DESC:FIELD
The present disclosure relates to the field of electric motors. More particularly focused on a motor with a three-layered cooling jacket and a method for thermal management.
DEFINITION
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
Aluminum Fins: The term "Aluminum Fins" refers to thin metal plates made of aluminum, attached to a heat exchanger to enhance heat dissipation.
Inner Oil Jacket: The term "Inner Oil Jacket" refers to the innermost layer of the oil circulation system that absorbs heat directly from the stator windings.
Intermediate Water Jacket: The term "Intermediate Water Jacket" refers to a cooling layer positioned between the inner and outer oil jackets, allowing heat transfer from oil to coolant.
Outermost Oil Jacket: The term "Outermost Oil Jacket" refers to the outermost layer of the oil circulation system that directs heated oil toward the heat exchanger for cooling.
Coolant Serpentine Jacket: The term "Coolant Serpentine Jacket" refers to a pathway for coolant inside the motor casing, designed in a winding pattern to optimize heat transfer.
Oil Pump: The term "Oil Pump" refers to a device that circulates oil through the cooling system to maintain temperature regulation.
Coolant Pump: The term "Coolant Pump" refers to a pump responsible for circulating coolant through the water jackets to transfer heat away from the system.
Thermal Bypass Valve: The term "Thermal Bypass Valve" refers to a valve that redirects oil flow during cold-start conditions, allowing rapid heating of the system.
Auxiliary Emergency Cooling Loop: The term "Auxiliary Emergency Cooling Loop" refers to a backup cooling system activated during high thermal loads to prevent overheating.
Pin-Fin Heat Exchanger: The term "Pin-Fin Heat Exchanger" refers to a heat dissipation component with small protruding fins that increase surface area, improving heat transfer efficiency.
Pin-Fin Heat Sink: The term "Pin-Fin Heat Sink" refers to a heat-dissipating structure with multiple protruding fins that increase air contact for better cooling.
Water-to-Air Heat Exchanger: The term "Water-to-Air Heat Exchanger" refers to a cooling device that transfers heat from coolant to ambient air, assisted by airflow.
Cross-Flow Tube Fin Heat Exchanger: The term "Cross-Flow Tube Fin Heat Exchanger" refers to a heat exchanger with tubes and fins arranged in a cross-flow pattern to maximize heat dissipation.
External Ambient Air Suction Fan: The term "External Ambient Air Suction Fan" refers to a fan that pulls in ambient air to enhance cooling efficiency within the heat exchanger.
Thermal Conductivity: The term "Thermal Conductivity" refers to the ability of a material to transfer heat efficiently, crucial for optimizing cooling system performance.
Convective Cooling: The term "Convective Cooling" refers to a cooling method where heat is removed through the movement of air or liquid over a heated surface.
Oxidation Resistance: The term "Oxidation Resistance" refers to the property of a material that prevents corrosion due to exposure to oxygen and high temperatures.
Localized Hotspot: The term "Localized Hotspot" refers to a specific area within the system that experiences excessive heat buildup, which can cause damage if not controlled.
Thermally Conductive Ceramic Layer: The term "Thermally Conductive Ceramic Layer" refers to a protective coating applied to metal surfaces to enhance heat transfer while preventing oxidation.
Staggered Configuration: The term "Staggered Configuration" refers to an arrangement of cooling fins or tubes in an offset pattern to improve airflow and heat dissipation.
Motor Control Unit/Power Electronics (MCU/PE): The term "Motor Control Unit/Power Electronics (MCU/PE)" refers to an electronic system responsible for regulating the operation of an electric motor by controlling voltage, current, and frequency. It ensures efficient power conversion, optimizes performance and protects the motor from faults such as overvoltage, overheating, and short circuits.
The above definitions are in addition to those expressed in the art.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Electric motors are widely used in various industries, including automotive, aerospace, and manufacturing, where they often operate under high-performance conditions that generate significant heat. Efficient heat management is crucial to maintaining the motor's performance, longevity, and reliability. Traditional cooling methods, such as air cooling or single-fluid cooling systems, often face limitations in effectively managing the thermal load without increasing the motor's size or complexity.
