Methods and systems for oil cooled rotor laminations

Patent metadata

Field	Value
Publication number	US-11799362-B2
Application number	US-202117448190-A
Country	US
Kind code	B2
Filing date	Sep 20, 2021
Priority date	Sep 20, 2021
Publication date	Oct 24, 2023
Grant date	Oct 24, 2023

Abstract

Various methods and systems are provided for a system for cooling an electric motor. The cooling system includes a primary coolant passage through a rotor shaft linked to a plurality of secondary passages though lamination stacks of a rotor configured to receive coolant at a central region of the lamination stacks.

First claim

The invention claimed is:

1. A cooling system for an electric motor, comprising:
a primary coolant passage through a rotor shaft linked to a plurality of secondary passages through lamination stacks of a rotor configured to receive coolant at a central region of the lamination stacks; and
a balancing plate coupled to an end of the lamination stacks of the rotor, the balancing plate positioned axially adjacent to end windings of a stator, wherein the balancing plate comprises one or more through channels in fluid communication with the plurality of secondary passages.

2. The cooling system of claim 1 , wherein the primary coolant passage is linked to the plurality of secondary passages via a plurality of corresponding connecting pathways at a central region of the rotor shaft with each secondary passage linked to the primary coolant passage via one corresponding connecting pathway.

3. The cooling system of claim 2 , wherein the primary coolant passage runs along a central axis of the rotor shaft from a first end of the rotor shaft to the central region of the rotor shaft where the primary coolant passage is linked to the plurality of secondary passages, the central region substantially equidistance from the first end and a second end of the rotor shaft.

4. The cooling system of claim 3 , wherein the plurality of secondary passages are arranged radially symmetrically around a central axis of the primary coolant passage and linked to the primary coolant passage via corresponding connecting pathways.

5. The cooling system of claim 4 , wherein the end is a first end of the lamination stacks, and wherein the plurality of secondary passages traverse through a length of the lamination stacks from the first end of the lamination stacks to a second end of the lamination stacks.

6. The cooling system of claim 5 , wherein the primary coolant passage is configured to flow coolant in a single direction from the first end of the rotor shaft to the central region of the rotor shaft, and wherein each of the plurality of secondary passages is configured to flow a first amount of coolant received from the primary coolant passage in a first direction from the central region of the of the lamination stacks to the first end of the lamination stacks and a second amount of coolant received from the primary coolant passage in a second direction from the central region of the of the lamination stacks to the second end of the lamination stacks.

7. The cooling system of claim 5 , wherein the balancing plate is a first balancing plate integrally connected to the first end of the lamination stacks and the first end of the rotor shaft, and further comprising a second balancing plate integrally connected to the second end of the lamination stacks and the second end of the rotor shaft, the second balancing plate also including one or more through channels.

8. The cooling system of claim 7 , wherein the one or more through passages in the first balancing plate are aligned with first ends of the plurality of secondary passages with each through channel of the one or more through channels in the first balancing plate corresponding to one of the plurality of secondary passages, the one or more through channels in the first balancing plate configured to route coolant from the first ends of the secondary passages to the end windings of the stator of the electric motor via a nozzle coupled to the first balancing plate.

9. The cooling system of claim 8 , wherein the one or more through channels in the second balancing plate is aligned with second ends of the plurality of secondary passages with each through channel of the one or more through channels in the second balancing plate corresponding to one of the plurality of secondary passages, the one or more through channels in the second balancing plate configured to route coolant from the second ends of the secondary passages to the end windings of the stator of the electric motor via another nozzle coupled to the second balancing plate.

10. The cooling system of claim 8 , wherein the primary coolant passage is configured to receive coolant from a reservoir via a coolant pump, the system further comprising a scavenge pump configured to return the coolant from the end windings of the stator to the reservoir for recirculation to the primary coolant passage.

11. A method for a cooling system of an electric motor, comprising:
flowing coolant from a primary coolant passage to a center of each of a plurality of secondary passages via corresponding connecting pathways;
flowing coolant to both ends of lamination stacks of a rotor via the plurality of secondary passages; and
routing coolant to end windings of a stator via through channels in balancing plates, the balancing plates including a first balancing plate coupled to a first end of the lamination stacks of the rotor, the first balancing plate positioned axially adjacent to the end windings of the stator.

12. The method of claim 11 , wherein the plurality of secondary passages traverse a length of the lamination stacks from the first end of the lamination stacks to a second end of the lamination stacks, each secondary passage of the plurality of secondary passages coupled to the primary coolant passage via a corresponding connecting pathway at the center of the secondary passage.

13. The method of claim 11 , wherein flowing coolant to both ends of lamination stacks include, for each secondary passage, flowing a first portion of the coolant received from the primary coolant passage to the first balancing plate coupled to the first end of the lamination stacks and flowing a second portion of the coolant received from the primary coolant passage to a second balancing plate coupled to a second end of the lamination stacks.

14. The method of claim 13 , wherein a direction of the flow of the first portion of coolant through a secondary passage is opposite to a direction of the flow of the second portion of coolant through the secondary passage.

15. The method of claim 13 , wherein routing coolant to the end windings via through channels in balancing plates includes spraying the first portion of coolant through a first nozzle receiving coolant from a first set of through channels in the first balancing plate to the end winding on the first end of the stator, and spraying the second portion of coolant through a second nozzle receiving coolant from a second set of through channels in a second balancing plate to the end winding on a second end of the stator.

16. The method of claim 11 , further comprising, flowing the coolant from the end windings to a coolant reservoir via a pump and a coolant return line, and recirculating the coolant to the primary coolant passage via the pump and a coolant supply line.

17. A system for an electric motor, comprising:
a rotor shaft radially enclosed within lamination stacks of a rotor;
a stator including end windings at a first end and a second end of the lamination stacks, the end windings enclosing the lamination stacks of the rotor;
a first balancing plate positioned at the first end of the lamination stacks of the rotor, the first balancing plate positioned axially adjacent to the end windings at the first end;
a primary passage passing through a central axis of the rotor shaft from a first end of the rotor to a central region of the rotor; and
two or more secondary passages passing through the lamination stacks of the rotor, each secondary passage configured to receive coolant flowing through the primary passage and flowing the coolant to the first end and the second end, wherein the first end and th

Assignees

• Dana Automotive Systems Group

Inventors

• Devreese Thibault
• Vanhee Steven
• Druant Joachim

Classifications

• H02K9/193 Primary

  with provision for replenishing the cooling medium; with means for preventing leakage of the cooling medium · CPC title

• B60K11/02

  with liquid cooling · CPC title

• H02K2209/00

  Specific aspects not provided for in the other groups of this subclass relating to systems for cooling or ventilating · CPC title

• H02K1/32 Primary

  with channels or ducts for flow of cooling medium · CPC title

• H02K7/04

  Balancing means · CPC title