Radially Adaptable Phase Lead Connection for Electric Machine Cooling
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Solution Overview
Problem
Conventional electric machine alternators face challenges in efficiently dissipating heat due to increased demands, leading to elevated component temperatures and reduced cooling efficiency, particularly in air-cooled systems where cooling air flow is restricted and heat transfer resistance is high.
Innovation Solution
The electronic package features a radially adaptable support structure with voids for phase leads and a metallic cooling tower that maximizes spatial dispersion of power modules, facilitates bi-directional cooling, and optimizes air flow, incorporating a heat sink with ribs and a central control electronics location for enhanced thermal management and structural stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cooling methods are used in air-cooled alternators, then the structure is simple, but the cooling efficiency is insufficient and heat dissipation is poor
Solution Approach 1:
The patent transitions from conventional planar mounting to three-dimensional radial mounting of power modules on the alternator housing. This spatial dimensionality change enables better heat dissipation by positioning modules in radially distributed locations with optimized air flow paths, allowing cooling air to access multiple surfaces simultaneously and improving overall cooling efficiency without complicating the basic structure
2Volume of moving object
If power modules are densely packed to reduce space, then the device size is reduced, but the cooling efficiency decreases and heat accumulation increases
Solution Approach 1:
The patent applies local quality optimization by positioning power modules at specific radial locations where cooling air flow is most effective. Each module is placed in a location that maximizes its exposure to cooling air while maintaining compact overall dimensions. The radial distribution allows different regions of the housing to serve different thermal management functions, achieving both compact size and effective heat dissipation
3Power
If the alternator is designed for high power output to meet vehicle demands, then the power capability increases, but the heat generation increases and cooling becomes more difficult
Solution Approach 1:
The patent converts the harmful heat generated by high-power operation into a beneficial thermal management system. The radial mounting configuration creates natural convection currents that utilize the heat itself to drive air flow through the housing. Additionally, the strategic placement of modules leverages the heat generation pattern to optimize cooling air distribution, turning the byproduct of high power operation into the driving force for effective thermal management
4Ease of operation
If conventional phase lead routing is used, then the connection is straightforward, but the spatial arrangement is limited and adaptability is poor
Solution Approach 1:
The patent introduces dynamic adaptability to the phase lead routing system. The phase leads are configured to flexibly route through the radially distributed power module locations, allowing the connection path to adapt to different module arrangements and housing configurations. This dynamic routing capability enables the same basic connection approach to work across various spatial arrangements while maintaining connection simplicity
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 configuration significantly reduces heat loss and temperature in power electronics, improves cooling efficiency, and enhances structural integrity, allowing for more uniform air flow and effective heat dissipation in both air-cooled and liquid-cooled electric machines.
Implementation Method 1
The electric machine is air-cooled and the rear frame member has an aperture through which cooling air flow is drawn generally axially... for cooling the electric machine at locations downstream of the aperture
Implementation Method 2
The support structure is formed out of a metal material and defines a heat sink in thermal communication with the plurality of power modules
Implementation Method 3
The radially inner surface defines an air passage axially extending between the first and second axial ends of the support structure
Data Source
AI summary
An electronic package connectable to an electric machine. The electronic package includes a support structure with a first axial end engaged with the electric machine. The support structure circumscribes the central axis and defines radially inner and outer wall surfaces. Power modules are disposed on and circumferentially distributed about the radially outer wall surface and include a power electronics device. Each module includes a phase terminal coupled with the power electronics device and disposed radially outwardly of the radially outer wall surface. The support structure defines a plurality of voids extending between the radially inner and outer wall surfaces. Each of the power modules are positioned proximate a separate one of the voids. Each void has a phase lead extending therethrough. Each phase lead is connected to a phase terminal and conductively couples it with a stator winding. An electric machine having an electronic package is also disclosed.