In particular, high-performance motors require cooling systems that can manage heat from multiple critical components, including the stator, windings, and power electronics, while maintaining a compact configuration. Current solutions often involve separate cooling systems for different components, leading to increased complexity and potential inefficiencies.
There is a need for an integrated cooling system that can simultaneously cool multiple critical components within a compact configuration. Such a system would not only improve the motor's thermal performance but also reduce its overall size and complexity, making it more suitable for applications with space constraints and high thermal loads.
Therefore, there is a need for a motor with a three-layered cooling jacket and a method for thermal management that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a motor casing with a three-layered cooling jacket.
Another object of the present disclosure is to provide a motor with a cooling system that effectively manages heat from critical components, including the stator, windings, and power electronics while maintaining a compact configuration.
Still another object of the present disclosure is to provide a motor with a cooling system that allows for efficient heat transfer between oil, coolant, and ambient air.
Yet another object of the present disclosure is to provide a motor with a cooling system that eliminates the need for multiple separate cooling systems.
Still another object of the present disclosure is to provide a motor with a cooling system that ensures reliable operation of the motor in high-temperature environments by maintaining optimal temperature levels across all critical components through advanced heat transfer mechanisms.
Still another object of the present disclosure is to provide a method for thermal management of an oil-cooled motor.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure provides an oil-cooled motor with an integrated three-layered cooling system, the oil-cooled motor comprising: a motor casing, a three-layered cooling system, an oil pump, a coolant pump, a water-to-air heat exchanger (Hx), a pin-fin heat sink, an aluminium fin, and a thermal management control unit.
The motor casing is configured to house a stator, a rotor, windings, and a shaft.
The three-layered cooling system includes: an inner oil jacket, an intermediate water jacket, and an outermost oil jacket.
The inner oil jacket, in direct thermal contact with the stator windings, is configured to circulate oil for heat absorption.
The intermediate water jacket, surrounding the inner oil jacket, is configured to circulate coolant for transferring heat from the inner oil jacket.
The outermost oil jacket, thermally coupled to a pin-fin heat exchanger (Hx) of a Motor Control Unit/Power Electronics (MCU/PE), is configured to dissipate heat from the MCU/PE.
The oil pump is configured to circulate oil through the inner oil jacket and the outermost oil jacket.
The coolant pump is configured to circulate coolant through the intermediate water jacket.
The water-to-air heat exchanger (Hx) is thermally coupled to the coolant flow path for dissipating heat to ambient or conditioned air.
The pin-fin heat sink is integrated with the MCU/PE and thermally interfaced with the outermost oil jacket for heat dissipation.
The thermal management control unit, receiving inputs from multiple temperature sensors, is configured to regulate oil and coolant pump speeds dynamically based on real-time heat dissipation requirements.
The three-layered cooling system ensures efficient heat dissipation by enabling independent yet synchronized operation of oil and coolant circulation paths.
In an embodiment, the inner oil jacket includes microchannels to maximize heat absorption from the stator windings.
In an embodiment, the outermost oil jacket includes a pin-fin array to enhance convective heat transfer.
In an embodiment, the thermal management control unit is configured with predictive algorithms to adjust cooling system parameters based on load conditions and thermal history.
In an embodiment, the coolant pump dynamically adjusts the flow rate based on predictive thermal load conditions.
In an embodiment, the motor further comprises a thermal bypass valve configured to reroute oil flow away from the heat exchanger when rapid motor heating is required during cold-start conditions.
In an embodiment, the heat exchanger includes a high-efficiency cross-flow fin structure to enhance air-cooling efficiency.
In an embodiment, the pin-fin heat sink integrated with the MCU/PE is made of a thermally conductive ceramic material to reduce electrical interference while enhancing heat dissipation.
In an embodiment, the motor further comprises a self-cleaning filtration integrated into the oil circulation path to remove contaminants and maintain long-term cooling efficiency.
