External Rotor Motor Insert Cooling Channel for Easier Manufacture
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Solution Overview
Problem
Existing external rotor motors with internally cooled stators require complex and costly processes to create cooling channels within housing components, limiting efficiency and increasing production costs.
Innovation Solution
The implementation of an insert with recesses on its exterior surface to form sections of a cooling channel, which is then inserted into a housing component, allows for cost-effective production of cooling channels without the need for complex processes like lost mold casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are created inside a housing component using lost mold casting process, then effective cooling of the stator is achieved, but production cost and manufacturing complexity increase significantly
Solution Approach 1:
The housing component is divided into two separate parts: the housing component itself and a separate insert. The insert contains the cooling channels formed by recesses on its exterior surface, while the housing component provides structural support. This segmentation allows the insert to be manufactured using simpler, more cost-effective processes while the housing component maintains its structural integrity.
Solution Approach 2:
The insert acts as an intermediary element that bridges the cooling function and the housing structure. By placing the insert into a receptacle of the housing component, the cooling channels are formed without requiring complex lost mold casting of the entire housing, thus reducing manufacturing complexity while maintaining cooling effectiveness.
2Strength
If cooling channels are integrated directly into the housing component, then structural integrity is maintained, but manufacturing process becomes complex and costly
Solution Approach 1:
The housing assembly is segmented into the housing component and a separate insert. The insert carries the cooling channel function with recesses on its exterior surface, while the housing component maintains pure structural support. This division allows each component to be optimized for its specific function and manufactured using appropriate processes.
Solution Approach 2:
The cooling channel function is extracted from the housing component and placed into a separate insert. This extraction removes the complexity of forming cooling channels directly in the housing, allowing the housing to be manufactured using simpler processes while the insert handles the cooling channel formation through its recesses.
3Ease of operation
If the insert is positioned using a tongue-and-groove joint, then rotational angle position is precisely controlled, but the wall thickness in contact with the stator increases
Solution Approach 1:
The tongue-and-groove joint is implemented partially, with the groove extending only over a portion of the axial length of the insert rather than the entire length. This partial implementation is sufficient to achieve the required rotational angle positioning accuracy while minimizing the increase in wall thickness, thus balancing positioning precision with thermal coupling requirements.
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 approach reduces production costs and effort while maintaining high performance and compact design, enabling effective cooling of both the stator and electronic components.
Implementation Method 1
a cooling channel that runs through an internal space surrounded by the stator
Implementation Method 2
an internally cooled stator
Implementation Method 3
the cooling channel can run along the lower face of the cooling plate in the direction of flow
Data Source
AI summary
An electric motor has a stator, a rotor surrounding the stator, a shaft connected to the rotor in a rotationally fixed manner, and a housing. The housing has first and second housing components, which together enclose a motor compartment in which are arranged the stator and the rotor. A cooling channel extends in an interior space surrounded by the stator. A first end of the shaft is arranged in the motor compartment and a second end of the shaft protrudes from the housing. The first housing component has an inner part which protrudes into the stator. In accordance with this disclosure, it is envisaged that an insert is arranged in the interior space surrounded by the stator, which insert, together with the inner part of the first housing component, defines at least one section of the cooling channel.