US008.

970075B2

(12) United States Patent (10) Patent No.: US 8,970,075 B2

Rippel et al. (45) Date of Patent: Mar. 3, 2015
(54) LIQUID COOLED ELECTRIC MOTOR 6,121,707 A 9, 2000 Bell et al.
6, 191,511 B1 2/2001 Zysset
6,281,610 B1 8/2001 Kliman et al.
(75) Inventors: Wally E. Rippel. Altadena, CA (US); 6,329,731 B1 12/2001 Arbanas et al.
Christopher C. Moore, LaVerne, CA 6,685,447 B2 * 2/2004 Mabe et al. ................ 417/423.8
(US); Paul F. Carosa, Covina, CA (US) 6,727,609 B2 * 4/2004 Johnsen .......................... 310,52
6,994,602 B2 2/2006 Ries
(73) Assignee: AC Propulsion, Inc., San Dimas, CA 7,002,318 B1 2/2006 Schulz et al.
(US) 7,156,195 B2 1/2007 Yamagishi et al.
7,489,057 B2 2/2009 Zhou et al.
(*) Notice: Subject to any disclaimer, the term of this 758. E: 3. E. ? al.
patent is extended or adjusted under 35 8,022,582 B2* 9 2011 Dames et al. ... 310,54
U.S.C. 154(b) by 135 days. 2003/0132673 A1* 7/2003 Zhou et al. ...................... 310,54
2005, 0023266 A1 2/2005 Ueno et al.
2008.0024020 A1 1/2008 undet al. ....................... 310, 61
(21) Appl. No.: 13/570,169 2008/0179982 A1 7, 2008 Kramer
(22) Filed: Aug. 8, 2012 2010/O127585 A1 5, 2010 Fee et al.
(65) Prior Publication Data FOREIGN PATENT DOCUMENTS
US 2014/0042841 A1 Feb. 13, 2014 WO 2008/O12269 1, 2008
OTHER PUBLICATIONS
(51) Int. Cl.
HO2K9/9 (2006.01) International Search Report and Written Opinion in International
HO2K5/20 (2006.01) Application No. PCT/US2013/0540 13, mailed Feb. 3, 2014.
(52) U.S. Cl.
USPC .............................. 310/54; 310/60 A; 310/61 * cited by examiner
(58) Field of Classification Search
None Primary Examiner — Tran Nguyen
See application file for complete search history. (74) Attorney, Agent, or Firm — Charles C. H. Wu: Charles
C. H. Wu & Associates, APC
(56) References Cited
U.S. PATENT DOCUMENTS (57) ABSTRACT
A liquid-cooled, radial air gap electric motor includes a stator,
3,480,810 A 11, 1969 Potter a rotor, a rotor shaft, two end bells, a housing, a coolant
3,791,331 A 2/1974 Dilley manifold system, and a coolant Sump. The rotor includes a
3,822,967 A * 7/1974 Cade et al. .................... 417.368
3,883,273 A * 5/1975 King ................ ... 417/410.3 plurality of axially directed slots located near its periphery.
3,922,114. A * 1 1/1975 Hamilton et al. ............. 417.366 The coolant manifold system directs a first portion of liquid
4,181,474. A 1, 1980 Shaw ............................ 417.366 coolant to flow past Some portion of the stator and a second
4,198,191 A 4, 1980 Pierce portion of liquid coolant to flow through the rotor slots. Some
4,311,932 A 1, 1982 Olson
4,647,805 A 3/1987 Flygare et al. or all of the liquid coolant is received by the coolant sump
5.448,118 A 9, 1995 Nakamura et al. from which the coolant may be recirculated.
5,698.912 A 12/1997 Rasch et al.
