Rotor Endcap Furrowed Periphery for Stator Cooling
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Solution Overview
Problem
Resistive heating of stator windings in electric machines limits mechanical output and degrades performance due to thermal constraints, necessitating effective cooling solutions.
Innovation Solution
The rotor endcap features a furrowed outer periphery with concentric circumferential ridges and channels to distribute coolant evenly across the end windings, ensuring efficient heat dissipation and mechanical energy output enhancement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If stator windings carry high electric current to generate torque, then mechanical output increases, but resistive heating increases and limits performance
Solution Approach 1:
The patent extracts heat from the stator windings by introducing a coolant flow path that directly contacts the windings. The coolant absorbs heat generated by resistive heating and carries it away, allowing higher currents to be sustained without excessive temperature rise, thereby resolving the contradiction between power output and temperature control.
Solution Approach 2:
The patent employs a hydraulic cooling system where coolant flows through channels formed by the furrowed outer periphery of the rotor endcap and along the stator windings. This fluid-based heat removal mechanism enables effective thermal management, allowing the system to maintain high power output while controlling winding temperatures within acceptable limits.
2Temperature
If coolant flow rate increases to improve cooling, then temperature control improves, but system complexity and energy consumption increase
Solution Approach 1:
The patent merges the cooling function with the existing rotor endcap structure by forming coolant channels within the endcap itself and utilizing the furrowed outer periphery as part of the cooling pathway. This integration eliminates the need for separate, complex cooling components and reduces overall system complexity while maintaining effective temperature control.
Solution Approach 2:
The rotor endcap serves multiple functions: it provides structural support for the rotor, seals the rotor assembly, and now also acts as a coolant distribution manifold through its furrowed outer periphery and internal channels. This multi-functionality reduces the need for additional dedicated cooling components, simplifying the overall system while improving thermal management.
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 distributes coolant to various axial locations of the end windings, reducing resistive heating and enhancing mechanical output by improving thermal management within the electric machine.
Implementation Method 1
A rotor may be disposed within the stator and including an endcap having an outer face defining outlets and a furrowed outer periphery with an edge configured to distribute coolant released from the outlets onto the outer face to different axial locations of the end windings during rotation
Data Source
AI summary
A vehicle electric machine may include a stator having end windings extending axially from the stator. A rotor may be disposed within the stator and including an endcap having an outer face defining outlets and a furrowed outer periphery with an edge configured to distribute coolant released from the outlets onto the outer face to different axial locations of the end windings during rotation. The furrowed outer periphery may taper toward an in inner flat portion. The outlets may be contained within the inner flat portion. The furrowed outer periphery may be symmetric about any axis perpendicular to and passing through an axis of rotation of the rotor. The outer face may further define channels extending from the outlets to the edge. The channels may be recessed in the outer face. The furrowed outer periphery may define concentric circumferential ridges.