English:
[0002] Many electric machines include cooling systems. The cooling systems take on various forms and are configured to reduce operating temperatures of the electric machine to extend component service life or provide enhancement to peak power ratings. Electric motors often times will include a cooling system having a rotor or armature driven fan. The fan guides a cooling fluid through the electric motor to dissipate heat. Other cooling systems include passing a fluid through a coolant jacket that surrounds a portion of the electric machine and direct spraying of coolant onto one or more internal components of the electric machine.
[0003] Disclosed is an electric machine including a housing having an outer surface and an inner surface. A stator is fixedly mounted to the inner surface. The stator includes a stator core, and a plurality of windings supported by the stator core. The plurality of windings includes a first end turn portion and a second end turn portion. An adaptable cooling system is fluidically connected to the housing. The adaptable cooling system includes a first coolant circuit configured to guide a coolant in a heat exchange relationship with the stator core, and a second coolant circuit configured to guide a coolant in a heat exchange relationship with one of the first and second end turn portions. A thermal control module is operably connected to the adaptable cooling system. The thermal control module includes a coolant demand schedule described in a machine specific coolant map and is configured and disposed to selectively adapt coolant delivery to the first and second coolant circuits based on the coolant demand schedule.
[0004] Also disclosed is a thermal control module for an electric machine. The thermal control module includes a coolant map having a coolant demand schedule for the electric machine. The controller is configured and disposed to control coolant delivery to the electric machine based on the coolant demand schedule.
[0005] Further disclosed is an electric machine including a housing having an outer surface and an inner surface. A stator fixedly mounted to the inner surface. The stator includes a stator core, and a plurality of windings supported by the stator core. The plurality of windings includes a first end turn portion and a second end turn portion. A rotor is arranged within the housing and rotatably mounted relative to the stator. An adaptable cooling system is fluidically connected to the housing. The adaptable cooling system includes a first coolant circuit configured to guide a coolant in a heat exchange relationship with the stator core, and a second coolant circuit configured to guide a coolant in a heat exchange relationship with the rotor. A thermal control module includes a coolant demand schedule described in a machine specific coolant map and is operably connected to the adaptable cooling system. The thermal control module is configured and disposed to selectively adapt coolant delivery to the first and second coolant circuits based on the coolant demand schedule.
[0006] Still further disclosed is an electric machine including a housing having an outer surface and an inner surface. A stator fixedly mounted to the inner surface. The stator includes a stator core, and a plurality of windings supported by the stator core. The plurality of windings includes a first end turn portion and a second end turn portion. A rotor is arranged within the housing and rotatably mounted relative to the stator. An adaptable cooling system is fluidically connected to the housing. The adaptable cooling system includes a first coolant circuit configured to guide a coolant in a heat exchange relationship with one of the first and second end turn portions, and a second coolant circuit configured to guide a coolant in a heat exchange relationship with the rotor. A thermal control module includes a coolant demand schedule described in a machine specific coolant map and is operably connected to the adaptable cooling system. The thermal control module is configured and disposed to selectively adapt coolant delivery to the first and second coolant circuits based on the coolant demand schedule.
[0007] Yet still further discloses is an electric machine including a housing including an outer surface and an inner surface and a stator fixedly mounted to the inner surface. The stator includes a stator core, and a plurality of windings supported by the stator core. The plurality of windings includes a first end turn portion and a second end turn portion. A rotor is arranged within the housing and rotatably mounted relative to the stator. An adaptable cooling system is fluidically connected to the housing. The adaptable cooling system includes a first coolant circuit configured to guide a coolant in a heat exchange relationship with the stator core, and a second coolant circuit configured to guide a coolant in a heat exchange relationship with one of the first and second end turn portions. A thermal control module is operably connected to the adaptable cooling system. The thermal control module is configured and disposed to selectively adapt coolant delivery to the first and second coolant circuits based on coolant temperature at an outlet of at least one of the first and second coolant circuits.
[0008] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0009] FIG. 1 depicts an electric machine including an adaptive cooling system in accordance with an exemplary embodiment;
[0010] FIG. 2 depicts a chart illustrating a coolant map describing a motor cooling demand schedule of the electric machine in FIG. 1;
[0011] FIG. 3 depicts an electric machine including an adaptive cooling system in accordance with another aspect of an exemplary embodiment; and
[0012] FIG. 4 depicts a flow chart illustrating a method of cooling the electric machine of FIG. 1.