In an embodiment, the motor casing is coated with a nano-ceramic thermal insulation layer to minimize heat losses.
In an embodiment, the motor further comprises an AI-driven diagnostics module that analyses temperature trends and operating conditions to predict potential overheating risks.
In an embodiment, the cooling is configured to be compatible with biodegradable synthetic oil for environmental sustainability.
In an embodiment, the aluminium fins are thermally coupled to the pin-fin heat exchanger to enhance heat dissipation efficiency, the aluminium fins increasing the surface area for improved convective cooling and facilitating enhanced thermal regulation of the Motor Control Unit/Power Electronics (MCU/PE).
The present disclosure provides a method for the thermal management of an oil-cooled motor, the method comprising:
o detecting motor temperature through distributed temperature sensors;
o dynamically adjusting oil flow rate via the variable-speed oil pump based on temperature feedback;
o synchronizing coolant pump operation with the oil pump to optimize heat transfer;
o activating a fan at variable speeds based on heat exchanger temperature conditions; and
o utilizing a thermal management control unit to predictively regulate cooling system components based on real-time and historical thermal data.
In an embodiment, the method includes a control unit that continuously refines its cooling strategy using machine learning algorithms trained on operational data.
In an embodiment, the method includes an auxiliary emergency cooling loop is activated under extreme thermal loads to prevent thermal runaway conditions.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A motor casing with a three-layered cooling jacket and a method for thermal management, of the present disclosure will now be described with the help of the accompanying drawing in which:
Figures 1 illustrate a block diagram of the present disclosure; and
Figures 2 illustrate a block diagram of a three-layered cooling jacket system, in accordance with the present disclosure; and
Figures 3 illustrate a method of the present disclosure.
LIST OF REFERENCE NUMERALS
100 Oil-cooled motor
102 Motor casing
104 Stator
106 Rotor
108 Windings
110 Shaft
112 Three-layered cooling system
114 Inner oil jacket
116 Intermediate water jacket
118 Outermost oil jacket
120 Pin-fin heat exchanger (Hx)
120a Alumininmu fins
122 Motor Control Unit/Power Electronics (MCU/PE)
124 Oil pump
126 Coolant pump
128 Water-to-air heat exchanger (Hx)
130 Pin-fin heat sink
132 Thermal management control unit
144 Fan (variable-speed for air cooling)
150 Oil sump (oil storage and regulation)
152 Cross-flow tube fin heat exchanger
154 External ambient air suction fan
156 Coolant serpentine jacket (inside motor casing)
158 Oil serpentine jacket (outer oil circulation path)
200-210 Method and Method Steps
DETAILED DESCRIPTION
The present disclosure relates to an oil-cooled motor (partially oil-filled) configuration to enhance thermal management through the use of a three-layered coolant jacket construction within a single compact casing. The motor's unique configuration integrates concentric oil and water jackets, an inbuilt pin fin heat exchanger, and strategically placed fins on the exterior of the casing, all working together to efficiently dissipate heat generated by the motor's components.
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
When an element is referred to as being “engaged to,” "connected to," or "coupled to" another element, it may be directly engaged, connected, or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Therefore, the present disclosure is a motor casing with a three-layered cooling jacket inside the casing (110). The present disclosure is explained in Figure 1- Figure 3.
The present disclosure provides an oil-cooled motor (100) with an integrated three-layered cooling system and a method for thermal management.
The present disclosure relates to an oil-cooled motor (100) integrated with a three-layered cooling system (112) configured to enhance thermal management efficiency. The system employs a combination of oil and coolant-based thermal dissipation techniques to maintain optimal operating temperatures under varying load conditions.
The oil-cooled motor comprises a motor casing (102), a stator (104), a rotor (106), windings (108), a shaft (110), a three-layered cooling system (112), an inner oil jacket (114), an intermediate water jacket (116), an outermost oil jacket (118), a pin-fin heat exchanger (120), a Motor Control Unit/Power Electronics (MCU/PE) (122), an oil pump (124), an oil sump (150), a coolant pump (126), a water-to-air heat exchanger (128), a pin-fin heat sink (130), a cross-flow tube fin heat exchanger (152), an external ambient air suction fan (154), a coolant serpentine jacket (156), an oil serpentine jacket (158), and a nano-ceramic thermal insulation layer on the motor casing (102).
