Rotor Oil-Cooling Runner Layout for Low-Speed Energy Loss
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Solution Overview
Problem
Existing motor cooling technologies, such as water cooling, suffer from low power density and high structural precision requirements, while oil cooling methods waste kinetic energy by continuously circulating coolant at low speeds, leading to inefficient heat dissipation and increased manufacturing costs.
Innovation Solution
A rotor design with a cylindrical iron core and shaft, featuring a cooling passage with strategically placed runners that utilize centrifugal force to circulate coolant oil only when necessary, reducing kinetic energy loss and enhancing heat dissipation by incorporating damping features in the runners to manage flow resistance based on speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If oil cooling heat dissipation is used to replace water cooling heat dissipation, then heat dissipation effect is improved, but kinetic energy loss increases at low speeds due to continuous coolant circulation
Solution Approach 1:
The patent applies the dynamics principle by making the cooling system adaptive to rotational speed. The damping runner creates speed-dependent flow resistance that automatically adjusts coolant circulation: at low speeds, high flow resistance prevents unnecessary circulation and reduces kinetic energy loss; at high speeds, centrifugal force overcomes the resistance to enable effective heat dissipation. This dynamic adaptation resolves the contradiction between heat dissipation effectiveness and energy loss.
Solution Approach 2:
The patent changes the flow resistance parameter of the cooling system based on operational conditions. The damping runner is designed with specific geometric parameters (cross-sectional area, length, orientation) that create variable flow resistance characteristics. This parameter change allows the system to maintain high flow resistance at low speeds to prevent energy loss, while allowing adequate flow at high speeds for effective cooling, thus resolving the technical contradiction.
2Temperature
If water cooling heat dissipation is used, then cooling capability is provided, but power density is low and structural precision requirements are high
Solution Approach 1:
The patent employs oil cooling instead of water cooling, utilizing the hydraulic properties of oil as the coolant medium. Oil provides better lubrication, higher boiling point, and improved heat transfer characteristics compared to water, enabling higher power density applications. The hydraulic design of the cooling passage with damping runner optimizes oil flow dynamics to achieve effective cooling while reducing structural precision requirements.
3Temperature
If coolant oil flows continuously in the cooling passage, then heat dissipation is maintained, but kinetic energy is lost at low speeds when heat generation is minimal
Solution Approach 1:
The patent applies partial action by providing just enough cooling at each operational level. The damping runner creates sufficient flow resistance to prevent excessive coolant circulation at low speeds when heat generation is minimal, while still allowing adequate cooling when needed. This partial action approach avoids the excessive energy consumption of continuous full-flow cooling while maintaining necessary heat dissipation capabilities.
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 reduces kinetic energy loss at low speeds and ensures effective heat dissipation at high speeds, increasing maximum rotational speed and prolonging peak power duration while maintaining structural stability and reducing manufacturing costs.
Implementation Method 1
Pushed by a centrifugal force generated when the rotor rotates, coolant oil in the first runner tends to flow from the inlet of the first runner to the outlet of the first runner
Implementation Method 2
a damping characteristic of the first runner can prevent a flowing tendency of the coolant oil cause by the centrifugal force, thereby reducing a kinetic energy loss of a motor
Implementation Method 3
When the coolant oil arrives at the outlet of the first runner and sprays, heat at an end portion of the rotor iron core can be taken away, thereby dissipating heat for the end portion of the rotor iron core
Data Source
AI summary
A rotor includes a rotor iron core, a rotor shaft, and a fastening plate. The rotor iron core includes a first and a second end, and extends along an axial direction. The first fastening plate is fastened to at least the first or second end, and includes a through hole and a first runner. An inlet of the first runner communicates with the through hole. An outlet of the first runner is on a surface of a side of the fastening plate. The rotor shaft includes a second runner and a third runner in the rotor shaft. An inlet of the second runner is at one end of the at least one end of the rotor shaft. An outlet of the second runner communicates with an inlet of the third runner. An outlet of the third runner communicates with the inlet of the first runner.