[0013] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0015] Electric machine 2 is also shown to include a rotor assembly 40 including a rotor body 44 supported by a shaft 50. Rotor body 44 can take on a variety of forms and many include windings and/or permanent magnets. Shaft 50 includes a first end 52 supported at first end wall 10 through a first bearing 54, and a second end 56 supported at second end wall 12 through a second bearing 58. It should be understood that rotor assembly 40 should not be limited to being supported at both ends of shaft 50. Rotor body 44 may also be supported in a cantilevered fashion from one of first and second end walls 10 and 12.
[0016] In accordance with an aspect of the exemplary embodiment, electric machine 2 includes an adaptive cooling system 70. Adaptive cooling system 70 includes a first coolant circuit 72, a second coolant circuit 74, a third coolant circuit 76, and a fourth coolant circuit 78. First coolant circuit 72 includes an inlet portion 80 that passes a coolant in a heat exchange relationship with stator core 24 and an outlet portion 82 that guides the coolant from housing 4. It should be understood that coolant can be passed through a jacket (not shown) formed in housing 4 in a heat exchange relationship with stator core 24 or may be passed through passages formed in stator core 24. Other mechanisms for exchanging heat between the coolant and the stator core may also be employed.
[0017] Second coolant circuit 74 includes a first inlet section 84 that delivers coolant toward first end turn portion 30 and a first outlet section 86 that guides coolant from housing 4. Similarly, third coolant circuit 76 includes a second inlet section 88 that passes a coolant toward second end turn portion 32 and a second outlet section 90 that guides the coolant from housing 4. The coolant may be passed in a heat exchange relationship with first and second end turn portions 30 and 32 through a variety of delivery systems including both direct and indirect contact with windings 28. Fourth cooling circuit 78 is shown connected in parallel with first cooling circuit 72 and delivers cooling fluid through rotor 44. More specifically, fourth cooling circuit 78 includes a rotor inlet section 91 that is fluidly connected to inlet portion 80 and rotor 44 through shaft 50. Fourth cooling circuit 78 also includes a cooling fluid outlets (not shown) provided on an outer periphery of rotor 44. The cooling fluid outlet allow coolant to pass from rotor 44 and pass to first outlet section 86 and/or third outlet section 90.
[0018] Adaptive cooling system 70 is also shown to include a first valve 92 arranged in inlet portion 80, a second valve 94 arranged in first inlet section 84, and a third valve 96 arranged in second inlet section 88. Adaptive cooling system 70 is further shown to include an inlet 100 fluidically connected to inlet portion 80 and first and second inlet sections 84 and 88. Inlet 100 is also fluidically connected to a pump 102 that delivers coolant into selected ones of first coolant circuit 72, second coolant circuit 74, third coolant circuit 76 and fourth coolant circuit 78. An outlet 104 is fluidically connected to outlet portion 82, and first and second outlet sections 86 and 90. Outlet 104 may deliver the coolant to a heat exchanger (not shown) and back to inlet 100 or to another system (also not shown).
[0019] In accordance with an aspect of the exemplary embodiment inlet 100 includes an inlet temperature sensor 106 and outlet 104 includes an outlet temperature sensor 108. Inlet temperature sensor 106 is arranged to sense a temperature of coolant flowing into inlet 100 and outlet temperature sensor 108 is arranged to sense a temperature of coolant flowing through outlet 104. At this point it should be understood that although cooling circuit 78 is shown connected in parallel with cooling circuit 72 in FIG. 1, and therefore also controlled by valve 92, it is also understood that cooling circuit 78 could be connected to inlet 100 having a separate valve (not shown). With such an arrangement, cooling circuit 78 could be controlled independently of cooling circuit 72. Electric machine 2 is also shown to include a motor controller 110. Motor controller 110 receives sensed operational parameters of the motor from sensors 112. Sensors 112 are configured to detect one or more operating parameters such as current draw, rotor speed, rotor torque and/or voltage. Motor controller 110 defines and measures operational parameters of electric machine 2. Motor controller 110 also includes, or is operably connected with, a thermal control module 116. Thermal control module 116 is operably connected with input temperature sensor 106, output temperature sensor 108 and valves 92, 94 and 96.