The three-layered cooling system (112) comprises an inner oil jacket (114), an intermediate water jacket (116), and an outermost oil jacket (118), each performing a distinct role in thermal management. An oil pump (124) and coolant pump (126) are utilized to circulate respective fluids, dynamically regulated by a thermal management control unit based on real-time thermal conditions.
The cooling system (112) is further integrated with additional heat dissipation components, including a water-to-air heat exchanger (128), a pin-fin heat exchanger (120), an oil sump (150), and an external ambient air suction fan (154), ensuring efficient cooling across the motor and power electronics. The AI-driven diagnostics module enables predictive thermal analysis to prevent overheating risks.
The oil-cooled motor (100) employs a three-layered cooling system (112) to regulate its thermal conditions efficiently. The system integrates oil circulation, coolant circulation, thermal control, and emergency heat regulation mechanisms, ensuring optimal temperature management under varying operating conditions.
The oil pump (124) initiates oil circulation by directing it through the inner oil jacket (114), which is in direct thermal contact with the stator windings (108). As the motor operates, heat generated within the stator windings (108) is transferred to the circulating oil. To enhance heat absorption efficiency, the inner oil jacket (114) incorporates microchannels, increasing the surface area for thermal exchange.
After absorbing heat, the oil moves through the outermost oil jacket (118), which surrounds the intermediate water jacket (116). At this stage, heat dissipation is facilitated through two key components: the pin-fin heat exchanger (120), which transfers heat from the oil to the cooling elements of the Motor Control Unit/Power Electronics (MCU/PE) (122), improving overall system efficiency, and the pin-fin heat sink (130), which further enhances convective heat transfer by providing an extended surface area for thermal dissipation.
Once the oil has completed the heat exchange process, it is stored and regulated within the oil sump (150) before recirculation. The self-cleaning filtration system (138) ensures that contaminants and debris are removed from the oil, maintaining long-term cooling efficiency.
To further regulate the temperature of the motor, a coolant pump (126) facilitates the circulation of coolant through the intermediate water jacket (116). This water jacket encases the inner oil jacket (114), allowing it to absorb excess heat from the heated oil. This dual-fluid heat transfer mechanism ensures that the system maintains optimal efficiency under varying loads.
The coolant, now carrying absorbed heat, is directed toward the water-to-air heat exchanger (128). This exchanger is equipped with a high-efficiency cross-flow tube fin heat exchanger (152), which optimizes the transfer of heat from the coolant to ambient air. To further enhance this process, an external ambient air suction fan (154) regulates airflow, increasing heat dissipation efficiency.
Additionally, a coolant serpentine jacket (156) is integrated within the motor casing (102). This serpentine flow path increases the coolant’s residence time, allowing for better thermal exchange and improved cooling performance.
To ensure real-time adaptability, a thermal management control unit dynamically regulates the operation of the oil pump (124) and coolant pump (126). This control unit receives continuous feedback from distributed temperature sensors, which monitor heat levels at various locations within the motor.
In one embodiment, the aluminum fins (120a) are integrated with the pin-fin heat exchanger (120) to enhance heat dissipation efficiency. The aluminum fins (120a) are thermally coupled to the Motor Control Unit/Power Electronics (MCU/PE) (122), allowing effective heat transfer from the high-temperature components. The fins (120a) increase the surface area for improved convective cooling, facilitating better thermal regulation of the system.
The AI-driven diagnostics module analyzes historical temperature trends and real-time operating conditions to predict potential overheating risks. By leveraging machine learning algorithms, the module refines the cooling strategy dynamically, ensuring efficient heat dissipation while minimizing energy consumption.
In scenarios where thermal demand fluctuates due to varying load conditions, the system automatically adjusts pump speeds and modifies coolant circulation rates to prevent temperature spikes, ensuring consistent performance and extended motor lifespan.
