Rotor Fluid Flow Path for Stator Tooth Cooling in Drive Units
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Solution Overview
Problem
Existing electric drive units face challenges in effectively cooling the stator assembly through fluid flow paths, which can lead to reduced efficiency and performance.
Innovation Solution
The drive unit incorporates a rotor assembly with a fluid flow path that conveys fluid from an interior hollow defined by the rotor shaft to a fluid passage within the rotor mid plate and radially outboard to the stator assembly, utilizing a unique configuration of teeth and plates to enhance fluid distribution and contact with the stator assembly, allowing for improved cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional fluid flow path is used in existing electric drive units, then the structure is simple, but the cooling effectiveness of the stator assembly is insufficient
Solution Approach 1:
The rotor assembly is divided into multiple segments including a rotor shaft, rotor mid plate, and rotor end plates, each defining portions of the fluid flow path. This segmentation allows the cooling fluid to be distributed through multiple channels to different regions of the stator assembly, improving cooling effectiveness while maintaining manageable structural complexity
Solution Approach 2:
The rotor assembly serves dual functions: it acts as both the rotating component for power generation and as the fluid distribution system for cooling. The rotor mid plate and rotor end plates simultaneously provide structural support and define fluid passages, eliminating the need for separate cooling components and reducing overall device complexity
2Reliability
If fluid is not effectively conveyed to the stator assembly, then the device complexity is reduced, but the performance and longevity of the drive unit deteriorates
Solution Approach 1:
The rotor assembly's rotation itself drives the fluid circulation through the defined passages. The centrifugal force and pressure differentials created during rotor rotation automatically move the cooling fluid from the rotor shaft through the mid plate and end plates to the stator assembly, eliminating the need for external pumps or complex control systems while ensuring reliable fluid delivery
Solution Approach 2:
The fluid flow path is nested within the rotor assembly structure. The rotor shaft, mid plate, and end plates are arranged concentrically with fluid passages integrated into each component, creating a compact nested arrangement that delivers cooling fluid efficiently without requiring additional external cooling infrastructure
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 enables efficient cooling of the stator assembly, enhancing the performance and longevity of the drive unit by ensuring effective fluid circulation and contact with critical components.
Implementation Method 1
fluid is conveyed along the portion of the fluid flow path from the interior hollow to the fluid passage and radially outboard therefrom to the third axial extent of the plurality of teeth of the stator assembly core
Implementation Method 2
fluid is conveyed along the portion of the fluid flow path from the interior hollow to the fluid passage and radially outboard therefrom to the third axial extent of the plurality of teeth of the stator assembly core
Data Source
AI summary
A drive unit includes a stator assembly with a stator assembly core having a plurality of teeth that extend from a first end to a second end of the stator assembly core. The teeth have first, second, and third axial extents. The radially inboardmost portions of the first and second axial extents are radially inboard of the radially inboardmost portions of the third axial extent. The drive unit also includes a rotor assembly with first and second rotor bodies, a rotor mid plate, first and second rotor end plates, and a rotor shaft. The rotor assembly defines a portion of a fluid flow path of the drive unit including an interior hollow defined by the rotor shaft and a fluid passage defined by the rotor mid plate. Fluid is conveyed along the portion of the fluid flow path from the interior hollow to the fluid passage to the third axial extent.