Stator Radial Seal Cooling Channels for Directly Cooled Windings
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Solution Overview
Problem
E-machines face challenges in providing effective cooling while maintaining a compact, low-weight design, which can lead to increased costs, complexity, and reduced performance due to elevated temperatures.
Innovation Solution
An e-machine system with a stator member featuring a radial seal member that seals off winding slots, allowing for coolant flow channels to directly cool the stator windings, supported by a lightweight and efficiently manufactured design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling features are added to cool the e-machine, then cooling effectiveness is improved, but device complexity and weight increase
Solution Approach 1:
The radial seal member is integrated with the stator core to form a unified structure, eliminating the need for separate cooling components. The seal member itself serves dual functions: sealing the slots and forming coolant flow channels, thereby reducing device complexity while maintaining effective cooling
Solution Approach 2:
The radial seal member performs multiple functions simultaneously: it seals the winding slots, provides structural support, and creates coolant flow passages. This multi-functionality reduces the overall component count and system complexity while achieving effective cooling
2Temperature
If cooling features are added to cool the e-machine, then cooling effectiveness is improved, but weight increases
Solution Approach 1:
The cooling flow channels are formed within the existing radial seal member structure rather than adding separate cooling components. This integration ensures that the weight increase is minimal since the seal member material is already present and serves dual purposes
Solution Approach 2:
The radial seal member serves multiple functions including sealing, structural support, and coolant flow channel formation. This multi-functionality eliminates the need for additional dedicated cooling components, thereby minimizing weight increase while achieving effective cooling
3Temperature
If traditional cooling methods are used, then cooling is provided, but manufacturing efficiency decreases and costs increase
Solution Approach 1:
The radial seal member is divided into multiple segments that can be manufactured separately and then assembled around the stator core. This segmentation enables simplified manufacturing processes for each segment while maintaining the overall cooling functionality, thereby improving manufacturing efficiency
Solution Approach 2:
The radial seal member integrates sealing and cooling functions into a single component that can be manufactured using standard processes. This integration reduces the number of manufacturing steps and assembly operations required, improving manufacturing efficiency while maintaining effective cooling
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 system provides efficient cooling to the stator windings while maintaining a compact and lightweight structure, enhancing performance and manufacturing efficiency.
Implementation Method 1
The radial seal member seals off the slot on the inner radial area
Implementation Method 2
The flow channel is configured to receive a flow of coolant for cooling the stator winding segment
Implementation Method 3
coolant for cooling the stator winding segment
Data Source
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AI summary
A e-machine includes a stator member having a longitudinal axis, a first axial end, and a second axial end. The stator member includes a core that supports a plurality of windings. The core includes an inner radial area that extends along the longitudinal axis between the first axial end and the second axial end. The core includes a slot extending between the first axial end and the second axial end. The slot is configured to receive a stator winding segment of the plurality of windings. The e-machine also includes a radial seal member attached to the core. The radial seal member seals off the slot on the inner radial area. Furthermore, the e-machine includes a flow channel cooperatively defined by the radial seal member and the slot of the core. The flow channel is configured to receive a flow of coolant for cooling the stator winding segment.