Under extreme thermal loads, the system employs an auxiliary emergency cooling loop to prevent thermal runaway conditions. This loop is activated when standard cooling mechanisms are insufficient, providing an additional path for rapid heat dissipation.
During cold-start conditions, rapid motor heating is often required to bring the system to optimal operating temperatures. To facilitate this, the thermal bypass valve reroutes oil flow away from the heat exchanger (128), allowing the oil to retain heat and warm up the motor components more quickly. Once the system reaches the desired temperature, normal circulation resumes to prevent overheating.
By incorporating these advanced thermal management techniques, the oil-cooled motor (100) achieves enhanced reliability, improved efficiency, and extended durability across various operating conditions.
Figure 1 provides overall disclosure functionality, where an oil-cooled motor (100) comprises a motor casing (102) that houses a stator (104), a rotor (106), windings (108), and a shaft (110). The three-layered cooling system (112) consists of an inner oil jacket (114) in direct thermal contact with the stator windings (108), an intermediate water jacket (116) surrounding the inner oil jacket (114), and an outermost oil jacket (118) thermally coupled to a pin-fin heat exchanger (120) integrated with aluminum fins (120a) of the Motor Control Unit/Power Electronics (MCU/PE) (122). The oil pump (124) circulates oil through the inner oil jacket (114) for heat absorption and through the outermost oil jacket (118) for additional cooling. The coolant pump (126) facilitates coolant flow through the intermediate water jacket (116) and directs it toward the water-to-air heat exchanger (128) for heat dissipation, supported by an external ambient air suction fan. The cooling system (112) is optimized using a pin-fin heat sink (130), a cross-flow tube fin heat exchanger (152), a coolant serpentine jacket (156), and an oil serpentine jacket (158). An oil sump (150) regulates oil flow, ensuring continuous thermal efficiency. A thermal management control unit dynamically adjusts the oil pump (124) and coolant pump (126) speeds based on real-time temperature feedback. Additionally, an auxiliary emergency cooling loop (146) is activated under extreme thermal loads, while a thermal bypass valve (134) reroutes oil flow during cold-start conditions to allow rapid heating. The AI-driven diagnostics module (140) predicts overheating risks and optimizes cooling strategies based on historical and real-time data.
Figure 2 provides the three-layered jacked cooling system functionality where the initially oil-cooled motor (100) incorporates an advanced cooling system (112) designed to optimize thermal management. The system utilizes an oil pump (124) to circulate oil through the cooling pathways, including an oil serpentine jacket (158), ensuring effective heat dissipation. The oil is stored and regulated within an oil sump (150) before recirculation. A coolant pump (126) directs coolant flow through a coolant serpentine jacket (156), which enhances heat transfer efficiency. The coolant then moves towards the water-to-air heat exchanger (128), where it releases heat to ambient or conditioned air. A cross-flow tube fin heat exchanger (152) further optimizes air-cooling efficiency, while an external ambient air suction fan (154) regulates airflow, ensuring effective dissipation. The Motor Control Unit/Power Electronics (MCU/PE) (122) is integrated with the cooling system to maintain optimal operating conditions. The thermal management system dynamically regulates pump speeds and heat exchanger operation to maintain efficient temperature control, preventing overheating and ensuring long-term reliability of the motor.
Figures 3 illustrate a flowchart that includes the steps involved in a method (200) for thermal management of an oil-cooled motor , in accordance with an embodiment of the present disclosure. The order in which method (200) steps are described is not intended to be construed as a limitation, and any number of the described method (200) steps may be combined in any order to implement the method (200), or an alternative method. Furthermore, the method (200) may be implemented by processing a resource or an electronic device(s) through any suitable hardware, non-transitory machine-readable medium/instructions, or a combination thereof. The method (200) comprises the following steps:
At step (202), the method (200) can include detecting motor temperature through distributed temperature sensors (142).
At step (204), the method (200) can include dynamically adjusting oil flow rate (136) via the variable-speed oil pump (124) based on temperature feedback.