5,831.409 A 1 1/1998 Lindberg et al. 24 Claims, 9 Drawing Sheets

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U.S. Patent Mar. 3, 2015 Sheet 2 of 9 US 8,970,075 B2
U.S. Patent Mar. 3, 2015 Sheet 3 of 9 US 8,970,075 B2
U.S. Patent Mar. 3, 2015 Sheet 4 of 9 US 8,970,075 B2

Fig. 4A
U.S. Patent Mar. 3, 2015 Sheet 5 of 9 US 8,970,075 B2
U.S. Patent Mar. 3, 2015 Sheet 6 of 9 US 8,970,075 B2
U.S. Patent Mar. 3, 2015 Sheet 7 Of 9 US 8,970,075 B2
U.S. Patent Mar. 3, 2015 Sheet 8 of 9 US 8,970,075 B2
U.S. Patent Mar. 3, 2015 Sheet 9 Of 9 US 8,970,075 B2
 US 8,970,075 B2
1. 2
LIQUID COOLED ELECTRIC MOTOR FIG. 2 is a section view which depicts a rotor, stator and
housing for an electric motor in accordance with an embodi
TECHNICAL FIELD ment.
FIG. 3A is an end sectional view which depicts a coolant
The present disclosure is directed generally to the field of 5 inlet and rotor shaft for an electric motor in accordance with
electric motors. an embodiment.
FIG.3B is a cross sectional view taken along line 3B-3B of
BACKGROUND FIG 3A
FIG. 4A is a front-side view which depicts a rotor end-plate
In electric motors, torque is approximately proportionate and end ring for an electric motor in accordance with an
to the product of current and magnetic flux density. In turn, embodiment.
two primary loss components exist which are related to these FIG. 4B is a rear-side view which depicts a rotor end-plate
two quantities. The current-related loss component is due to and end ring for an electric embodiment in accordance with
current flow through conductors (e.g., losses within windings 15
an embodiment.
and rotor bars); this loss component is proportionate to the FIG. 4C is a section view taken along line 4C-4C of FIG.
square of the rms current. The second loss component physi 4B which depicts a coolant channel for an electric motor in
cally takes place in magnetic core elements such as the lami accordance with an embodiment.
nations and is approximately proportionate to the square of FIGS.5A and 5B are, respectively, front and rear exploded
the product of magnetic flux density and electrical frequency. views of a liquid-cooled electric motor in accordance with
Two key consequences of these relations are first that energy one embodiment.
efficiency is optimized at points of operation where the con FIG. 6 is a system block diagram illustrating a liquid
ductor and magnetic losses are approximately equal; and cooled electric motor, Sump and recirculating coolant pump
second that through-power can be increased without loss of in accordance with an embodiment.
efficiency provided speed (electrical frequency) is main 25 FIG. 7A is an end sectional view of a stator for an electric
tained proportionate to torque. motor in accordance with an embodiment.
AS speed and torque are increased, heat dissipation FIG. 7B is a cross sectional view taken along line 7B-7B of
increases. Therefore improved cooling methods are required FIG. 7A.
to limit temperatures to required values. In the case of induc FIG. 8 is an assembly diagram of a rotor for an electric
tion motors this is a particular challenge as a significant 30
motor in accordance with an embodiment.
fraction of the total heat dissipation physically occurs within
the rotor due to the IR losses associated with the rotor bars DESCRIPTION OF EXAMPLE EMBODIMENTS
and end rings. Air cooling generally becomes insufficient
when heat flux values exceed associated thresholds. Unfortu Example embodiments are described herein in the context
nately, liquid cooling techniques for Such rotors have proved 35
of an electric traction motor useable, for example, as a drive
cumbersome in the past due to problems associated with motor for an electrically-powered vehicle. Those of ordinary
transferring fluid flow between rotating and non-rotating skill in the art will realize that the following description is
members. Additional problems exist, Such as preventing the illustrative only and is not intended to be in any way limiting.
radial air gap between the rotor and stator from flooding with Other embodiments will readily suggest themselves to such
coolant as this greatly adds to drag loss at high speeds. Other 40
challenges with liquid cooling include ease of mechanical skilled persons having the benefit of this disclosure. Refer
assembly, uniformity of cooling, prevention of air entrapment ence will now be made in detail to implementations of the
in the coolant, and in some cases, the need for insulating the example embodiments as illustrated in the accompanying
rotor and stator from the housing. drawings. The same reference indicators will be used to the
45 extent possible throughout the drawings and the following
OVERVIEW description to refer to the same or like items.
