Stator Spray Manifold Layout for E-Machine Thermal Control
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Solution Overview
Problem
Conventional cooling systems for e-machines, such as electric motors and generators, are inefficient in effectively circulating cooling fluid to the stator, leading to performance limitations due to excessive thermal conditions.
Innovation Solution
A cooling system with a manifold member that includes a plurality of nozzles arranged circumferentially around the axis of rotation, directing cooling fluid towards the stator end turns, and utilizing gravity-assisted flow to enhance heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling systems are used for the stator, then the structure is simple, but the cooling effectiveness is limited and thermal conditions are excessive
Solution Approach 1:
The cooling system is segmented into multiple nozzles distributed circumferentially around the stator, with each nozzle providing localized cooling to specific regions. This segmentation allows for more comprehensive heat removal compared to conventional single-point cooling systems.
Solution Approach 2:
Different regions of the stator receive cooling fluid through specifically positioned nozzles, creating localized cooling zones where heat generation is highest. The circumferential arrangement ensures that each segment of the stator winding end turns receives targeted cooling attention.
2Productivity
If cooling fluid is sprayed directly at the stator, then heat removal is improved, but misting, evaporation, and deposit formation increase
Solution Approach 1:
The system utilizes gravity-assisted flow to create equipotential cooling conditions, allowing the cooling fluid to flow naturally along the stator surface without excessive pressure. This reduces fluid velocity, minimizing misting and evaporation while maintaining effective heat transfer.
Solution Approach 2:
The system replaces high-pressure forced spray mechanisms with gravity-assisted flow, substituting mechanical energy with gravitational potential energy. This substitution reduces the kinetic energy of the cooling fluid, thereby reducing harmful effects like misting and deposit formation while maintaining cooling effectiveness.
3Area of stationary object
If multiple nozzles are arranged circumferentially around the stator, then cooling coverage is improved, but the device complexity increases
Solution Approach 1:
The circumferential nozzle arrangement serves multiple functions simultaneously: it provides uniform cooling coverage, facilitates gravity-assisted flow distribution, and creates a self-regulating cooling pattern. This multi-functionality reduces the need for additional complex control mechanisms.
Solution Approach 2:
The cooling system merges the functions of fluid distribution, flow direction control, and cooling coverage into a single integrated nozzle arrangement. The circumferential positioning combines multiple cooling functions into one structural configuration, reducing overall system 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
The system efficiently delivers cooling fluid to the stator, reducing misting, evaporation, and deposit formation, thereby improving e-machine performance and operational efficiency.
Implementation Method 1
utilizing gravity-assisted flow to enhance heat removal
Implementation Method 2
a cooling system that provides a cooling fluid to the stator
Data Source
AI summary
An e-machine includes a housing with a cooling fluid inlet and a cooling fluid outlet. The e-machine includes a rotating group supported for rotation about an axis of rotation within the housing. The cooling fluid inlet and the cooling fluid outlet are disposed on opposite sides of the axis of rotation. The e-machine includes a stator disposed within the housing. The e-machine includes a plurality of nozzles in fluid communication with the cooling fluid inlet to receive a cooling fluid therefrom. The plurality of nozzles are arranged about the axis of rotation and generally toward the stator. The arrangement of the plurality of nozzles is directed generally in a circumferential direction with respect to the axis of rotation from the cooling fluid inlet to the cooling fluid outlet.