At step (206), the method (200) can include synchronizing coolant pump (126) operation with the oil pump (124) to optimize heat transfer.
At step (208), the method (200) can include activating an external ambient air suction fan (154) at variable speeds based on heat exchanger (128) temperature conditions;
At step (210), the method (200) can include utilizing a thermal management control unit (132) to predictively regulate cooling system (112) components based on real-time and historical thermal data.
In an embodiment, the method includes an auxiliary emergency cooling loop that is activated under extreme thermal loads to prevent thermal runaway conditions.
In an embodiment, the method includes a thermal management control unit that continuously refines its cooling strategy using machine learning algorithms trained on operational data.
The present disclosure provides a motor casing with a three-layered cooling jacket and a method for thermal management, demonstrated through the following anecdotal examples to illustrate its functionality and practical applications.
In an example, during high-speed highway operation, the oil-cooled motor (100) experiences increased power demand, generating significant heat in the stator windings (108). The oil pump (124) increases circulation through the inner oil jacket (114), allowing efficient heat absorption. Heated oil then moves into the outermost oil jacket (118), where the pin-fin heat exchanger (120) and pin-fin heat sink (130) dissipate heat effectively. Simultaneously, the coolant pump (126) adjusts its flow through the intermediate water jacket (116) to maintain optimal cooling. This synchronized operation ensures that the motor (100) maintains efficiency and prevents overheating even under continuous high-speed conditions.
In an example, during uphill driving in high ambient temperatures, the motor casing (102) is exposed to sustained thermal loads. The coolant pump (126) increases flow through the intermediate water jacket (116) to enhance heat transfer from the oil circulation path. The water-to-air heat exchanger (128), assisted by the cross-flow tube fin heat exchanger (152), efficiently dissipates excess heat. The external ambient air suction fan (154) adjusts speed based on real-time temperature conditions, ensuring continuous motor operation without thermal limitations.
In an example, in cold-start conditions, the thermal bypass valve reroutes oil flow away from the heat exchanger (128) to retain heat within the motor (100). This accelerates warm-up, allowing the stator windings (108) and other components to reach optimal operating temperature more quickly. Once the system reaches the required thermal level, normal cooling circulation resumes, preventing excessive energy consumption while ensuring smooth motor performance.
In an example, in stop-and-go traffic, frequent acceleration, and braking cycles cause fluctuating thermal loads. The AI-driven diagnostics module continuously monitors these variations and dynamically adjusts oil pump (124) and coolant pump (126) speeds. By predicting temperature trends based on real-time and historical data, the system ensures cooling efficiency while optimizing energy usage. This prevents sudden overheating and allows stable operation despite unpredictable driving conditions.
In an example, during heavy-load towing, increased torque demand results in sustained heating of the stator windings (108). To prevent thermal overload, the auxiliary emergency cooling loop activates, providing additional heat dissipation. This ensures that the motor (100) operates within safe thermal limits, preventing performance degradation and allowing sustained high-power operation.
In an example, in dusty or debris-prone environments, contaminants in the air could affect oil circulation efficiency. The self-cleaning filtration integrated into the oil circulation path continuously removes particles, preventing blockages and maintaining long-term cooling performance. This ensures reliable motor operation even in harsh environmental conditions.
In an example, during high-load motor operation, the heat generated by the MCU/PE (122) is transferred to the pin-fin heat exchanger (120) via conduction. The aluminum fins (120a) further enhance heat dissipation by increasing airflow exposure, allowing the heat exchanger (120) to effectively release thermal energy into the surrounding environment. This configuration ensures that the system (100) maintains optimal thermal performance, preventing overheating and improving the overall efficiency and reliability of the cooling system (112).
In an example, in industrial applications requiring continuous high-power output, the nano-ceramic thermal insulation layer on the motor casing (102) minimizes heat loss, enhancing overall cooling efficiency. The AI-driven diagnostics module further refines cooling strategies based on load conditions, allowing extended operation without thermal failure.
