Stator Winding Cooling Channels for Compact E-Machines
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Solution Overview
Problem
E-machine systems face challenges in providing effective cooling while maintaining a compact, low-weight package, which can lead to increased costs, complexity, and manufacturing difficulties.
Innovation Solution
The e-machine system incorporates a stator core with slots that house winding members arranged in a radial configuration, featuring alternating cross-sectional profiles with angled transverse sides that define fluid flow channels, allowing coolant to circulate directly through the windings for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling features are added to the e-machine system, then cooling effectiveness is improved, but device complexity and part count increase
Solution Approach 1:
The cooling channels are integrated directly into the winding members themselves, merging the electrical winding function with the thermal management function. The winding members contain internal cooling passages that allow coolant flow, eliminating the need for separate cooling system components and reducing overall device complexity while maintaining effective cooling.
Solution Approach 2:
The winding members serve dual functions: they provide the necessary electrical windings for motor operation and simultaneously act as cooling channels. This multi-functionality reduces the number of separate components needed in the system, addressing the contradiction between cooling effectiveness and device complexity.
2Temperature
If cooling features are added to the e-machine system, then cooling effectiveness is improved, but manufacturing difficulty and costs increase
Solution Approach 1:
By combining the cooling channels with the winding members in a single integrated component, the manufacturing process is simplified. The cooling passages are formed as part of the winding member structure, reducing the number of separate manufacturing steps and assembly operations required, thereby lowering manufacturing difficulty and costs.
3Temperature
If traditional cooling features are added, then cooling effectiveness is improved, but weight and size increase
Solution Approach 1:
The cooling system is merged with the existing winding members, eliminating the need for additional separate cooling components that would add weight and size. The integrated design uses the same structural material for both the winding and cooling channel functions, optimizing weight efficiency.
4Temperature
If cooling features are added to the e-machine system, then cooling effectiveness is improved, but manufacturing time increases
Solution Approach 1:
The integration of cooling channels into the winding members allows for combined manufacturing of both features in a single process or single assembly operation, reducing the total manufacturing time compared to producing separate cooling components and assembling them later.
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 enables effective cooling of the e-machine, reduces weight and size, and enhances manufacturing efficiency with a lower part count, while providing robust support for the windings.
Implementation Method 1
a fluid coolant system that is fluidly coupled to the e-machine and configured to circulate fluid coolant therethrough
Data Source
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AI summary
An e-machine with a stator core has a slot and winding members with longitudinal segments that are received therein. The longitudinal segments are arranged in a radial arrangement with a first cross-sectional profile a second cross-sectional profile of the segments in the slot. The first cross-sectional profile and the second cross-sectional profile respectively include a first radial side and a second radial side facing opposite radially with respect to the longitudinal axis. The first cross-sectional profile and the second cross-sectional profile respectively includes a transverse side disposed at an acute angle relative to the first radial side, respectively, and disposed at an obtuse angle relative to the second radial side, respectively. The first cross-sectional profile is inverted relative to the second cross-sectional profile with the transverse side of the first cross-sectional profile and the transverse side of the second cross-sectional profile cooperatively defining a fluid flow channel through the slot.