[0020] At lower speeds, up to about base speed of electric machine 2, it may be more desirable to reduce I R or copper losses at first and second end turn portions 30 and 32. In such cases, valves 92, 94 and 96 are selectively controlled to deliver more coolant to second and third coolant circuits 74 and 76 than that being delivered to first coolant circuit 72 and fourth coolant circuit 78. Thermal control module 116 may also be configured to detect other parameters of electric machine 2 to determine how changes in coolant delivery affect performance. Thermal control module 116 may then store information to create a machine specific temperature map for electric machine 2. Thermal control module 116 may then employ the machine specific temperature map to control positions of valves 92, 94 and 96 to enhance machine operation across all speed and torque ranges.
[0021] In addition to the above, thermal control module 1 16 monitors coolant inlet temperature and coolant outlet temperature through inlet temperature sensor 106 and outlet temperature sensor 108. Based on the coolant inlet temperature and coolant outlet temperature, thermal control module 116 signals pump 102 to adjust coolant flow rate through adaptive cooling system 70. More specifically, thermal control module 116 may signal pump 102 to reduce coolant flow rate when temperatures are below a predetermined threshold in order to reduce power requirements for the system and enhance overall system efficiency.
[0022] At this point it should be understood that thermal control module 116 may be embedded in motor controller 110 or may be a separate component that may connect with motor controller 110. If a separate component, thermal control module 116 may be offered as an accessory that may be integrated into existing electric machines without requiring extensive modification. Further, while illustrated as being linked to sensors 106 and 108, and valves 92, 94 and 96, thermal control module 116 may include integrated valves and sensors that control cooling flow within an associated electric machine.
[0023] More specifically, thermal control module 116 includes a coolant map 120 describing a motor cooling demand schedule 182, illustrated in FIG. 2, that correlates operating speed to losses in stator 24 or iron losses 184 and loses in stator windings 28 or copper losses 186 as well as combined losses 188. Coolant map 120 and associated motor cooling demand schedules are developed during development of electric machine 2. As will be discussed more fully below, thermal control module 116 controls coolant flow through electric machine 2 based on coolant map 120. At lower speeds, up to about base speed of electric machine 2, it may be more desirable to reduce I R or copper losses 186 at first and second end turn portions 30 and 32. In such cases, first, second, and third valves 92, 94 and 96 are selectively controlled to deliver more coolant to second and third coolant circuits 74 and 76 than that being delivered to first coolant circuit 72 and fourth coolant circuit 78. At higher speeds, it may be more desirable to reduce iron losses 184. In such a case, first, second, and third valves 92, 94 and 96 are selectively controlled to deliver more coolant to first coolant circuit 72 and fourth coolant circuit 74 that is delivered to second and third coolant circuits 74 and 76. In short, thermal control module 116 relies on coolant map 120 to determine cooling demand and coolant flow through electric machine 2.
[0024] At this point it should be understood that thermal control module 116 may be embedded in motor controller 110 or may be a separate component that may connect with motor controller 110. If a separate component, thermal control module 116 may be offered as an accessory that may be integrated into existing electric machines without requiring extensive modification. Further, while illustrated as being linked to valves 92, 94 and 96, thermal control module 116 may include integrated valves that control cooling flow within an associated electric machine.
[0025] Reference will now be made to FIG. 3, wherein like reference numbers represent corresponding parts in the respective views in describing a motor controller 190 in accordance with another aspect of the exemplary embodiment. Motor controller 190 receives sensed operational parameters of the motor from sensors 196. Sensors 196 are configured to detect one or more operating parameters such as current draw, rotor speed, rotor torque and/or voltage. Motor controller 190 is linked to a thermal control module 200. Thermal control module 200 is connected to inlet temperature sensor 106, outlet temperature sensor 108 as well as valves 92, 94 and 96. Input from sensors 146 is passed to thermal control module 200 which in turn, may control (based on the value of input sensors 146) valves 92, 94 and 96 to adapt coolant delivery through respective ones of first, second, third and/or fourth coolant circuits 72, 74, 76 and/or 78 to reduce operating temperatures and improve machine performance. In the exemplary embodiment shown, thermal control module 200 is operatively connected to a first outlet temperature sensor 206 positioned at fluid return circuit 90, a second outlet temperature sensor 208 positioned at coolant return circuit 82, and a third outlet temperature sensor 210 positioned at coolant return circuit 86.
