Stator Tooth Cooling Channels for Peak-Load Motor Heat
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Solution Overview
Problem
Electric motors generate thermal energy as a byproduct of torque production, which can negatively impact motor performance and reliability, necessitating effective cooling solutions to manage thermal stress and extend motor life.
Innovation Solution
The electric motor incorporates a stator with cooled teeth, featuring first cooling channels defined by each stator tooth and radial cross-channels to distribute coolant, along with a fluid dam to direct coolant away from the airgap, enhancing thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electric motor operates at peak load, then torque production increases, but thermal stress increases adversely affecting performance and reliability
Solution Approach 1:
The patent converts the harmful thermal energy generated during torque production into a manageable cooling requirement by implementing cooling channels within stator teeth. The coolant flowing through these channels absorbs the heat generated during peak load operation, transforming the harmful thermal stress into a controllable thermal management system that maintains reliability under high power conditions.
Solution Approach 2:
The patent introduces coolant as an intermediary substance that mediates between the heat-generating stator teeth and the motor environment. The cooling channels provide a pathway for this intermediary to absorb and transport thermal energy away from critical components, preventing thermal stress from directly impacting motor reliability during high torque production.
2Reliability
If cooling system is added to reduce thermal stress, then motor reliability improves, but device complexity increases
Solution Approach 1:
The patent merges the cooling function with the existing stator tooth structure by forming cooling channels within the stator teeth themselves. This integration combines the structural support function of stator teeth with the thermal management function of cooling channels, eliminating the need for separate external cooling systems and reducing overall device complexity.
Solution Approach 2:
The stator teeth are designed to serve multiple functions simultaneously: providing structural support for windings, establishing magnetic flux paths, and housing cooling channels for thermal management. This multi-functionality reduces the need for additional dedicated cooling components, thereby improving reliability without proportionally increasing device complexity.
3Temperature
If cooling channels are defined by stator teeth, then thermal stress is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent segments the stator core into multiple laminations, with cooling channels formed within individual stator teeth. This segmentation allows each cooling channel to be independently formed during standard lamination manufacturing processes, avoiding the need for high-precision machining of complex three-dimensional cooling passages and reducing overall manufacturing precision requirements.
Solution Approach 2:
The patent changes the manufacturing approach from precision-machined cooling channels to channels formed through lamination stacking and bonding processes. By altering the manufacturing parameters and methods, the system achieves effective cooling while working within the capabilities of standard electrical steel lamination production, thereby reducing the stringency of manufacturing precision requirements.
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 cooling system effectively reduces thermal stress, enhances motor reliability, and allows for longer motor life under peak loads, while also quieting motor operation and enabling higher speed performance.
Implementation Method 1
each first cooling channel may be defined by a respective stator tooth and configured to receive and pass therethrough a fluid to cool the corresponding stator tooth
Implementation Method 2
configured to receive and pass therethrough a fluid to cool the corresponding stator tooth
Data Source
AI summary
An electric motor includes a stator having a stator core constructed from a ferromagnetic material and having an external stator surface. The stator core includes a stator core body and a plurality of stator teeth extending therefrom and the plurality of stator teeth define conductor slots therebetween. The electric motor also includes at least one rotor, each having an external rotor surface, a plurality of magnetic poles, and configured to rotate relative to the stator about a rotational axis. The stator also includes a plurality of stator conductors arranged within the conductor slots and configured to establish a rotating magnetic field exerting a torque on the rotor(s) via interaction with the magnetic poles. The stator additionally includes a plurality of first cooling channels, each defined by a respective stator tooth and configured to receive and pass therethrough a fluid to cool the corresponding stator tooth.