Rotor Shaft Cooling Channel Layout for Higher Turbulence Heat Dissipation
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Solution Overview
Problem
Existing rotor arrangements for electric machines, particularly in motor vehicles, face challenges in effectively dissipating heat due to limitations in cooling channel design, which affects the efficiency and performance of the rotor and overall electric machine.
Innovation Solution
The proposed rotor arrangement features a design where the spacing regions between the rotor shaft and rotor body are divided into inlet and outlet channels, forming a cooling channel that increases coolant flow rate and turbulence, with sealing portions ensuring a fluid-tight separation and efficient heat dissipation, and a spin-off ring for uniform coolant distribution, enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the spacing regions between rotor shaft and rotor body are used as cooling channels, then heat dissipation is improved, but the cooling efficiency is insufficient due to low flow rate and turbulence
Solution Approach 1:
The spacing regions are divided into multiple inlet channels and outlet channels by sealing portions, creating segmented cooling pathways that increase flow rate and turbulence for improved heat dissipation efficiency
Solution Approach 2:
The rotor shaft is designed with flattened cross-sectional paths in spacing regions and circular-cylindrical paths in contact regions, creating dynamic flow characteristics that enhance turbulence and cooling efficiency while maintaining structural integrity
2Temperature
If the rotor shaft is spaced apart from the rotor body to form cooling channels, then heat dissipation is improved, but the mechanical connection strength is reduced
Solution Approach 1:
The rotor shaft and rotor body are connected through distributed contact regions that provide sufficient mechanical strength while spacing regions between them form effective cooling channels, achieving both structural integrity and thermal management
Solution Approach 2:
Different regions of the rotor shaft have different cross-sectional shapes: flattened paths in spacing regions for cooling and circular-cylindrical paths in contact regions for mechanical connection, optimizing both thermal and mechanical performance locally
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 improves heat dissipation by increasing the flow rate and turbulence of the coolant, effectively cooling the rotor body and shaft, and allows for efficient cooling of the stator end windings, leading to enhanced performance and reliability of the electric machine.
Implementation Method 1
The spacing regions are divided into an inlet channel and an outlet channel, which are fluidically interconnected on a first axial rotor end face via a deflection region and are fluidically separated from one another on a second axial rotor end face in a connection region
Implementation Method 2
This design improves heat dissipation by increasing the flow rate and turbulence of the coolant
Implementation Method 3
a spin-off ring for uniform coolant distribution, enhancing cooling efficiency
Data Source
AI summary
A rotor assembly for an electric machine, having a rotor shaft rotateable about an axis of rotation, a rotor body. The rotor shaft is arranged coaxially in a receiving opening of the rotor body and is connected to the rotor body for conjoint rotation, a plurality of spacing regions distributed around the circumference about the axis of rotation between an outer circumference of the rotor shaft and an inner circumference of the receiving opening, and contact regions, the rotor shaft and the rotor body spaced apart from one another in the spacing regions and in contact with one another in the contact regions, wherein each of the spacing regions is divided into an inlet channel and an outlet channel which are fluidically interconnected on a first axial rotor end face via a deflection region and fluidically separated from one another on a second axial rotor end face in a connection region.