[0026] Thermal control module 200 receives input signals from outlet temperature sensors 206, 208 and 210 indicating, for example, higher heat rejection in one coolant return branch in relation to another. Based on the signals from one or more of outlet temperature sensors 206, 208 and 210, thermal control module 200 controls coolant delivery to first, second, third and fourth coolant circuits 72, 74, 76, and 78 by adjusting the rate of flow in each circuit. For example, temperature at outlet temperature sensor 208 may indicate a need for more cooling at stator core 24 than currently required for first and second end turn portions 30 and 32. In such a case, valves 92, 94, 96 are selectively controlled to deliver more coolant to first coolant circuit 72 and fourth coolant circuit 78 than that being delivered to second and third coolant circuits 74 and 76. Thermal control module 200 may also be configured to detect other parameters of electric machine 2 to determine how changes in coolant delivery affect performance. Thermal control module 200 may then store information in its memory to create an improved and optimized temperature map specific to a particular machine and or duty cycle.
[0027] In addition to the above, thermal control module 200 monitors coolant inlet temperature and coolant outlet temperature through inlet temperature sensor 106 and outlet temperature sensors 206, 208 and/or 210. Based on the coolant inlet temperature and coolant outlet temperature(s), thermal control module 200 signals pump 102 to adjust coolant flow rate through adaptive cooling system 70. More specifically, thermal control module 200 may signal pump 102 to reduce coolant flow rate when temperatures are below a predetermined threshold in order to reduce power requirements for the system and enhance overall system efficiency.
[0028] At this point it should be understood that thermal control module 200 may be embedded in motor controller 190 or may be a separate component that may connect with motor controller 190. If a separate component, thermal control module 200 may be offered as an accessory that may be integrated into existing electric machines without requiring extensive modification. Further, while illustrated as being linked to valves 92, 94 and 96, thermal control module 200 may include integrated valves that control cooling flow within an associated electric machine.
[0029] Reference will now be made to FIG. 4 in describing a method 300 of operating electric machine 2 in accordance with an exemplary embodiment. Motor controller 110 initially determines one or more operating parameters of electric machine 2 in block 304. The operating parameters may include operating speed, operating current, operating torque and/or voltage or coolant temperature at inlet 100, outlet portion 82, first outlet section 86 and/or second outlet section 90. The operating parameter(s) are passed to thermal control module 116/200 for review. In accordance with an aspect of the exemplary embodiment, thermal control module 116/200 may compare the operating parameters with the machine specific coolant map) 120 or simply adjust coolant flow based on coolant temperature in block 306. A cooling demand is determined in block 308 based on cooling parameters associated with the operating parameters. If no cooling or change in cooling is required, the operating parameter(s) continue to be monitored. If a cooling change is indicated, an amount of iron cooling is determined in block 310 and an amount of cooper cooling desired is determined in block 312. At this point, thermal control module 116 selectively opens one or more of valves 92, 94, and/or 96 to direct coolant through one or more of the first, second, third, and/or fourth coolant circuits 72, 74,76, and/or 78 as indicated in block 314 and operating parameters then continue to be monitored.
[0030] At this point it should be understood that the exemplary embodiments provide a system or systems for selectively delivering coolant to portions of an electric machine. Coolant flow to particular components can be selectively tailored to address real time operating conditions. In this manner, additional coolant flow can be channeled to a component that may need increased heat removal to enhance overall performance of the electric machine. By selectively controlling coolant flow, the cooling system size can be reduced. More specifically, the cooling system need not be designed to accommodate maximum cooling demand for all components. Cooling demand for components of an electric machine vary during operation. As discussed above, during high speed operation, the stator core may benefit from additional cooling to reduce iron losses while the end turn portions may not require as much cooling. Conversely, during low speed operation up to
[0031] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims.