In the interest of clarity, not all of the routine features of the
A liquid-cooled, radial air gap electric motor includes a implementations described herein are shown and described. It
stator, a rotor, a rotor shaft, two end bells, a housing, a coolant will, of course, be appreciated that in the development of any
manifold system, and a coolant Sump. The rotor includes a 50 Such actual implementation, numerous implementation-spe
plurality of axially directed slots located near its periphery. cific decisions must be made in order to achieve the develop
The coolant manifold system directs a first portion of liquid er's specific goals, such as compliance with application- and
coolant to flow past Some portion of the stator and a second business-related constraints, and that these specific goals will
portion of liquid coolant to flow through the rotor slots. Some vary from one implementation to another and from one devel
or all of the liquid coolant is received by the coolant sump 55 oper to another. Moreover, it will be appreciated that such a
from which the coolant may be recirculated. development effort might be complex and time-consuming,
but would nevertheless be a routine undertaking of engineer
BRIEF DESCRIPTION OF THE DRAWINGS ing for those of ordinary skill in the art having the benefit of
this disclosure.
The accompanying drawings, which are incorporated into 60 In accordance with one embodiment a liquid coolant flow
and constitute a part of this specification, illustrate one or is provided to an electric motor so that the volume of coolant
more examples of embodiments and, together with the is controlled so that a volume of air persists within the motor
description of example embodiments, serve to explain the so that the rotor-stator radial air gap is not flooded with the
principles and implementations of the embodiments. coolant. For many of the internal flow paths, liquid-tight seals
In the drawings: 65 need not be provided—thus saving expense. The only truly
FIG. 1 is a section view of an electric motor which identi liquid-tight seals that are required are those which interface
fies coolant flow paths in accordance with an embodiment. between the coolant and the external environment. This
 US 8,970,075 B2
3 4
approach does not require the use of a scavenge pump-only directed by interior surface 61 of rotor front endplate 62
a simple coolant recirculating pump thus saving further toward coolant exit port 64 in rotor front endplate 62 which is
expense. close to the longitudinal axis of rotation 10. (By constraining
In accordance with one embodiment, a manifold system the fluid to exit close to the center of rotation, kinetic losses
directs a first portion of a liquid coolant feed to flow over a are minimized.)
peripheral Surface of a stator of a liquid-cooled electric motor, Coolant flow for the stator, after exiting inlet radial holes 54
while directing a second remaining portion of the liquid cool in coolant inlet port 40, is directed by a combination of
ant feed to flow into the rear end of the rotor shaft. Additional coolant inlet manifold 66 and rear coolant baffle 68 to flow
coolant flow paths may also be included. The second portion through annular port 56 such that heat is removed from the
of the liquid coolant feed then exits the shaft via radially 10 peripheral surface 70 of the stator core 28. In accordance with
directed holes in the shaft and is then directed by an endplate one embodiment, radially directed cooling fins 72 (illustrated
to flow through axial passages orports within the rotor. At the in FIG. 2) may be added to the periphery of stator core 28 to
opposite end of the rotor, flow is received by a similar end augment this element of heat transfer. Coolant flow received
plate and is then directed to either re-enter the shaft, or to exit from annular port 56 is constrained to pass through holes
the endplate at a location which is close to the axis of rotation, 15 within front coolant baffle 74. The number of these holes and
thus minimizing kinetic losses under high-speed conditions. their respective diameters are selected such that a desired
The two endplates also enable easier balancing of the electric pressure drop occurs—which in turn establishes flow unifor
motor during manufacture by allowing screws or bolts of mity within the annular port. This helps establish uniform
selected lengths to be inserted at desired locations. (Alterna cooling for stator core 28 and motor windings 30. The selec
tively, material can be removed from selected portions of the tion of the number and size of these holes is within the ability
endplates to achieve the desired balance in the conventional of those of ordinary skill in the art and depends upon the exact
manner.) Finally, the endplates serve to capture cast end rings dimensions of the corresponding motor and its associated
via peripheral corresponding keyed elements—thus enabling parts.
high-speed operation without mechanical failure of the end Coolant flow from both the rotor and stator is received by
rings, while alleviating the need for external capture rings. 25 drainage cavity 76. Drainage cavity 76 in turn drains liquid
(Alternatively, conventional external capture rings can be coolant via front drain port 78 and rear drain port 80 into
placed over the end rings to provide the needed hoop Support coolant Sump 82. Coolant exits coolant Sump 82 via coolant
for the end rings.) Coolant flow from both the stator and rotor outlet 84. Front shaft liquid seal 86 prevents liquid coolant
is recovered by a sump located at the bottom of the motor. The from leaking via front rotor shaft bearing 26.
