3D Stator Housing Cooling Structure for Space-Limited Motors
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Solution Overview
Problem
Electric machines face challenges in cooling due to limited space, where structural and cooling features compete, requiring a trade-off between power density and performance.
Innovation Solution
The integration of a cooling structure within the stator housing of electric machines, utilizing additive manufacturing to create a three-dimensional cooling structure with tortuous pathways, vapor chambers, and evaporator/condenser portions, which enhances heat transfer to a cooling fluid flowing along the machine's surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling features are added to the electric machine, then cooling efficiency is improved, but the available space for structural features is reduced
Solution Approach 1:
The cooling structure is integrated into the stator housing, merging the cooling function with the structural housing component. This eliminates the need for separate cooling components and maximizes the use of available space within the stator housing for cooling features.
Solution Approach 2:
The cooling structure utilizes three-dimensional tortuous pathways within the stator housing, transitioning from traditional two-dimensional cooling surfaces to volumetric cooling channels. This allows efficient heat transfer while occupying minimal space within the housing.
2Power
If structural features are prioritized in the electric machine design, then power density is improved, but cooling performance deteriorates
Solution Approach 1:
The cooling structure incorporates localized features such as vapor chambers and evaporator/condenser portions positioned at specific high-heat-generation areas within the stator housing. This provides targeted cooling where needed most, maintaining power density while improving cooling performance at critical locations.
Solution Approach 2:
The cooling structure utilizes phase change parameters through vapor chambers and evaporator/condenser portions, where the working fluid transitions between liquid and vapor phases to efficiently transfer heat. This parameter change enables high-performance cooling within limited space, resolving the trade-off between power density and cooling performance.
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 increases cooling efficiency while maintaining power density, allowing for improved performance by efficiently dissipating heat through the use of additive manufacturing techniques and innovative cooling designs.
Implementation Method 1
enhances heat transfer to a cooling fluid flowing along the machine's surfaces
Implementation Method 2
cooling fluid flowing along the machine's surfaces
Implementation Method 3
vapor chambers, and evaporator/condenser portions
Implementation Method 4
evaporator/condenser portions
Implementation Method 5
evaporator/condenser portions
Data Source
AI summary
An electric motor may include a stator assembly comprising a stator housing, and one or more rotors coupled to the stator by a rotor shaft assembly. The stator housing may include a cooling structure that has a plurality of cooling body portions and a plurality of cooling conduits defined by the plurality of cooling body portions. A method of forming a stator housing for an electric machine may include additively manufacturing a stator housing that includes a cooling structure defining a fluid domain, coupling a working fluid source to the stator housing and introducing a working fluid into the fluid domain defined by the cooling structure, and sealing the cooling structure with the working fluid contained within the fluid domain of the cooling structure. A method of cooling an electric machine may include heating the working fluid in the fluid domain and flowing the working fluid through the fluid domain, and transferring heat from the cooling structure to a cooling fluid flowing along one or more cooling surfaces contacting a surface of the electric machine.