中文:
[0002]许多电机包括冷却系统。冷却系统采用多种形式并且被构造成降低电机的工作温度以延长部件使用寿命或者提供对峰值额定功率的增强。电动机(electricmotor)通常会包括具有转子或电枢驱动的风扇的冷却系统。该风扇导引冷却流体通过电动机以散热。其他冷却系统包括:使流体经过围绕电机的一部分的冷却剂夹套(jacket)并且指引冷却剂喷洒至电机的一个或更多个内部部件上。
[0003]公开了一种电机,该电机包括壳体,该壳体具有外表面和内表面。定子被固定地安装至内表面。定子包括定子芯和由定子芯支承的多个绕组。多个绕组包括第一端匝部和第二端匝部。可适应的(adaptable)冷却系统流体连接至壳体。可适应的冷却系统包括第一冷却剂回路和第二冷却剂回路,该第一冷却剂回路被构造成以与定子芯处于热交换关系的方式导引冷却剂,该第二冷却剂回路被构造成以与第一端匝部和第二端匝部中的一个端匝部处于热交换关系的方式导引冷却剂。热控模块可操作地连接至可适应的冷却系统。热控模块包括在机器(machine)特定的冷却剂图中描述的冷却剂需求表(schedule),热控模块被构造并且设置成:基于冷却剂需求表来选择性地调整(adapt)通向第一冷却剂回路和第二冷却剂回路的冷却剂传送。
[0004]还公开了一种用于电机的热控模块。该热控模块包括冷却剂图,该冷却剂图具有用于电机的冷却剂需求表。控制器被构造并且设置成基于冷却剂需求表来控制通向电机的冷却剂传送。
[0005]还公开了一种电机,该电机包括壳体,该壳体具有外表面和内表面。定子被固定地安装至内表面。定子包括定子芯和由定子芯支承的多个绕组。多个绕组包括第一端匝部和第二端匝部。转子布置在该壳体内并且相对于定子可旋转地安装。可适应的冷却系统流体连接至该壳体。可适应的冷却系统包括第一冷却剂回路和第二冷却剂回路,该第一冷却剂回路被构造成以与定子芯处于热交换关系的方式导引冷却剂,该第二冷却剂回路被构造成以与转子处于热交换关系的方式导引冷却剂。热控模块包括在机器特定的冷却剂图中描述的冷却剂需求表,热控模块可操作地连接至可适应的冷却系统。热控模块被构造并且设置成基于冷却剂需求表来选择性地调整通向第一冷却剂回路和第二冷却剂回路的冷却剂传送。
[0006]又进一步公开了一种电机,该电机包括壳体,该壳体具有外表面和内表面。定子被固定地安装至内表面。定子包括定子芯和由定子芯支承的多个绕组。多个绕组包括第一端匝部和第二端匝部。转子布置在该壳体内并且相对于定子可旋转地安装。可适应的冷却系统流体连接至壳体。可适应的冷却系统包括第一冷却剂回路和第二冷却剂回路,该第一冷却剂回路被构造成以与第一端匝部和第二端匝部中的一个端匝部处于热交换关系的方式导引冷却剂,该第二冷却剂回路被构造成以与转子处于热交换关系的方式导引冷却剂。热控模块包括在机器特定的冷却剂图中描述的冷却剂需求表,热控模块可操作地连接至可适应的冷却系统。热控模块被构造并且设置成基于冷却剂需求表来选择性地调整通向第一冷却剂回路和第二冷却剂回路的冷却剂传送。
[0007]又再进一步公开了一种电机,该电机包括壳体和定子,该壳体包括外表面和内表面,该定子被固定地安装至内表面。定子包括定子芯和由定子芯支承的多个绕组。多个绕组包括第一端匝部和第二端匝部。转子布置在壳体内并且相对于定子可旋转地安装。可适应的冷却系统流体连接至壳体。可适应的冷却系统包括第一冷却剂回路和第二冷却剂回路,该第一冷却剂回路被构造成以与定子芯处于热交换关系的方式导引冷却剂,该第二冷却剂回路被构造成以与第一端匝部和第二端匝部中的一个端匝部处于热交换关系的方式导引冷却剂。热控模块可操作地连接至可适应的冷却系统。热控模块被构造并且设置成基于在第一冷却剂回路和第二冷却剂回路中的至少一个冷却剂回路的出口处的冷却剂温度来选择性地调整通向第一冷却剂回路和第二冷却剂回路的冷却剂传送。
[0008]下面的描述不应视为以任何方式进行限制。参照附图,以相似的方式对相同的元件进行标号。
[0009]图1描绘了根据示例性实施方式的包括可适应的冷却系统的电机;
[0010]图2描绘了示图,示出了对图1中的电机的电动机冷却需求表进行描述的冷却剂图;
[0011]图3描绘了根据示例性实施方式的另一方面的包括可适应的冷却系统的电机;以及
