Electric motor heating/cooling system

• US 10,128,705 B2
• Filed: 11/30/2017
• Issued: 11/13/2018
• Est. Priority Date: 06/07/2016
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Inc.
• Inventors: Yang, Bozhi, Martins, Tomas Vianna, Graves, Scott Michael, Swint, Ethan, Bellemare, Eric, Fedoseyev, Lev, Dellal, Benjamin, Olsen, Leif E., Hain, Alexander
• Primary Examiner(s): Lam, Thanh
• Application Number:
  US15/827,435
• Publication Number:
  US 20180091012A1
• Time in Patent Office: 348 Days
• Field of Search: 310 52- 59, 310 61- 63, 310 60 A
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/6567 Liquids
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings
• CPC Class Codes: H02K 1/274 the rotor consisting of two or more circumferentially positioned magnets
• CPC Class Codes: H02K 1/32 with channels or ducts for flow of cooling medium
• CPC Class Codes: H02K 11/00 Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection casings, enclosures or supports H02K5/00
• CPC Class Codes: H02K 11/40 Structural association with grounding devices
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 5/16 Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields magnetic bearings H02K7/09
• CPC Class Codes: H02K 5/1732 radially supporting the rotary shaft at both ends of the rotor H02K5/1737 takes precedence
• CPC Class Codes: H02K 7/003 Couplings; Details of shafts means for mounting rotors on shafts H02K1/28
• CPC Class Codes: H02K 7/083 radially supporting the rotary shaft at both ends of the rotor H02K7/086, H02K7/09 take precedence
• CPC Class Codes: H02K 9/193 with provision for replenishing the cooling medium; with means for preventing leakage of the cooling medium
• CPC Class Codes: H02K 9/197 in which the rotor or stator space is fluid-tight, e.g. to provide for different cooling media for rotor and stator
• CPC Class Codes: H02P 29/62 for raising the temperature of the motor
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

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.

Claims

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.