Electric Motor Rotor Cooling Circuit Design
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Solution Overview
Problem
Current electric motor cooling solutions are either expensive and complex, such as circulating oil through the shaft or using specific bearings with internal cooling circuits, which are difficult to implement and costly.
Innovation Solution
A rotor design with internal channels for coolant circulation within the lamination stack and flanges, allowing for efficient heat removal without significant structural modifications, utilizing inlet and outlet channels and connecting channels for coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If oil circulation through shaft or specific bearings with internal cooling circuits is used, then heat removal effectiveness is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The cooling circuit is segmented into multiple independent channels: inlet channels in the shaft, connecting channels in the flanges, and outlet channels. This segmentation allows the cooling function to be distributed across existing structural components rather than requiring a single complex integrated system, thereby improving heat removal effectiveness while maintaining structural simplicity.
Solution Approach 2:
The shaft and flanges are designed to serve dual functions: mechanical support/rotation and coolant transport. The inlet and outlet channels are integrated into the shaft structure, and connecting channels are formed in the flanges, allowing these components to simultaneously perform their mechanical roles and cooling functions without adding separate dedicated cooling structures.
2Temperature
If oil circulation through shaft or specific bearings with internal cooling circuits is used, then heat removal effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The shaft and flanges are designed to serve dual functions: mechanical support/rotation and coolant transport. The inlet and outlet channels are integrated into the shaft structure, and connecting channels are formed in the flanges, allowing these components to simultaneously perform their mechanical roles and cooling functions without adding separate dedicated cooling structures.
Solution Approach 2:
The cooling circuit functionality is merged with the existing mechanical components (shaft and flanges). Rather than adding separate cooling devices, the patent combines the coolant transport function into the structural components that already exist in the rotor assembly, thereby achieving effective cooling without increasing manufacturing cost.
3Temperature
If conventional cooling solutions are used, then heat removal is achieved, but ease of implementation decreases
Solution Approach 1:
The cooling circuit is segmented into multiple independent channels: inlet channels in the shaft, connecting channels in the flanges, and outlet channels. This segmentation allows the cooling function to be distributed across existing structural components rather than requiring a single complex integrated system, thereby improving heat removal effectiveness while maintaining structural 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 design effectively removes heat generated during operation with minimal structural changes, providing a cost-effective cooling solution for electric motors.
Implementation Method 1
the shaft is provided with at least one first internal channel for circulating a coolant, called the inlet channel, and with at least one second internal channel for circulating a coolant, called the outlet channel
Implementation Method 2
arranged to enable a better removal of the heat generated during its operation
Implementation Method 3
the front flange, respectively the rear flange, is configured to form with the front lateral face, respectively the rear lateral face, of the lamination stack at least two front connecting channels, respectively at least two rear connecting channels, inside which a coolant can circulate
Implementation Method 4
circulating a coolant through the end flanges generates few modifications in the general structure of the electric motor and, therefore, offers a relatively inexpensive solution to the problem of heat removal
Data Source
AI summary
A rotor having channels for circulating a cooling fluid, a rotor shaft which is mounted for rotation about an axis, and a lamination stack which is mounted coaxially on the shaft. The lamination stack includes first internal cavities and second internal cavities which are symmetrical relative to the axis of the shaft and relative to each other. The two second internal cavities extend axially through the whole of the lamination stack so that they open, at the first end, into a front lateral face of the lamination stack and, at the other end, into a rear lateral face. The two second internal cavities are configured to allow a cooling fluid to circulate inside the lamination stack. A plurality of permanent magnets are received inside the first internal cavities. A front flange and a rear flange which are mounted coaxially on the shaft are arranged on either side of the lamination stack so as to be contiguous with the front and rear lateral faces, respectively.