Pressurized Gravity-Fed Liquid Cooling Electric Motor
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Solution Overview
Problem
Electric motors generate excessive heat during operation, which existing cooling systems may not effectively dissipate, particularly in complex structures like stators and rotors, leading to potential temperature hazards.
Innovation Solution
A liquid cooling system that combines pressurized and gravity-fed coolant distribution, using a manifold and trays to direct coolant jets onto critical motor components, including a pump driven by the gearbox to circulate oil that lubricates gears and efficiently cools the motor through an intercooler and heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple pressure-based distribution openings are used to cool complex motor surfaces, then cooling coverage is improved, but the risk of clogging and manufacturing complexity increases
Solution Approach 1:
The cooling system is segmented into two distinct functional zones: a manifold with limited pressure-based openings for primary cooling, and trays with multiple gravity-fed openings for secondary distribution. This segmentation allows each zone to perform its specific function optimally while avoiding the clogging issues that would arise from having numerous pressure-based openings in the manifold.
Solution Approach 2:
The trays act as intermediary components between the manifold and the motor surfaces. They receive pressurized liquid from the manifold and redistribute it through gravity-fed openings, serving as a mediator that transforms the high-pressure flow into a distributed cooling pattern without requiring multiple pressure openings in the manifold itself.
2Temperature
If multiple pressure-based distribution openings are used to achieve uniform coolant distribution, then cooling uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The system segments the coolant distribution function between the manifold (pressure-based single opening) and the trays (gravity-fed multiple openings). The trays are simple components that can be easily manufactured with multiple openings, while the manifold remains simple with fewer openings, collectively achieving uniform distribution without complex manufacturing requirements.
Solution Approach 2:
Instead of creating multiple pressure-based openings in the manifold to achieve uniform distribution, the invention inverts the approach by using a single pressure opening that feeds trays, which then use gravity to distribute coolant uniformly through their multiple openings. This reverses the conventional approach and simplifies manufacturing.
3Temperature
If active cooling is applied to heat-sensitive parts, then temperature safety is improved, but system complexity increases
Solution Approach 1:
The cooling system utilizes the motor's own rotational energy to drive the pump, making the system self-powered and eliminating the need for an external power source. The gravity-fed trays also provide passive distribution, reducing the need for additional active components. This self-service approach maintains temperature safety while minimizing system complexity.
Solution Approach 2:
The liquid cooling system serves multiple functions: it cools the motor components, lubricates the gearbox, and is powered by the gearbox itself. The oil performs both cooling and lubrication duties, while the pump serves as both a cooling system component and a gearbox-driven element. This multi-functionality reduces overall system complexity.
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 system ensures effective cooling of electric motor components by minimizing pressure-based distribution openings, preventing clogging, and ensuring uniform coolant distribution, thereby maintaining safe temperatures and simplifying manufacturing.
Implementation Method 1
a pump for liquid to cool the electric motor; the manifold receiving the liquid under pressure
Implementation Method 2
a heat exchanger that removes heat from the liquid
Implementation Method 3
the first tray having a third opening that performs gravity-fed liquid distribution onto the first end turns
Implementation Method 4
a first opening that directs a first liquid jet onto the stator; a second opening that directs a second liquid jet onto the first tray
Data Source
AI summary
A liquid cooling system for an electric motor includes: a pump for liquid to cool the electric motor; a heat exchanger that removes heat from the liquid; a manifold extending above a stator of the electric motor, the manifold receiving the liquid under pressure and having a first opening that directs a first liquid jet onto the stator; and a first tray above first end turns of the stator, the manifold having a second opening that directs a second liquid jet onto the first tray, the first tray having a third opening that performs gravity-fed liquid distribution onto the first end turns.