Dual-Sided Stator Cooling Covers for Uniform Axial Flow
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Solution Overview
Problem
Current cooling systems for electric vehicle motors are inefficient and ineffective in uniformly distributing cooling fluid, leading to hotspots and reduced performance due to non-homogeneous stator windings, loss of velocity, and obstruction by components like busbars and support structures.
Innovation Solution
A dual-sided axial cooling system with cover assemblies that discharge cooling fluid in an axial direction onto stator end windings, featuring openings arranged circumferentially or irregularly to facilitate uniform flow and drainage, and busbars coated with dielectric material to enhance fluid distribution and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling fluid is radially injected or directed at stator windings, then cooling is provided to motor components, but non-uniform flow distribution and hotspots occur due to non-homogeneity of stator windings and obstruction by components
Solution Approach 1:
The cooling system segments the cooling fluid delivery into multiple axial openings distributed around the stator circumference. Each opening delivers cooling fluid to a specific radial position, ensuring uniform distribution across the stator windings and eliminating hotspots caused by non-homogeneous winding structures.
Solution Approach 2:
The invention transitions from radial cooling injection to axial cooling delivery. By changing the dimension of cooling fluid delivery from radial to axial direction, the system bypasses obstructions caused by busbars and support structures, achieving uniform flow distribution without hotspots.
2Temperature
If cooling channels are integrated within stator windings, then cooling efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts the cooling channels from the stator winding structure itself and relocates them to the external housing or cover. This separation maintains effective cooling contact with the stator while simplifying the overall structure, avoiding the complexity of integrating channels within the windings.
Solution Approach 2:
The housing or cover acts as an intermediary component that houses the cooling channels and directs cooling fluid axially onto the stator. This intermediary structure simplifies manufacturing compared to integrating channels directly into windings, while still achieving effective heat transfer.
3Temperature
If cooling media velocity is increased to improve cooling, then cooling effectiveness improves, but velocity is lost as cooling media travels through the motor
Solution Approach 1:
The cooling fluid is pre-accelerated through axial passages in the housing before being delivered to the stator. This preliminary acceleration ensures high velocity at the point of contact with the stator windings, maximizing cooling effectiveness before the fluid enters the motor interior where velocity would otherwise be lost.
4Reliability
If components like busbars and support structures are placed in the motor, then electrical connection and structural support are provided, but flow obstruction and non-uniform cooling occur
Solution Approach 1:
The invention changes the dimension of cooling fluid delivery from radial to axial direction, allowing cooling fluid to flow past busbars and support structures without obstruction. The axial flow path enables uniform cooling distribution while maintaining the necessary electrical and structural components in their functional positions.
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 system improves cooling efficiency by ensuring uniform distribution and drainage of cooling fluid, reducing hotspots and enhancing the performance and reliability of electric vehicle motors.
Implementation Method 1
cooling fluid... discharge the cooling fluid in an axial direction toward stator end windings
Data Source
AI summary
A dual axial cooling system for an electric motor includes a cover assembly provided at first and second axial ends of a stator of the electric motor. Each cover assembly includes a first side portion that is oriented so as to face an interior of the stator, with a plurality of holes formed in the first side portion. A second side portion is coupled to the first side portion, so that a passage is formed between the first and second side portions. A supply nozzle portion is in fluid communication with the plurality of openings via the passage defined between the first and second side portions. The plurality of openings receive cooling fluid from the supply nozzle portion, and discharge the cooling fluid in an axial direction, from each axial end portion of the stator, to provide axial cooling in two axial directions into the stator.