Integrated Rotary Motor Wiring and Refrigerant Path Cooling
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Solution Overview
Problem
Existing rotary electric machines face challenges in downsizing due to the separate configuration of terminal blocks and refrigerant flow paths, which increases overall size and limits effective cooling of heat-generating components.
Innovation Solution
An integrated structure is introduced where electric power wires and a refrigerant flow path are positioned in proximity from different directions, forming a compact and molded structure with insulating resin, enhancing cooling performance and reducing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the terminal block and refrigerant flow path are configured separately and arranged adjacent to each other, then the cooling direction is predetermined (downward or lateral), but the overall size increases
Solution Approach 1:
The terminal block and refrigerant flow path are merged into a single integrated structure where the refrigerant flow path is formed within the terminal block body. This integration eliminates the need for separate adjacent components, reduces overall size, and enables multi-directional cooling of the electric power wires from front, rear, and side directions simultaneously
2Ease of manufacture
If the terminal block and refrigerant flow path are configured separately, then the components can be manufactured independently, but the overall size increases and space efficiency decreases
Solution Approach 1:
The terminal block and refrigerant flow path are integrated into a single molded structure that can be manufactured as one piece using injection molding or similar processes. This unified manufacturing approach maintains ease of production while significantly reducing the overall size compared to separate adjacent components
3Device complexity
If electric power wires are cooled from a single direction, then the cooling structure is simple, but the cooling effectiveness is limited and electrical resistance increases
Solution Approach 1:
The integrated terminal block structure enables the refrigerant flow path to cool electric power wires from multiple directions (front, rear, and side) simultaneously. This multi-directional cooling approach enhances heat dissipation effectiveness, maintains lower electrical resistance, and does not significantly increase structural complexity
Solution Approach 2:
The refrigerant flow path is designed to approach and cool the electric power wires from multiple spatial dimensions (front, rear, and side directions) rather than a single direction. This multi-dimensional cooling arrangement significantly improves cooling effectiveness without requiring complex additional components
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
The integrated structure effectively cools electric power wires, reduces transverse cross-sectional area and weight, and maintains stable component arrangement, achieving compact size and improved cooling efficiency.
Implementation Method 1
a first flow path that constitutes a refrigerant flow path through which a refrigerant flows
Implementation Method 2
the rotary electric machine generates heat due to copper loss and iron loss. In a case of the rotary electric machine that is an in-vehicle drive source, a large current flows therethrough. Thus, an amount of heat generated is also large
Data Source
AI summary
To achieve excellent cooling performance and compactness, one refrigerant flow path, through which a refrigerant flows, and two electric power wires, through each of which a current to energize a rotary electric machine flows, are provided. The two electric power wires are arranged inside an integrated structure portion in such a manner to be in proximity to the refrigerant flow path 110 from different directions.