[0012]图4描绘了示出对图1的电机进行冷却的方法的流程图。
[0013]在本文中参照附图以示例而非限制性的方式呈现了所公开的装置和方法的一个或更多个实施方式的详细描述。
[0015]电机2还被示出为包括转子组件40,转子组件40包括由轴50支承的转子本体44。转子本体44可以采用多种形式,所述多种形式中的许多形式包括绕组和/或永磁体。轴50包括通过第一轴承54支承在第一端壁10处的第一端52,以及通过第二轴承58支承在第二端壁12处的第二端56。应理解的是,转子组件40不应限于支承在轴50的两端处。转子本体44还可以以悬臂式的方式从第一端壁10和第二端壁12中的一个支承。电机2还被示出为包括接线端子(terminalblock)64,接线端子64提供绕组28与外部电源或负载之间的接口。
[0016]根据示例性实施方式的一方面,电机2包括可适应的冷却系统70。可适应的冷却系统70包括:第一冷却剂回路72、第二冷却剂回路74、第三冷却剂回路76以及第四冷却剂回路78。第一冷却剂回路72包括:以与定子芯24处于热交换关系的方式传送冷却剂的入口部80,以及从壳体4导引冷却剂的出口部82。应理解的是,可以使冷却剂通过在壳体4中形成的与定子芯24处于热交换关系的夹套(没有示出),或者可以使冷却剂通过在定子芯24中形成的通道。还可以采用用于在冷却剂与定子芯之间进行热交换的其他机构。
[0017]第二冷却剂回路74包括:向第一端匝部30传送冷却剂的第一入口段84,以及从壳体4导引冷却剂的第一出口段86。类似地,第三冷却剂回路76包括:向第二端匝部32传送冷却剂的第二入口段88,以及从壳体4导引冷却剂的第二出口段90。可以通过包括与绕组28直接和间接接触的各种传送系统以与第一端匝部30和第二端匝部32处于热交换关系的方式来传递冷却剂。第四冷却回路78被示出为与第一冷却回路72以并联的方式连接,并且通过转子44传送冷却流体。更具体地,第四冷却回路78包括:通过轴50流体连接至入口部80和转子44的转子入口段91。第四冷却回路78还包括设置在转子44的外边缘上的冷却流体出口(没有示出)。冷却流体出口使得冷却剂能够从转子44传递并且能够传递至第一出口段86和/或第三出口段90。
[0018]可适应的冷却系统70还被示出为包括:布置在入口部80中的第一阀92、布置在第一入口段84中的第二阀94以及布置在第二入口段88中的第三阀96。可适应的冷却系统70还被示出为包括:流体连接(fluidicallyconnected)至入口部80以及第一入口段84和第二入口段88的入口100。入口100还流体连接至泵102,泵102将冷却剂传送至从第一冷却剂回路72、第二冷却剂回路74、第三冷却剂回路76以及第四冷却剂回路78中选择的一个冷却剂回路中。出口104流体连接至出口部82以及第一出口段86和第二出口段90。出口104可以将冷却剂传送至热交换器(没有示出)并且将冷却剂传送回入口100或传送至另一系统(也没有示出)。
[0019]根据示例性实施方式的一方面,入口100包括入口温度传感器106,并且出口104包括出口温度传感器108。入口温度传感器106被布置成感测流入入口100的冷却剂的温度,并且出口温度传感器108被布置成感测流过出口104的冷却剂的温度。在此,应理解的是,虽然在图1中冷却回路78被示出为与冷却回路72并联连接,因此冷却回路78也由阀92控制,但是还要理解的是,冷却回路78还可以以具有单独的阀(没有示出)的方式连接至入口100。在这样布置的情况下,冷却回路78可以独立于冷却回路72被控制。电机2还被示出为包括电动机控制器110。电动机控制器110从传感器112接收电动机的感测的工作参数。传感器112被构造成检测一个或更多个工作参数,例如电流消耗、转子速度、转子扭矩和/或电压。电动机控制器110限定和测量电机2的工作参数。电动机控制器110还包括热控模块116,或者与热控模块116可操作地连接。热控模块116与输入温度传感器106、输出温度传感器108以及阀92、阀94和阀96可操作地连接。