In an operative configuration, the oil-cooled motor (100) utilizes a three-layered cooling system (112) to ensure efficient heat management under varying thermal conditions. The inner oil jacket (114) remains in direct contact with the stator windings (108), allowing rapid heat absorption and oil circulation through the oil pump (124). The intermediate water jacket (116) acts as a secondary cooling layer, transferring heat from the oil to the coolant, which is then circulated by the coolant pump (126). Heat dissipation is further enhanced by the outermost oil jacket (118), thermally interfaced with the pin-fin heat exchanger (120) and pin-fin heat sink (130), which aid in cooling the Motor Control Unit/Power Electronics (MCU/PE) (122). The thermal management control unit dynamically regulates oil and coolant flow rates, optimizing cooling efficiency in response to real-time thermal loads. Additional cooling mechanisms, including the water-to-air heat exchanger (128), cross-flow tube fin heat exchanger (152), and external ambient air suction fan (154), work in conjunction to maintain motor temperature within safe operational limits. The AI-driven diagnostics module continuously monitors thermal conditions and predicts potential overheating risks, ensuring proactive cooling adjustments. The system is also equipped with an auxiliary emergency cooling loop to handle extreme thermal loads and a thermal bypass valve to facilitate rapid heating during cold-start conditions. This integrated cooling approach enables the motor (100) to sustain high efficiency and reliability across diverse operating environments.
Advantageously, the oil-cooled motor (100) overcomes the limitations of conventional cooling systems by providing an advanced multi-layered thermal management solution. The three-layered cooling system (112) ensures that heat is effectively dissipated while minimizing temperature fluctuations that could affect motor performance. Unlike traditional air-cooled systems that struggle under high thermal loads, the integration of oil and coolant circulation enables rapid and efficient heat transfer. The real-time dynamic adjustments made by the thermal management control unit (132) allow optimized energy usage, reducing unnecessary cooling effort and improving overall system efficiency. The inclusion of AI-driven diagnostics further enhances system reliability by predicting overheating risks and adapting cooling strategies accordingly. The auxiliary emergency cooling loop provides an additional safeguard against thermal runaway, ensuring continued operation in demanding conditions. The self-cleaning filtration prevents oil contamination, maintaining long-term cooling efficiency. Furthermore, the nano-ceramic thermal insulation layer on the motor casing (102) reduces heat loss, enhancing overall performance and longevity. The system’s ability to operate with biodegradable synthetic oil promotes environmental sustainability. By implementing these advanced cooling strategies, the invention provides a robust, adaptable, and energy-efficient solution that ensures high-performance motor operation across a wide range of real-world applications.
The functions described herein may be implemented in hardware, executed by a processor, firmware, or any combination thereof. Other examples and implementations are within the scope and spirit of the disclosure and appended claims. The present disclosure can be implemented by a processor, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including distributed such that portions of functions are implemented at different physical locations.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, a motor casing with a three-layered cooling jacket and a method for thermal management which;
• effectively manages heat from critical components, including the stator, windings, and power electronics, while maintaining a compact configuration;
• allows for efficient heat transfer between oil, coolant, and ambient air;
• eliminates the need for multiple separate cooling systems; and
• ensures reliable operation of the motor in high-temperature environments by maintaining optimal temperature levels across all critical components through advanced heat transfer mechanisms.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. An oil-cooled motor (100) with an integrated three-layered cooling system, said oil-cooled motor (100) comprising:
• a motor casing (102) configured to house a stator (104), a rotor (106), windings (108), and a shaft (110);
• a three-layered cooling system (112) including:
o an inner oil jacket (114), in direct thermal contact with the stator windings (108), configured to circulate oil for heat absorption;
o an intermediate water jacket (116), surrounding said inner oil jacket (114), configured to circulate coolant for transferring heat from said inner oil jacket (114); and
o an outermost oil jacket (118), thermally coupled to a pin-fin heat exchanger (Hx) (120) of a Motor Control Unit/Power Electronics (MCU/PE) (122), configured to dissipate heat from said MCU/PE (122);
• an oil pump (124) configured to circulate oil through the inner oil jacket (114) and the outermost oil jacket (118);
• a coolant pump (126) configured to circulate coolant through the intermediate water jacket (116);
• a water-to-air heat exchanger (Hx) (128) thermally coupled to the coolant flow path for dissipating heat to ambient or conditioned air;
• a pin-fin heat sink (130) integrated with the MCU/PE (122) and thermally interfaced with said outermost oil jacket (118) for heat dissipation; and
• a thermal management control unit (132), receiving inputs from multiple temperature sensors, configured to regulate oil and coolant pump speeds dynamically based on real-time heat dissipation requirements.