coolant Sump serves to allow entrapped air to separate from 30 Turning to FIG. 2, a cross-sectional view depicts a rotor
the coolant. assembly 52, a stator assembly 88 and a housing 38 for an
Turning now to the figures, FIG. 1 is a sectional view along electric motor 12 in accordance with an embodiment. Rotor
a longitudinal axis of rotation 10 of an electric motor 12 shaft 14, rotor core 16, stator core 28, and housing 38 are
which identifies coolant flow paths (shown by unnumbered illustrated in detail. Rotor core 16 is typically structured form
arrows) in accordance with an embodiment. FIG. 2 is a cross 35 stacked magnetic laminations—with rotor bar slots 90 added
sectional view taken along line 2-2 of FIG. 1 orthogonal to the to receive rotor bars 18 in accordance with conventional
view in FIG.1. Electric motor 12 includes both conventional practices for induction motors. In accordance with an
and new elements. The conventional elements include rotor embodiment, rotor axial cooling slots 50, proximate the rotor
shaft 14, rotor core 16, rotor bars 18, rear rotor end-ring 20, bars 18 are added to provide coolant passages (axial passages
front rotor end-ring 22, rear rotor shaft bearing 24, front rotor 40 parallel to the longitudinal axis of rotation 10) for additional
shaft bearing 26, stator core 28, motor windings 30 contained cooling of the affected areas. Coolant flow which passes
within stator slots 32 of the stator core 28, rear end-bell 34, through these passages serves to remove heat generated
rear end-bell interior face 35, front end-bell 36, and housing within rotor bars 18 and the end rings 20, 22.
38. In accordance with an embodiment, the electric motor 12
The liquid cooling system comprises parts which enable 45 includes an annular port 56 between the peripheral surface 70
the flow of a liquid coolant such that heat is removed from the of the stator core 28 and the inner surface 92 of housing 38.
rotor bars 18, end-rings 20 and 22, the active part of the Coolant flow directed through this region serves to remove
windings 30, the end turn portions of the motor windings 30 heat generated within the stator assembly 88 (both winding
and the stator core 28. Coolant inlet port 40 receives a flow of and core losses). With the addition of radially directed cool
liquid coolant (e.g., from a recirculating coolant pump 50 ing fins 72 to the peripheral surface 70 of the stator core 28,
(shown in FIG. 6)) and directs a first portion of the flow of this component of heat transfer is further improved. Yet fur
liquid coolant to a coaxial shaft port 42 within the rear end of ther improvements in this component of heat transfer can be
the rotor shaft 14 from where flow radially exits a hollowed achieved where stator cooling slots 58 are included within
out portion 44 of rotor shaft 14 through one or more shaft stator core 28 to form axial passages such that coolant flow
radial holes 46 and is directed by an interior surface 47 of 55 within these passages may provide additional heat transfer.
rotor rear endplate 48 to flow through a rotor coolant passage Optional Tie Rods 94 may be used to draw the opposing
formed by rotor axial cooling slots 50 within the rotor assem rotor endplates together such that the rotor core is com
bly 52. pressed. This serves to improve the rotor rigidity, while mini
A second portion of the flow of liquid coolant is directed mizing pockets between laminations in which coolant can
from coolant inlet port 40 through inlet radial holes 54 within 60 randomly collect. This helps avoid random accumulations of
coolant inlet port 40 to establish flow through annular port or coolant between laminations which might result in degraded
peripheral coolant passage 56 bounded by housing 38 and balance of the rotor.
the periphery of stator core 28. Alternatively, this second FIG. 3A is a sectional view taken along the longitudinal
portion of flow may also include flow paths within stator axis of the motor and FIG. 3B is cross sectional view taken
cooling slots 58 (illustrated in FIG. 2). At the front end of the 65 along line 3B-3B of FIG.3A which depict a coolant inlet port
motor 60, coolant which exits rotor axial cooling slots 50 40 and rotor shaft 14 for an electric motor 12 in accordance
(also referred to as the rotor coolant passage) is contained and with an embodiment. Coolant inlet port 40 and rotor shaft 14
 US 8,970,075 B2
5 6
are shown in detail. Inlet-shaft gap 96 exists between these cross sectional view taken along line 7B-7B of FIG. 7A.