[0020]在较低的速度,直至约电机2的基速下,可能更期望的是降低在第一端匝部30和第二端匝部32处的I2R或铜损耗。在这样的情况下,选择性地控制阀92、阀94和阀96,以向第二冷却剂回路74和第三冷却剂回路76传送比向第一冷却剂回路72和第四冷却剂回路78传送的冷却剂更多的冷却剂。热控模块116还可以被构造成:检测电机2的其他参数,以确定冷却剂传送的变化怎样影响性能。然后,热控模块116可以存储信息,以创建针对电机2的机器特定的温度图。然后,热控模块116可以采用电机特定的温度图来控制阀92、阀94和阀96的位置,以增强机器跨所有速度和扭矩范围的工作。
[0021]除上述的之外,热控模块116还通过入口温度传感器106和出口温度传感器108来监测冷却剂入口温度和冷却剂出口温度。基于冷却剂入口温度和冷却剂出口温度,热控模块116向泵102发送信号以通过可适应的冷却系统70来调节冷却剂流率。更具体地,热控模块116可以向泵102发送信号以在温度低于预定阈值时减小冷却剂流率,以便减少系统的功率需求并且增强整体的系统效率。
[0022]在此,应理解的是,热控模块116可以嵌入电动机控制器110或者可以是可以与电动机控制器110连接的单独的部件。如果热控模块116是单独的部件,则热控模块116可以被提供作为以下附件,该附件可以在不需要大量修改的情况下被集成至现有的电机中。此外,当热控模块116被示出为连接至传感器106和传感器108以及阀92、阀94和阀96时,热控模块116可以包括对在关联的电机内的冷却流进行控制的集成阀和传感器。
[0023]更具体地,热控模块116包括在图2中示出的描述电动机冷却需求表182的冷却剂图120,冷却剂图120将工作速度与定子24中的损耗或者铁损耗184进行关联,与定子绕组28中的损耗或者铜损耗186进行关联,以及与组合损耗188进行关联。在电机2的开发期间开发了冷却剂图120和关联的电动机冷却需求表。如将在下面更充分地讨论的,热控模块116基于冷却剂图120来控制冷却剂流经电机2。在较低的速度,直至约电机2的基速下,可能更期望的是降低在第一端匝部30和第二端匝部32处的I2R或铜损耗186。在这样的情况下,选择性地控制第一阀92、第二阀94和第三阀96以向第二冷却剂回路74和第三冷却剂回路76传送比向第一冷却剂回路72和第四冷却剂回路78传送的冷却剂更多的冷却剂。在较高的速度下,可能更希望降低铁损耗184。在这样的情况下,选择性地控制第一阀92、第二阀94和第三阀96以向第一冷却剂回路72和第四冷却剂回路74传送比向第二冷却剂回路74和第三冷却剂回路76传送的冷却剂更多的冷却剂。总之,热控模块116依赖冷却剂图120,以确定冷却需求和流过电机2的冷却剂。
[0024]在此,应理解的是,热控模块116可以嵌入电动机控制器110或者可以是可以与电动机控制器110连接的单独的部件。如果热控模块116是单独的部件,则热控模块116可以被提供作为以下附件,该附件可以在不需要大量修改的情况下被集成至现有的电机中。此外,当热控模块116被示出为连接至阀92、阀94和阀96时,热控模块116可以包括对在关联的电机内的冷却流进行控制的集成阀。
[0025]现在将参照图3,其中,在描述根据示例性实施方式的另一方面的电动机控制器190的相应的视图中,类似的附图标记表示对应的部件。电动机控制器190从传感器196接收电动机的感测的工作参数。传感器196被构造成检测一个或更多个工作参数,例如电流消耗、转子速度、转子扭矩和/或电压。电动机控制器190连接至热控模块200。热控模块200连接至入口温度传感器106、出口温度传感器108以及阀92、阀94和阀96。来自传感器146的输入被传递至热控模块200,这进而可以控制(基于输入传感器146的值)阀92、阀94和阀96以适于通过第一冷却剂回路72、第二冷却剂回路74、第三冷却剂回路76和/或第四冷却剂回路78中的相应的一个冷却剂回路进行冷却剂传送,以降低工作温度并且提高电机性能。在所示的示例性实施方式中,热控模块200可操作地连接至以下部件:置于流体返回回路90处的第一出口温度传感器206、置于冷却剂返回回路82处的第二出口温度传感器208以及置于冷却剂返回回路86处的第三出口温度传感器210。
