Stator Mounting Ear Cooling Channels for Vehicle Electric Machines
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Solution Overview
Problem
Electric machines in vehicles face challenges in thermal management, particularly in efficiently cooling the stator and rotor while minimizing interference with the magnetic flux path, which affects their performance and efficiency.
Innovation Solution
The design incorporates a stator core with radially positioned mounting ears that define cooling channels extending axially, and a housing with circumferential cooling passages that are in fluid communication, allowing for effective coolant circulation and thermal management without disrupting the magnetic flux path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are positioned within the stator core, then thermal management is improved, but the magnetic flux path is disrupted
Solution Approach 1:
The cooling channels are repositioned from the radial dimension (within the stator core) to the axial dimension (in the mounting ears extending axially). This dimensional shift allows cooling functionality without interfering with the radial magnetic flux path through the stator core.
Solution Approach 2:
The mounting ears serve as an intermediary structure that carries the cooling channels away from the stator core's active magnetic region. This mediator component enables thermal management while preserving the integrity of the magnetic flux path through the core.
2Temperature
If mounting ears are added to the stator core, then cooling capability is improved, but device complexity increases
Solution Approach 1:
The mounting ears are designed to serve multiple functions: providing structural support for mounting the stator core and simultaneously housing the cooling channels. This multi-functionality adds cooling capability without proportionally increasing complexity.
Solution Approach 2:
The cooling channel function is merged with the existing mounting ear structure rather than adding separate cooling components. This integration combines thermal management with structural support, reducing overall device complexity.
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 enhances the thermal management of electric machines by improving coolant circulation and heat dissipation, thereby increasing their efficiency and performance, especially in high-power applications like electric and hybrid-electric vehicles.
Implementation Method 1
coolant circulation and heat dissipation
Implementation Method 2
heat dissipation
Data Source
AI summary
A vehicle electric machine includes a stator core having an inner diameter defining a plurality of slots, an outer diameter, and a plurality of mounting ears disposed radially outboard of the outer diameter. At least one of the mounting ears defines a cooling channel extending in an axial direction of the stator core. A radial distance between a center of the stator core and the cooling channel is greater than a radial distance between the center and the outer diameter. The machine further includes windings having portions disposed in the slots and end windings adjacent to an end face of the stator core.