Ribbed Motor Housing Coolant Channels for Winding and Controller Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric motors for water sports devices, particularly surfboards, face challenges in cooling the windings effectively, leading to performance limitations and high manufacturing costs.
Innovation Solution
The electric motor design features a housing with ribs forming a coolant channel between the inner and outer walls, allowing for efficient coolant flow around the rotor and stator, utilizing aluminum or steel for heat conduction, and incorporating a bypass for enhanced heat dissipation, including a cooling plate and bearing cover for effective heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling system is added to cool the controller, then the controller temperature is reduced, but the cooling system is not suitable for cooling the windings and the device complexity increases
Solution Approach 1:
The patent combines the controller cooling function and winding cooling function into a single integrated coolant channel system. The coolant channel is formed within the housing structure itself, allowing one coolant flow to simultaneously cool both the controller (via the first section) and the windings (via the second section), thereby reducing device complexity while maintaining effective cooling of both components.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical support, contains the coolant channel for cooling, and directly participates in heat dissipation. The coolant channel integrated into the housing allows the same cooling system to serve both the controller and the windings, making the cooling system universal for multiple heat-generating components.
2Loss of energy
If the housing is made of aluminum or steel for heat conduction, then heat dissipation is improved, but the manufacturing cost increases
Solution Approach 1:
The patent merges the cooling channel function directly into the housing structure, eliminating the need for separate cooling channels or additional heat dissipation components. By forming the coolant channel within the housing itself, the design achieves effective heat dissipation through aluminum or steel while minimizing the number of parts and assembly steps, thereby controlling manufacturing costs.
Solution Approach 2:
The housing structure serves its own cooling needs by incorporating the coolant channel directly within it. The housing material (aluminum or steel) naturally conducts heat from the windings and controller to the coolant, eliminating the need for separate heat dissipation components and reducing manufacturing complexity.
3Temperature
If ribs are added to form coolant channels, then cooling effectiveness is improved, but the device complexity increases
Solution Approach 1:
The patent combines the structural support function and the cooling channel function into the same ribs within the housing. The ribs that provide mechanical support also form the coolant channels, allowing the cooling structure to be integrated with the housing rather than added as a separate component, thereby minimizing device complexity while improving cooling effectiveness.
Solution Approach 2:
The ribs within the housing serve dual purposes: providing mechanical structural support and forming the coolant channels for heat dissipation. This multi-functional design eliminates the need for separate cooling components, reducing device complexity while achieving effective winding cooling.
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 results in a powerful, cost-effective electric motor that efficiently cools the windings and controller, enhancing performance and durability while maintaining a low manufacturing cost.
Implementation Method 1
utilizing aluminum or steel for heat conduction
Implementation Method 2
a section of a coolant channel extending between the inner wall and the outer wall for a coolant flow
Implementation Method 3
at least one rib has an breakthrough which permits the flow of coolant from one side of one rib to another side of one rib
Data Source
AI summary
The invention relates to an electric motor with a housing (800) with a shaft (604) aligned in the direction of a longitudinal axis (L) and with an inner wall (801) and an outer wall (802) arranged around it, between which at least a section of a coolant channel (601) for a coolant flow runs, and with a rotor (606) arranged in the interior of the housing (800) and a stator (607), wherein ribs (803) aligned in the direction of the longitudinal axis (L) are arranged between the inner wall (801) and the outer wall (802), which ribs form lateral walls of the section of the coolant channel (601), and at least one rib (803) has a breakthrough (804) which permits the coolant flow from one side of the at least one rib (803) to another side of the at least one rib (803).