Stator End-Coil Cooling Cap for Uniform Motor Heat Dissipation
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Solution Overview
Problem
Current methods for cooling stator coils in electric vehicle motors face inefficiencies, including low cooling efficiency when indirectly cooling through the motor housing and non-uniform cooling when directly spraying fluids, limiting motor output and reliability.
Innovation Solution
An apparatus featuring a cooling cap unit with inlet and outlet flow paths that cover the end coil of the stator, allowing for direct and uniform cooling, utilizing fluid circulation to enhance heat dissipation and including a cap fixing unit for secure attachment, which can be applied to both ends of the stator in an axial direction, compatible with various cooling types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the stator coil is indirectly cooled through the motor housing, then the cooling system is simple in structure, but the cooling efficiency of the stator coil is low
Solution Approach 1:
The patent introduces a cooling cap as an intermediary component that directly contacts the stator coil end turns. This cooling cap receives cooling fluid through inlet flow paths and distributes it to cooling the stator coil, acting as a mediator between the cooling fluid and the stator coil to achieve efficient direct cooling while maintaining system simplicity
Solution Approach 2:
The cooling system is segmented into distinct functional components: the cooling cap unit with inlet flow path units, outlet flow path units, and internal flow paths. This segmentation allows the cooling function to be specifically targeted at the stator coil end turns while keeping the overall system structure manageable and modular
2Reliability
If the stator coil is cooled by directly spraying cooling fluid, then the cooling efficiency is improved, but the cooling is non-uniform since the oil is not evenly sprayed
Solution Approach 1:
The cooling cap serves as a controlled intermediary that receives cooling fluid through inlet flow paths and distributes it uniformly through internal flow paths to the stator coil end turns. This intermediary structure ensures even distribution of cooling fluid, eliminating the non-uniform cooling problem associated with direct spraying methods
Solution Approach 2:
The cooling cap is specifically designed to target the end turns of the stator coil, which are the hottest regions. The inlet and outlet flow paths are positioned and configured to create localized high-quality cooling exactly where it is needed most, ensuring uniform cooling distribution in the critical thermal zones
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 solution achieves high cooling efficiency and reliability, enabling increased motor output by concentrating heat dissipation from the stator coils, preventing damage during high-speed driving and allowing universal application across different cooling types.
Implementation Method 1
a cooling cap unit covering an end coil of a stator coil bundle, coupled to a stator, and having, formed therein, a flow path through which fluid is able to flow
Implementation Method 2
fluid is supplied into the cooling cap unit through an inlet flow path unit, and the fluid having passed through the inside of the cooling cap unit is discharged through an outlet flow path unit
Data Source
AI summary
An apparatus for cooling a coil of a motor includes a cooling cap unit covering an end coil of a stator coil bundle, coupled to a stator, and having, formed therein, a flow path through which fluid is able to flow; an inlet flow path unit formed at one part of the cooling cap unit, and forming an inlet path through which fluid is introduced into the cooling cap unit; an outlet flow path unit formed at the other part of the cooling cap unit, and forming an outlet path through which fluid is discharged to an outside of the cooling cap unit; and a cap fixing unit fixing the cooling cap unit to the stator or a motor housing.