Stator Winding Cooling Passages 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 design, which is essential for reducing costs and manufacturing time, as traditional cooling features often increase complexity, size, and weight.
Innovation Solution
The e-machine system incorporates a stator core with non-circular longitudinal winding segments arranged in an abutting configuration to form fluid passageways, allowing for direct coolant flow between the axial ends, coupled with a fluid coolant system to enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling features are added to e-machine systems, then cooling effectiveness is improved, but device complexity, size, weight, and manufacturing costs increase
Solution Approach 1:
The patent merges the cooling function with the existing winding structure by forming fluid passageways within the slot insulation material that surrounds the windings. This integration eliminates the need for separate cooling components, thereby improving cooling effectiveness while avoiding increased device complexity
Solution Approach 2:
The slot insulation material serves multiple functions: it provides electrical insulation between windings and the stator core, mechanical support for the windings, and now also serves as the medium through which cooling fluid flows. This multi-functionality achieves effective cooling without adding dedicated cooling components
2Temperature
If traditional cooling features are added to e-machine systems, then cooling effectiveness is improved, but weight increases
Solution Approach 1:
The cooling function is merged into the existing slot insulation material rather than adding separate cooling components. This integration achieves effective cooling while minimizing weight increase since the cooling function is embedded within existing structural material
Solution Approach 2:
The slot insulation material acts as a thin-walled structure that contains and directs cooling fluid flow. This thin-film approach provides effective cooling channels without the weight penalty of traditional thick-walled cooling housings or separate cooling assemblies
3Temperature
If traditional cooling features are added to e-machine systems, then cooling effectiveness is improved, but manufacturing time and costs increase
Solution Approach 1:
The fluid passageways are formed within the slot insulation material during the insulation manufacturing process, before the windings are installed. This preliminary formation of cooling channels eliminates the need for post-assembly cooling system installation, thereby reducing manufacturing time and costs while achieving effective cooling
Solution Approach 2:
The manufacturing processes for insulation and cooling channels are merged into a single operation. The slot insulation material is manufactured with embedded cooling passages, eliminating the need for separate cooling component manufacturing and assembly, thus improving manufacturing efficiency while providing 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
This design achieves effective cooling, reduces part count, and simplifies manufacturing, resulting in a compact, lightweight e-machine system with improved manufacturing efficiency and reduced costs.
Implementation Method 1
a fluid coolant system configured to provide a coolant fluid into the cavity for flow along the fluid passageway between the first axial end and the second axial end
Implementation Method 2
Some e-machine systems may generate heat during operation, may operate in high-temperature environments, etc. Elevated temperatures may hinder performance and/or cause other disadvantages. Thus, e-machine systems are proposed that include cooling features
Data Source
AI summary
An e-machine includes a stator core having a first axial end and a second axial end that are separated along a longitudinal axis. The stator core has a slot that extends between the first axial end and the second axial end. The e-machine further includes a plurality of winding members. The plurality of winding members comprise a plurality of longitudinal segments that are received in the slot and that extend between the first axial end and the second axial end. Individual ones of the plurality of longitudinal segments have a cross-sectional profile that is non-circular. The plurality of longitudinal segments are disposed in an abutting arrangement to define a fluid passageway within the slot and between neighboring ones of the plurality of longitudinal segments. The fluid passageway extends between the first axial end and the second axial end of the stator core.