Wherein said three-layered cooling system (112) ensures efficient heat dissipation by enabling independent yet synchronized operation of oil and coolant circulation paths.
2. The oil-cooled motor (100) as claimed in claim 1, wherein said inner oil jacket (114) includes microchannels to maximize heat absorption from the stator windings (108).
3. The oil-cooled motor (100) as claimed in claim 1, wherein said outermost oil jacket (118) includes a pin-fin array to enhance convective heat transfer.
4. The oil-cooled motor (100) as claimed in claim 1, wherein said thermal management control unit (132) is configured with predictive algorithms to adjust cooling system parameters based on load conditions and thermal history.
5. The oil-cooled motor (100) as claimed in claim 1, wherein said coolant pump (126) dynamically adjusts the flow rate based on predictive thermal load conditions.
6. The oil-cooled motor (100) as claimed in claim 1, further comprises a thermal bypass valve (134) configured to reroute oil flow away from the heat exchanger (128) when rapid motor heating is required during cold-start conditions.
7. The oil-cooled motor (100) as claimed in claim 1, wherein said heat exchanger (128) includes a high-efficiency cross-flow fin structure to enhance air-cooling efficiency.
8. The oil-cooled motor (100) as claimed in claim 1, wherein said pin-fin heat sink (130) integrated with the MCU/PE (122) is made of a thermally conductive ceramic material to reduce electrical interference while enhancing heat dissipation.
9. The oil-cooled motor (100) as claimed in claim 1, further comprises a self-cleaning filtration integrated into the oil circulation path to remove contaminants and maintain long-term cooling efficiency.
10. The oil-cooled motor (100) as claimed in claim 1, wherein said motor casing (102) is coated with a nano-ceramic thermal insulation layer to minimize heat losses.
11. The oil-cooled motor (100) as claimed in claim 1, further comprises an AI-driven diagnostics module that analyses temperature trends and operating conditions to predict potential overheating risks.
12. The oil-cooled motor (100) as claimed in claim 1, wherein said cooling (112) is configured to be compatible with biodegradable synthetic oil for environmental sustainability.
13. The oil-cooled motor (100) as claimed in claim 1, wherein the aluminum fins (120a) are thermally coupled to the pin-fin heat exchanger (120) to enhance heat dissipation efficiency, the aluminum fins (120a) increasing the surface area for improved convective cooling and facilitating enhanced thermal regulation of the Motor Control Unit/Power Electronics (MCU/PE) (122).
14. A method (200) for thermal management of an oil-cooled motor (100), said method (200) comprising:
• detecting motor temperature through distributed temperature sensors;
• dynamically adjusting oil flow rate via the variable-speed oil pump (124) based on temperature feedback;
• synchronizing coolant pump (126) operation with the oil pump (124) to optimize heat transfer;
• activating a fan (144) at variable speeds based on heat exchanger (128) temperature conditions; and
• utilizing a thermal management control unit (132) to predictively regulate cooling system (112) components based on real-time and historical thermal data.
15. The method (200) as claimed in claim 13, wherein said control unit (132) continuously refines its cooling strategy using machine learning algorithms trained on operational data.
16. The method (200) as claimed in claim 13, wherein an auxiliary emergency cooling loop is activated under extreme thermal loads to prevent thermal runaway conditions.

Dated this 05th day of April, 2025

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT TO THE APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, CHENNAI