Electric motor heating/cooling system

Patent metadata

Field	Value
Publication number	US-10128705-B2
Application number	US-201715827435-A
Country	US
Kind code	B2
Filing date	Nov 30, 2017
Priority date	Jun 7, 2016
Publication date	Nov 13, 2018
Grant date	Nov 13, 2018

Abstract

An electric motor includes a case, a stator that includes a stator laminaiton and end-windings, a rotor coupled to the case via at least one rotor bearing. The rotor includes a hollow cylindrical body, a first shaft portion, and a second shaft portion. The hollow cylindrical body includes an inner wall, an outer wall, a first distal end, and a second distal end. The first shaft portions couples to the first distal end and the second shaft portion couples to the second distal end. The second shaft portion includes a fluid feed tube formed therewith having a fluid receive end and a fluid feed end, the fluid feed end extending to a central inner portion of the hollow cylindrical body. A plurality of fluid exit ports adjacent the first distal end and the second distal end of the hollow cylindrical body spray fluid onto components of the stator.

First claim

The invention claimed is:

1. An electric motor comprising:
a case;
a stator that includes a stator lamination and end-windings; and
a rotor coupled to the case via at least one rotor bearing, the rotor comprising:
a hollow cylindrical body having an inner wall, an outer wall, a first distal end, and a second distal end;
a first shaft portion coupled to the first distal end of the hollow cylindrical body;
a second shaft portion coupled to the second distal end of the hollow cylindrical body, the second shaft portion including a fluid feed tube formed therewith having a fluid receive end and a fluid feed end, the fluid feed end extending to a central inner portion of the hollow cylindrical body; and
a plurality of fluid exit ports adjacent the first distal end and the second distal end of the hollow cylindrical body configured to spray fluid onto at least the end-windings of the stator.

2. The electric motor of claim 1 , further comprising:
at least one drive motor fluid pump configured to pump the fluid into the fluid receive end of the fluid feed tube; and
a fluid reservoir.

3. The electric motor of claim 1 , wherein the fluid feed end of the fluid feed tube comprises a plurality of fluid spray ports formed in the second shaft portion and configured to spray fluid onto the inner wall of the hollow cylindrical body.

4. The electric motor of claim 1 , further comprising a cylindrical laminated stack coupled to the outer wall of the hollow cylindrical body and including a plurality of permanent magnets.

5. The electric motor of claim 1 , wherein a distance from the central inner portion of the hollow cylindrical body to the plurality of fluid exit ports is based upon a specified fluid film thickness to support rotor cooling.

6. The electric motor of claim 1 , further comprising:
a drive motor fluid pump having a drive motor fluid pump outlet and a drive motor fluid pump inlet;
fluid circulation piping having:
an output portion coupled between the drive motor fluid pump outlet and the fluid receive end of the second shaft portion;
an input portion coupled between a fluid collection point on the case and the drive motor fluid pump inlet; and

drive motor fluid pump electronics.

7. The electric motor of claim 6 , further comprising a radiator configured to cool the fluid.

8. The electric motor of claim 7 , further comprising a heat exchanger coupled between the drive motor fluid pump and the radiator.

9. A rotor for use with a stator having a stator lamination and end-windings, the rotor comprising:
a hollow cylindrical body having an inner wall, an outer wall, a first distal end, and a second distal end;
a first shaft portion coupled to the first distal end of the hollow cylindrical body;
a second shaft portion coupled to the second distal end of the hollow cylindrical body, the second shaft portion including a fluid feed tube formed therewith having a fluid receive end and a fluid feed end, the fluid feed end extending to a central inner portion of the hollow cylindrical body; and
a plurality of fluid exit ports adjacent the first distal end and the second distal end of the hollow cylindrical body configured to spray fluid onto at least the end-windings of the stator.

10. The rotor of claim 9 , further comprising at least one rotor bearing that rotatingly couple the rotor to the stator.

11. The rotor of claim 9 , wherein the fluid feed end of the fluid feed tube comprises a plurality of fluid spray ports formed in the second shaft portion and configured to spray fluid onto the inner wall.

12. The rotor of claim 9 , further comprising a cylindrical laminated stack coupled to the outer wall of the hollow cylindrical body and including a plurality of permanent magnets.

13. The rotor of claim 9 , wherein a distance from the central inner portion of the hollow cylindrical body to the plurality of fluid exit ports is based upon a specified fluid film thickness to support rotor cooling.

14. A method for operating an electric motor comprising:
pumping fluid into a hollow cylindrical body of a rotor via a fluid feed tube that is oriented along an axis of rotation of the rotor;
spraying the fluid from a plurality of fluid exit ports of the fluid feed tube onto an inner wall of the hollow cylindrical body of the rotor, the fluid further flowing along the inner wall of the hollow cylindrical body from a central portion towards fluid exit ports located adjacent distal ends of the hollow cylindrical body while the rotor is rotating; and
spraying the fluid from the fluid exit ports onto at least end-windings of a stator of the electric motor.

15. The method of claim 14 , wherein spraying the fluid from the plurality of fluid exits ports onto the inner wall of the hollow cylindrical body comprises spraying the fluid onto a central portion of the inner wall of the hollow cylindrical body.

16. The method of claim 15 , wherein a distance from the central inner portion of the hollow cylindrical body to the plurality of fluid exit ports is based upon a specified fluid film thickness to support rotor cooling.

17. The method of claim 14 , further comprising:
circulating the fluid from the electric motor to a heat exchanger;
exchanging heat between the fluid and the heat exchanger; and
circulating the fluid from the heat exchanger to the electric motor.

18. The method of claim 17 , further comprising circulating coolant between a radiator and the heat exchanger.

19. The method of claim 18 , further comprising circulating the coolant between the heat exchanger and a battery.

20. The method of claim 14 , further comprising adjusting flow of the fluid based upon at least a temperature of the rotor.

Assignees

• Tesla Inc

Inventors

• Yang Bozhi
• Martins Tomas Vianna
• Graves Scott Michael
• Swint Ethan
• Bellemare Eric
• Fedoseyev Lev
• Dellal Benjamin
• Olsen Leif E
• Hain Alexander

Classifications

• H02K1/274

  the rotor consisting of two or more circumferentially positioned magnets · CPC title

• H02K11/00

  Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection (casings, enclosures or supports H02K5/00) · CPC title

• H02K5/1732

  radially supporting the rotary shaft at both ends of the rotor (H02K5/1737 takes precedence) · CPC title

• H02K9/197

  in which the rotor or stator space is fluid-tight, e.g. to provide for different cooling media for rotor and stator · CPC title

• H02K7/083

  radially supporting the rotary shaft at both ends of the rotor (H02K7/086, H02K7/09 take precedence) · CPC title