Spray Bar Cooling for Electric Machine Stator Heat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric machines in electrified vehicles generate significant heat during low-speed/high-torque operations, limiting their functionality if heat is not actively managed.
Innovation Solution
A cooling system incorporating a spray bar positioned adjacent to the rear face of the stator, with nozzles directing coolant between adjacent back irons and onto end windings, effectively managing thermal energy and enhancing performance by allowing higher torque and speed operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electric machines operate at low speed/high torque conditions, then power output is improved, but heat generation increases limiting functionality
Solution Approach 1:
The patent extracts the cooling function from the electric machine housing and implements it as a separate, dedicated cooling system. The cooling system includes a coolant circulation path with pumps, radiators, and internal coolant channels within the housing, separating the thermal management function from the structural housing to effectively manage heat during low-speed/high-torque operations
Solution Approach 2:
The patent introduces coolant as an intermediary substance to transfer heat away from the electric machine components. The coolant circulates through designated channels in the housing and motor assembly, absorbing heat from the electric machine and transporting it to external cooling components, thereby enabling sustained high-power operation
2Temperature
If active cooling system is implemented, then thermal energy management is improved, but device complexity increases
Solution Approach 1:
The patent merges the cooling system components with the existing electric machine assembly. The housing serves dual purposes as both structural enclosure and coolant containment, with coolant channels integrated into the housing walls. The motor assembly also incorporates internal coolant flow paths, combining thermal management functions with existing structural elements to reduce overall system complexity
Solution Approach 2:
The housing is designed to perform multiple functions: it provides structural support for the electric machine while simultaneously serving as a coolant reservoir and heat dissipation structure. The same housing components that protect the motor also contain and direct coolant flow, eliminating the need for separate cooling-specific structural elements
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
The cooling system actively manages thermal energy, enabling electric machines to operate at higher torques and speeds, thereby increasing their performance capabilities.
Implementation Method 1
A cooling system incorporating a spray bar positioned adjacent to the rear face of the stator, with nozzles directing coolant between adjacent back irons and onto end windings, effectively managing thermal energy
Data Source
AI summary
This disclosure details cooling systems for cooling electric components, such as electric machines, within electrified vehicles. Exemplary cooling systems may include a spray bar positioned relative to a rear face of a stator of the electric machine. In some embodiments, the spray bar may be positioned axially between the rear face of the stator and a torque converter housing. One or more nozzles of the spray bar are configured to direct a coolant between adjacent back irons of the stator, onto end windings of the stator, or both. Actively cooling the stator allows the electric machine to operate at higher torques and speeds, thereby increasing performance.