two members (40, 14) which allows shaft rotation without Electrical connections 110 to stator assembly 88 are shown.
significant friction. In turn, the inlet-shaft gap 96 causes a FIG. 8 is an assembly diagram of a rotor assembly 52 for an
small “bypass flow” of coolant. This flow results in coolant electric motor in accordance with an embodiment. In this
drainage into drainage cavity 76 which in turn drains into embodiment balance screws 112 are used at the front and rear
coolant sump 82 via drain ports 78, 80. of the rotor assembly 52 to balance the rotor to reduce vibra
FIG. 4A is a front-side elevational view which depicts a tion during rotation. Tie rods 94 are secured with tie rod
front-side end-view for the rotor assembly 52 in accordance washers 114 and tie rod nuts 116.
with an embodiment. Rotor front endplate (62) and rear end While embodiments and applications have been shown and
plate (48) and corresponding cast end rings (20, 22) are illus 10 described, it would be apparent to those skilled in the art
trated in detail. (It should be noted that the rear 48 and front 62 having the benefit of this disclosure that many more modifi
endplates are similar.) Keyed elements 98 of the endplates cations than mentioned above are possible without departing
engage corresponding keyed elements 99 of the end rings as from the inventive concepts disclosed herein. The invention,
shown in one example in order to provide attachment, radial therefore, is not to be restricted except in the spirit of the
Support and retention for the end rings (22, 20) thus helping to 15 appended claims.
prevent mechanical failure under high-speed conditions.
They do this by engaging one another and any appropriate What is claimed is:
shape other than the symmetrical wedges 98.99 as shown 1. A liquid-cooled, radial air gap electric motor compris
which accomplishes this may be used. Blind tapped holes 100 1ng:
enable screws of selected sizes to be inserted into the end a stator having motor windings;
plates 62, 48 for the purpose of adjusting rotor balance. This a rotor having an at least partially hollow rotor shaft con
approach eliminates the conventional need for machine figured to rotate about a longitudinal axis of rotation;
removal of material to provide balance and thus enables the a housing:
balance operation to be completed while the rotor is situated a coolant Sump disposed at the bottom of the housing:
within the balance machine. (The conventional approach can, 25 a first and a second end-bell, the first end-bell disposed at a
of course, be used instead if desired). Tie rod holes 102 are first end of the motor housing and the second end-bell
provided so that tie rods 94 can extend from rotor front disposed at a second end of the motor housing, the first
endplate 62, through rotor core 16, to the rotor rear endplate and second end-bells carrying rotor shaft bearings Sup
48 so that the entire rotor assembly 52 can be compressed. porting the at least partially hollow rotor shaft; and
FIG. 4B is a front-side elevational view which depicts a 30 a coolant manifold coupled to the first end-bell and con
front-side end-view for an electric motor 12 in accordance figured to receive a liquid coolant through a coolant inlet
with an embodiment. Rotor front endplate (62) and rear end port from a liquid coolant source and to distribute the
plate (48) and corresponding cast end rings (20, 22) are illus liquid in at least a the first path into the at least partially
trated in detail. (It should be noted that the rear 48 and front 62 hollow rotor shaft, wherein from the at least partially
endplates are similar.) Endplate coolant channels 104 provide 35 hollow rotor shaft the liquid coolant may flow radially
a coolant flow path from the exit points on rotor shaft 14 to outward in operation through one or more shaft radial
entry points on the face of the rotor. holes in the at least partially hollow rotor shaft and then
FIG. 4C is a section view along line 4C-4C of FIG. 4B longitudinally into a rotor coolant passage formed in the
which depicts a coolant channel for an electric motor in rotor, and then into the Sump, the second path radially
accordance with an embodiment. Endplate coolant channels 40 outward in operation through one or more inlet radial
104 are illustrated in detail. holes in the coolant inlet port and then longitudinally
FIGS.5A and 5B are, respectively, front and rear exploded into a peripheral coolant passage formed in a gap dis
views of a liquid-cooled electric motor in accordance with posed between the housing and the stator, and then into
one embodiment. the Sump.
