Motor Stator Back-Iron Cooling via Internal Channels

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Solution Overview

Problem

Existing electric motors suffer from poor cooling characteristics of the windings and stator core, leading to overheating which decreases efficiency and degrades performance.

Innovation Solution

A motor stator design featuring stacked annular laminates with coolant openings that communicate to form cooling channels inside the stator core, including circumferentially extending slots to facilitate efficient cooling without the need for pressurization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional solid stator core design is used, then structural simplicity is maintained, but cooling efficiency deteriorates leading to overheating

Engineering Contradiction:

Improvestator core temperatureVSAvoidstator core structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The stator core is segmented into multiple stacked annular laminates instead of being a solid structure. Each laminate contains coolant openings that align with adjacent laminates to form continuous cooling channels, enabling effective heat dissipation while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stator core incorporates a porous-like structure with coolant openings and channels formed within the laminates. This allows cooling fluid to flow through the stator core, efficiently removing heat from the windings and core without requiring pressurization systems

Inventive Principle:

Principle #31Porous materials

2Temperature

If cooling channels are added to improve cooling, then temperature control improves, but manufacturing complexity increases

Engineering Contradiction:

Improvestator core temperatureVSAvoidstator laminate fabrication

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The cooling system is divided into discrete coolant openings in each laminate that align to form continuous channels. This segmentation allows standard stamping processes to be used for each laminate while achieving complex cooling geometry when assembled

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Coolant openings are pre-formed in each individual laminate during the stamping process before assembly. The openings are positioned and sized to automatically align with adjacent laminates, creating functional cooling channels without requiring post-assembly machining or complex tooling

Inventive Principle:

Principle #10Preliminary action

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 design effectively cools the stator core, enhancing motor efficiency and performance by creating a gravity-driven cooling fluid path through the stator core, reducing the risk of overheating.

Implementation Method 1

cooling fluid path through the stator core

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

efficiently cool the motor stator

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

gravity-driven cooling fluid path

Methodology Applied

Scientific EffectGravity-driven flow: Gravitation

Data Source

PatentUS11218050B2Motor stator back-iron cooling through internal channels

Publication Date: 2022.01.04 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A motor stator includes a plurality of stacked annular stator laminates defining a stator core having a plurality of stator teeth on an inner diameter thereof, at least some of the plurality of stator laminates including a plurality of coolant openings therethrough. The plurality of coolant openings of adjacent stator laminates communicate with one another in order to define cooling channels inside the stator core. At least some of the plurality of stator laminates include the plurality of coolant openings including a plurality of generally circumferentially extending slots.