaseous volume (15), means (16) for converting the electrical energy received by the engine (10) into mechanical energy, including a stator (64) and a rotor (62), the stator (64) comprising at least some coils (86), means (18) for liquid cooling of the internal compartment (14), and means (20) for thermal coupling between the internal compartment (14) and the liquid cooling means (18). The thermal coupling means (20) include a heat exchanger (108) mounted on the frame (12) in the internal compartment (22), having a support (116) applied to the frame (12) and at least one radial projection (118) extending towards the central axis A-A'.