[0026]热控模块200从出口温度传感器206、208和210接收以下输入信号,所述信号例如指示在一个冷却剂返回分支中的排热相对于另一冷却剂返回分支中的排热更高。基于来自出口温度传感器206、208和210中的一个或更多个温度传感器的信号,热控模块200通过调节每个回路中的流量速率来控制通向第一冷却剂回路72、第二冷却剂回路74、第三冷却剂回路76和第四冷却剂回路78的冷却剂传送。例如,在出口温度传感器208处的温度可以指示在定子芯24处需要的冷却比当前第一端匝部30和第二端匝部32需要的冷却更多。在这样的情况下,选择性地控制阀92、阀94和阀96以向第一冷却剂回路72和第四冷却剂回路78传送比向第二冷却剂回路74和第三冷却剂回路76传送的冷却剂更多的冷却剂。热控模块200还可以被构造成检测电机2的其他参数以确定冷却剂传送的变化怎样影响性能。然后,热控模块200可以在其存储器中存储信息,以创建特定于具体的机器和/或占空比的改进和优化的温度图。
[0027]除上述的之外,热控模块200通过入口温度传感器106和出口温度传感器206、出口温度传感器208和/或出口温度传感器210来监测冷却剂入口温度和冷却剂出口温度。基于冷却剂入口温度和一个或更多个冷却剂出口温度,热控模块200向泵102发送信号以通过可适应的冷却系统70来调节冷却剂流率。更具体地,热控模块200可以向泵102发送信号以在温度低于预定阈值时减小冷却剂流率,以便减少系统的功率需求并且增强整体的系统效率。
[0028]在此,应理解的是,热控模块200可以嵌入电动机控制器190或者可以是可以与电动机控制器190连接的单独的部件。如果热控模块200是单独的部件,则热控模块200可以被提供作为以下述附件,该附件可以在不需要大量修改的情况下被集成至现有的电机中。此外,当热控模块200被示出为连接至阀92、阀94和阀96时,热控模块200可以包括对在关联的电机内的冷却流进行控制的集成阀。
[0029]现在将参照图4来描述根据示例性实施方式的操作电机2的方法300。首先,在框304中,电动机控制器110确定电机2的一个或更多个工作参数。工作参数可以包括:工作速度、工作电流、工作扭矩和/或工作电压或者入口100处的冷却剂温度、出口部82处的冷却剂温度、第一出口段86处的冷却剂温度和/或第二出口段90处的冷却剂温度。一个或更多个工作参数被传输至热控模块116/200以供检查。根据示例性实施方式的一方面,在框306中,热控模块116/200可以将工作参数与机器特定的冷却剂图120进行比较,或者仅基于冷却剂温度来调节冷却剂流。在框308中,基于与工作参数关联的冷却参数来确定冷却需求。如果不需要冷却或者不需要改变冷却,则继续监测一个或更多个工作参数。如果指示了冷却改变,则在框310中确定铁冷却的量并且在框312中确定期望的铜冷却的量。在此,如在框314中所示,热控模块116选择性地打开阀92、阀94和/或阀96中的一个或更多个阀以引导冷却剂通过第一冷却剂回路72、第二冷却剂回路74、第三冷却剂回路76和/或第四冷却剂回路78中的一个或更多个冷却剂回路,并且然后,继续监测工作参数。
[0030]在此,应理解,示例性实施方式提供了用于选择性地向电机的各部分传送冷却剂的一个或多个系统。可以选择性地调节至特定部件的冷却剂流以满足实时工作条件。以该方式,可以将另外的冷却剂流输送至需要增加热移除的部件,以增强电机的整体性能。通过选择性地控制冷却剂流,可以减小冷却系统的尺寸。更具体地,冷却系统不需要被设计成适应针对所有部件的最大冷却需求。针对电机的部件的冷却需求在工作期间会变化。如上所述,在高速工作期间,定子芯可以得益于另外的冷却以降低铁损耗,而端匝部可能不需要同样多的冷却。反之,在低速工作直至基速工作期间,端匝部可以得益于另外的冷却以降低I2R或铜损耗,而定子芯可能不需要同样多的冷却。
[0031]尽管已经参照一个或多个示例性实施方式描述了本发明,但是本领域技术人员要理解的是,在不偏离本发明的范围的情况下可以进行各种改变并且可以用等同元件替代本发明中的元件。此外,在不偏离本发明的基本范围的情况下,可以进行许多修改以使特定的情况或者材料适于本发明的教示。因此,本发明意在不限于作为构思用于实现本发明的最佳方式所公开的特定实施方式,而是本发明将包括落入权利要求的范围内的所有实施方式。