Stator Cooling Channels for Motor Heat Dissipation

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Solution Overview

Problem

High power density electric motors face efficiency losses and material degradation due to heat generation, leading to reduced integrity and performance, especially in constrained spaces.

Innovation Solution

The motor design incorporates a stator with channels between coils and a rotor featuring a core with vents and turbulators, along with a fan module assembly for enhanced airflow and cooling, utilizing both positive and negative pressure configurations to improve heat removal and reduce noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If high power density motor design is implemented with reduced size and weight, then power output per unit volume increases, but heat generation causes efficiency loss and material degradation

Engineering Contradiction:

Improvepower output per unit volumeVSAvoidefficiency loss due to heat generation

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The stator is segmented into multiple sections with individual cooling channels positioned between each stator coil and the rotor. This segmentation allows targeted cooling of high-heat-generation zones, improving thermal management efficiency without increasing overall motor size, thus maintaining high power density while reducing energy loss to heat.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A cooling fluid intermediary is introduced to transfer heat from the stator coils to the rotor area. The cooling channels provide a pathway for this intermediary fluid to absorb heat directly at the source (stator coils) and dissipate it through the rotor, effectively managing thermal energy and preventing efficiency loss while preserving compact motor dimensions.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Power

If high power density motor design is implemented with reduced size and weight, then power output per unit volume increases, but material degradation and loss of integrity occur

Engineering Contradiction:

Improvepower output per unit volumeVSAvoidmaterial integrity

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Cooling channels are pre-positioned between the stator coils and rotor during manufacturing, enabling proactive heat removal before thermal damage can occur to critical materials. This preliminary cooling action prevents material degradation and maintains structural integrity throughout motor operation, allowing sustained high power density performance.

Inventive Principle:

Principle #10Preliminary action

3Temperature

If cooling channels are added to the stator, then heat dissipation improves, but device complexity increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidstator structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling channels are merged with the stator coil structure, positioning cooling passages directly between the coils and rotor. This integration combines the cooling function with the existing stator architecture, improving heat dissipation efficiency while minimizing additional structural complexity compared to separate cooling systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stator structure serves multiple functions: it provides mechanical support for the coils, creates magnetic flux paths, and simultaneously houses the cooling channels for thermal management. This multi-functionality reduces overall device complexity by consolidating structural and thermal management roles into a single integrated component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 effectively increases cooling efficiency, reduces noise, and maintains motor integrity by enhancing airflow and heat dissipation, allowing for higher power density in a smaller, lighter form factor.

Implementation Method 1

the stator forms at least one stator channel, wherein the stator channels are located between the stator coils and the rotor

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

a fan module assembly for enhanced airflow and cooling

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

a rotor featuring a core with vents and turbulators, along with a fan module assembly for enhanced airflow and cooling

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 4

Motors may be used to convert electric energy into mechanical energy

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10454330B2Motor including stator cooling channel adjacent to stator slots

Publication Date: 2019.10.22 NIDEC MOTOR CORP

AI summary

A motor including a stator including a plurality of stator slots having stator coils disposed therein, and a rotor rotatable within the stator about a central axis. The stator includes a plurality of stator channel formed adjacent to the stator slots and extending in the axial direction of the central axis.