Stator Cooling Trough for Electric Machine Heat Dissipation
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Solution Overview
Problem
Electric machines in vehicles face challenges in effectively managing heat generated during operation, particularly in high-voltage components like stators and rotors, which can lead to overheating and reduced performance.
Innovation Solution
The implementation of annular or arch-shaped cooling troughs around the end windings of the stator, which are designed to receive a cooling fluid and direct it through an open channel to efficiently dissipate heat, includes a stator core with end faces and windings, and a housing with an orifice to direct oil into these channels for cooling the end windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal-management systems are added to cool the stator and rotor, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling trough is integrated directly into the stator structure, merging the cooling function with the stator component itself. This eliminates the need for separate cooling systems while providing effective temperature control for the windings.
Solution Approach 2:
A cooling fluid is introduced as an intermediary substance that circulates through the cooling trough to transfer heat away from the windings. This mediator enables thermal management without requiring direct mechanical cooling contact with the electrical components.
2Temperature
If cooling troughs are integrated into the stator structure, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The stator is divided into functional segments: the core structure and the integrated cooling trough. This segmentation allows the cooling trough to be manufactured separately and then assembled to the core, simplifying the overall manufacturing process while maintaining cooling efficiency.
Solution Approach 2:
The cooling trough serves multiple functions: it provides structural support, acts as a thermal management system, and serves as a mounting surface for the windings. This multi-functionality reduces the need for additional components and simplifies manufacturing.
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 effectively cools the end windings of electric machines, preventing overheating and enhancing the operational efficiency and reliability of electric machines in vehicles by maintaining optimal temperatures.
Implementation Method 1
The trough is connected to the end face such that the bottom engages the core, and the sidewall, bottom and end face cooperate to define an open channel around the end windings configured to receive fluid therein
Implementation Method 2
The orifice is arranged to direct oil into the open channel to cool the end windings
Data Source
AI summary
A vehicle electric machine includes a rotor, and a stator having a core with an end face and end windings adjacent to the end face. An annular cooling trough has an outer sidewall and a bottom. The trough is connected to the end face such that the bottom engages the core, and the sidewall, bottom and end face cooperate to define an open channel around the end windings configured to receive fluid therein.