Fluid-Cooled Motor Stator Assembly with Integrated Cooling Jacket
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Solution Overview
Problem
The manufacturing of stator assemblies for fluid-cooled motors is complex and costly, while existing methods do not adequately maximize performance and cooling capability.
Innovation Solution
A stator assembly design featuring a hollow main body with a cooling jacket that includes conduits for coolant, where the cooling jacket is molded directly over the main body, reducing manufacturing complexity and cost while enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods (shrink fitting aluminum layer, shrink fitting cooling jacket, finishing with end plates) are used, then cooling capability is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the cooling jacket and end plates into a single integrated component. The cooling jacket is formed as one piece with the end plates, eliminating the need for separate shrink fitting operations and reducing assembly steps. This merging of components directly reduces manufacturing complexity while maintaining the cooling functionality through the integrated coolant conduits.
Solution Approach 2:
The cooling jacket serves multiple functions simultaneously: it provides structural support as a housing component, contains the coolant conduits for thermal management, and integrates the end plate functions. This multi-functionality reduces the total number of parts needed while achieving both mechanical support and cooling capabilities.
2Productivity
If multiple separate components (aluminum layer, cooling jacket, end plates) are assembled, then structural integrity is achieved, but manufacturing time and cost increase
Solution Approach 1:
The cooling jacket and end plates are formed as a single integrated component, eliminating multiple assembly operations. This single-piece construction reduces manufacturing time and assembly steps while maintaining structural integrity through the continuous material structure and integrated design that eliminates weak points at joints and interfaces.
3Temperature
If coolant conduits are added to the stator assembly, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The coolant conduits are integrated directly into the cooling jacket structure rather than being separate components. The conduits are formed as inherent features of the cooling jacket itself, eliminating the need for separate conduit installation and reducing overall structural complexity while maintaining effective cooling pathways.
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 minimizes manufacturing complexity and cost while maximizing performance and cooling capability, effectively dissipating heat generated by the motor.
Implementation Method 1
a cooling jacket disposed around the main body, wherein the cooling jacket includes at least one conduit adapted to receive a coolant therein
Implementation Method 2
A pressurized coolant is caused to flow through the coolant apertures to cool the stator
Data Source
AI summary
A stator assembly for use in a fluid-cooled motor is disclosed, wherein a cooling jacket is disposed around a main body of the stator, the cooling jacket including at least one conduit adapted to receive a coolant therein, thereby minimizing a complexity and a cost of manufacture of the stator assembly, and maximizing a cooling capability of the stator assembly.