Radial Air Cooling Layout for Tight-Mounted Electric Machines
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Solution Overview
Problem
Existing air cooling systems for electric machines are inefficient, particularly in tight axial configurations, as they often obstruct airflow due to axial air intakes and outlets, leading to overheating and reduced efficiency and lifespan.
Innovation Solution
The electric machine design incorporates a radial air intake and outlet system with an air passage that directs airflow along a heat sink, allowing for efficient cooling and mounting in close proximity to adjacent structures without obstructing airflow, using a housing with thermally conductive materials and a passive heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If axial air intake and outlet are used in known air cooling designs, then cooling function is provided, but the design obstructs airflow in tight axial configurations and reduces mounting flexibility
Solution Approach 1:
The patent transitions from axial airflow configuration to radial airflow configuration. The air intake is positioned on the radial outer surface of the housing, and the air outlet is positioned on the axial end surface, creating a radial air passage that allows air to flow radially through the housing. This dimensional change enables the motor to be mounted in tight axial configurations without obstructing airflow, as the air passages extend radially outward from the motor assembly.
2Adaptability or versatility
If radial air passage with heat sink is implemented, then mounting flexibility in tight axial configurations is improved, but device complexity increases
Solution Approach 1:
The patent combines the air passage structure with the housing itself. The housing is designed to define the air passage, with the air intake on the radial outer surface and the air outlet on the axial end surface. The heat sink is integrated into this radial air passage configuration, allowing air to flow radially from the intake, through the heat sink, and out the outlet. This merging of functions reduces the number of separate components needed while maintaining the radial airflow configuration.
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 effectively prevents overheating by facilitating efficient airflow through the machine, extending the lifespan and improving the electrical and mechanical performance of the motor assembly and electronics.
Implementation Method 1
a heat sink positioned at least partially within the air passage and thermally connected to the electronics assembly
Implementation Method 2
directs the airflow along the heat sink
Data Source
AI summary
An electric machine includes a housing having an air intake, an air outlet, and defining an air passage therein. The air passage includes a first channel extending from the air intake in a radial direction and a second channel extending in the radial direction to the outlet. The electric machine further includes a motor assembly positioned within the housing that includes a shaft that rotates about a rotational axis that is generally perpendicular to the radial direction. The electric machine further includes an electronics assembly within the housing interior and a heat sink positioned at least partially within the air passage and thermally connected to the electronics assembly. Operation of the motor assembly draws an ambient airflow into the air passage in the radial direction through the air intake, directs the airflow along the heat sink, and exhausts the airflow through the air outlet in the radial direction.