FIG. 6 is a system block diagram illustrating a liquid 45 2. The electric motor of claim 1, wherein
cooled electric motor 12, Sump 82 configured to receive the coolant manifold includes a first circular coolant baffle
expended coolant from the motor 12 and recirculating coolant that forms a first annular region bounded by the stator
pump 106 configured to pump coolant from Sump 82 to cool and the first coolant baffle and an inner surface of the
ant inlet port 40 via a conventional radiator 107 for cooling housing.
the coolant in accordance with an embodiment. The coolant 50 3. The electric motor of claim 2, wherein
may be any Suitable liquid which can withstanda breakdown the first coolant baffle includes at least one radially directed
Voltage similar in magnitude to those present in the motor. hole configured so that a portion of the second path of
Low-viscosity oils are presently preferred for this application coolant flow is directed away from the first coolant
although other suitable materials may be used as will now be baffle.
apparent to those of ordinary skill in the art. The coolant 55 4. The electric motor of claim 2, wherein
quantity present in the motor should be limited so as to not the motor is configured so that a portion of the second path
flood the gap between the stator and the rotor. The stator of coolant flow is directed through a longitudinal pas
and/or the rotor may be electrically insulated from the hous Sage within a stator core of the stator.
ing if desired. A rotor speed and/or position sensor 108 may 5. The electric motor of claim 2, wherein
be provided. Such sensors may be mounted to the stator, 60 the peripheral Surface of the stator is equipped with at least
housing or end-bells (as shown) and optically observe the one radially directed cooling fin.
shaft or rotor (e.g., an optically detectable pattern thereon), or 6. The electric motor of claim 2, further comprising:
they may be coupled to the shaft. Magnetic sensors may also a second circular coolant baffle that forms a second annular
be used as can any other suitable sensors. Pump 106 may be region bounded by the stator and the second coolant
disposed within sump 82 and may be attached to sump 82. 65 baffle and an inner Surface of the housing, the second
FIG. 7A is an end sectional view of a stator for an electric annular region configured so that some coolant flow
motor in accordance with an embodiment and FIG. 7B is a along the second path is directed from the peripheral
 US 8,970,075 B2
7 8
coolant passage through at least one radially directed 15. The electric motor of claim 1, further comprising:
hole in the second coolant baffle away from the second a rotor speed sensor.
coolant baffle. 16. The electric motor of claim 1, further comprising:
7. The electric motor of claim 1, wherein the rotor further a rotor position sensor.
includes a plurality of rotor bars, a front end-ring and a rear 17. The electric motor of claim 1, further comprising:
end-ring. a front shaft liquid seal.
8. The electric motor of claim 1, wherein the rotor is a 18. The electric motor of claim 1, wherein the quantity of
wound rotor that includes a winding and at least one slip ring coolant is limited so that a gap between the rotor and stator is
and brush.
9. The electric motor of claim 1, wherein the rotor contains 10
not flooded with coolant during operation.
at least one permanent magnet. 19. The electric motor of claim 1, wherein the coolant
10. The electric motor of claim 1, wherein the rotor comprises a low viscosity oil.
includes at least one rotor endplate that includes at least one 20. The electric motor of claim 1, wherein the coolant is a
axially directed, tapped hole configured so that a screw can be liquid other than oil.
screwed into the tapped hole in order to adjust the mass 15
21. The electric motor of claim 2, wherein the first end-bell
balance of the rotor. and the first coolant baffle are formed as a single part.
11. The electric motor of claim 10 wherein the endplate and 22. The electric motor of claim 21, wherein the second
an end-ring are mutually attached with at least one pair of end-bell and the second coolant baffle are formed as a single
corresponding keyed elements. part.
12. The electric motor of claim 1, wherein the stator is 23. The electric motor of claim 1, further comprising a
electrically insulated from the housing. pump configured to pump coolant from the Sump to the cool
13. The electric motor of claim 1, wherein the rotor is ant inlet port.
electrically insulated from the housing. 24. The electric motor of claim 23, wherein the pump is
14. The electric motor of claim 1, wherein the rotor and the disposed within the Sump.
stator are electrically insulated from the housing. k k k k k