Electric Machine Stator Cooling via End Turn Member
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Solution Overview
Problem
Electric machines generate significant heat during operation, which can interfere with the coupling of the stator to the housing, leading to reduced performance and lifespan due to inadequate heat management.
Innovation Solution
An electric machine module with a housing that includes a coolant jacket and an end turn member with radially inward and outward flanges, positioned to enhance heat transfer and cooling by facilitating the flow of coolant adjacent to the stator end turns, and potentially integral with the housing for improved thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used with larger distances between coolant and heat-generating components, then the structure is simpler, but heat management effectiveness deteriorates
Solution Approach 1:
The end turn member is positioned within the machine cavity such that its flanges are nested adjacent to the stator end turns, with apertures through the end turn member providing direct coolant access. This nesting arrangement allows the cooling system to be integrated within the existing structural components, achieving effective heat management without adding external cooling apparatus.
Solution Approach 2:
The end turn member acts as an intermediary component between the coolant delivery system and the stator end turns. By positioning the end turn member with apertures adjacent to the stator end turns, it mediates the heat transfer process, allowing coolant to efficiently remove heat from the stator end turns while maintaining structural integrity.
2Temperature
If the end turn member is positioned closer to the stator end turns for better cooling, then heat transfer efficiency improves, but the coupling between housing and stator may be compromised
Solution Approach 1:
The end turn member features radially inward and outward flanges with specific local geometries positioned adjacent to the stator end turns. These local structural features provide both effective cooling contact surfaces and mechanical coupling stability, allowing the component to simultaneously achieve heat transfer efficiency and coupling reliability through its localized structural qualities.
3Temperature
If coolant apertures are positioned immediately adjacent to the stator end turns, then cooling effectiveness increases, but the housing structure becomes more complex
Solution Approach 1:
The end turn member serves multiple functions: it provides structural support for the stator end turns, facilitates coolant delivery through its apertures, and maintains coupling stability. By integrating these multiple functions into a single component, the system achieves effective cooling without requiring separate dedicated cooling structures in the housing.
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 solution effectively enhances heat energy transfer and cooling, minimizing the distance between the coolant and heat-generating components, thereby increasing the efficiency and lifespan of the electric machine by efficiently managing heat energy.
Implementation Method 1
a coolant jacket and at least one coolant aperture disposed through a portion of the housing... facilitating the flow of coolant adjacent to the stator end turns
Implementation Method 2
at least a portion of the end turn member can contact the housing... potentially integral with the housing for improved thermal conductivity
Data Source
AI summary
Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, an electric machine can be positioned within the machine cavity. In some embodiments, the electric machine can include a stator assembly including potted stator end turns. An end turn member can be positioned within the machine cavity and can include a radially inward flange and a radially outward flange axially extending from a central region. The end turn member is configured and arranged so that the flanges are substantially adjacent the stator end turns. The end turn member can include at least one second member aperture disposed through a portion of the central region.