Stator Lamination Channels With Damping for EV Motor NVH
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Solution Overview
Problem
Existing electric machine stators face challenges in reducing noise, vibration, and harshness (NVH) due to the absence of internal combustion engine masking sounds, with current solutions being complex, costly, and posing packaging and weight issues.
Innovation Solution
A stator assembly design featuring aligned apertures in laminations to form channels, filled with damping material to increase stiffness and reduce NVH, while alternating channels are used for coolant flow to cool the stator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If acoustic covers, modified housing ribs, stator winding wax, or acoustic shields are used to reduce NVH, then noise/vibration/harshness is reduced, but device complexity, cost, and packaging/weight challenges increase
Solution Approach 1:
The patent combines multiple functions into the stator assembly itself: the stator assembly integrates structural support, cooling (through channels), and NVH reduction (through damping material) functions, eliminating the need for separate acoustic covers, shields, or modified housing ribs
Solution Approach 2:
The stator assembly is designed as a multi-functional component that simultaneously provides mechanical support, thermal management through coolant channels, and acoustic damping through integrated damping material, making other dedicated NVH reduction components unnecessary
2Object-affected harmful factors
If acoustic covers, modified housing ribs, stator winding wax, or acoustic shields are used to reduce NVH, then noise/vibration/harshness is reduced, but cost increases
Solution Approach 1:
The damping material is integrated directly into the stator assembly structure during manufacturing, combining NVH reduction functionality with the base component production process and eliminating the need for separate NVH reduction components
Solution Approach 2:
The stator assembly serves multiple purposes including structural support, cooling, and NVH reduction, reducing the total component count and manufacturing cost compared to using separate dedicated components for each function
3Object-affected harmful factors
If acoustic covers, modified housing ribs, stator winding wax, or acoustic shields are used to reduce NVH, then noise/vibration/harshness is reduced, but packaging and weight challenges arise
Solution Approach 1:
The damping material is incorporated within the stator assembly's internal structure, merging the NVH reduction function with the existing structural component and avoiding additional external components that would increase weight and packaging requirements
Solution Approach 2:
The damping material is nested within the stator assembly structure, with the damping material positioned inside the stator assembly housing or structural framework, utilizing existing space rather than adding external components
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 minimizes NVH and improves overall stiffness and cooling efficiency, enhancing the performance of electric machines.
Implementation Method 1
A damping material is disposed in at least one channel of the plurality of channels to increase stiffness in the stacked configuration and reduce noise/vibration/harshness (NVH) in the electric machine
Implementation Method 2
at least one channel of the plurality of channels is a fluid channel configured to receive a flow of coolant fluid for cooling of the stator assembly
Data Source
AI summary
A stator assembly for an electric machine includes a plurality of stator laminations arranged in a stacked configuration and a plurality of apertures formed in each of the stator laminations. The plurality of apertures of the plurality of stator laminations are aligned to form a plurality of channels in the stacked configuration. A damping material is disposed in at least one channel of the plurality of channels to increase stiffness in the stacked configuration and reduce noise/vibration/harshness (NVH) in the electric machine.