Description:BACKGROUND
Technical Field
[0001] The embodiment herein generally relates to brushless Direct Current (DC) motors and more particularly, a cooling system for Brushless Direct Current (BLDC) motor and method thereof.
Description of Related Art
[0002] Technical challenges in the existing BLDC motor technologies are that the existing BLDC motor has inefficient heat dissipation in high-power applications due to limited heat transfer capacity of air-cooling systems leading to overheating and reduced motor efficiency.
[0003] Furthermore, the thermal stress on motor components due to inability of the BLDC motor to handle variable loads and speed variations. The existing BLDC motor has inadequate cooling due to the BLDC motor’s compact size or space-constrained motor designs. Also, lack of efficient self-cleaning cooling mechanisms leads to high maintenance and operational costs of cooling systems.
[0004] Main challenge is the environmental impact of traditional coolants and fluids. the complex cooling systems for high-performance motors leads to noise and vibration.
[0005] Accordingly, there remains a need for a cooling system for Brushless Direct Current (BLDC) motor and method thereof.
SUMMARY
[0006] In view of the foregoing, embodiments herein a provide a cooling system for Brushless Direct Current (BLDC) motor. The system includes an oil reservoir, an oil pump, a motor housing, an oil cooler or heat exchanger, a flow sensor, a temperature sensor, and a heat-laden oil. The oil reservoir is configured to store oil. The oil circulates within a BLDC motor system. The oil pump is configured to pump the oil throughout the BLDC motor system. The motor housing is configured with an oil cooling channel, wherein the oil flows through the oil cooling channel in order to cool BLDC motor core components.
[0007] Further the oil cooler or heat exchanger is configured to dissipate a heat absorbed by the oil into the surrounding environment. The flow sensor is configured to monitor the flow in the BLDC motor system. The temperature sensor is configured to monitor a temperature inside the BLDC motor system. The oil flow and temperature are adjusted if the oil flow falls below a first predefined value and the temperature exceeds a second predefined value. The heat-laden oil is pumped through a cooling passages or an oil channels around the BLDC motor core components to maximize the heat removal efficiency.
[0008] According to some embodiments herein, the oil comprises a high-performance dielectric fluid, or mineral oil.
[0009] According to some embodiments herein, the oil cooler or heat exchanger comprises a radiator or a heatsink.
[00010] According to some embodiments herein, the cooling system further comprises an oil filter that is configured to remove contaminants from the oil before the oil is returned to the BLDC motor.
[00011] In an aspect the embodiments herein provide a method for providing a cooling system for Brushless Direct Current (BLDC) motor. The method includes configuring, an oil reservoir, to store oil. The oil circulates within a BLDC motor system. The method further includes configuring, an oil pump, to pump the oil throughout the BLDC motor system. The method further includes configuring, a motor housing, with an oil cooling channel, wherein the oil flows through the oil cooling channel in order to cool BLDC motor core components. The method further includes configuring, an oil cooler or heat exchanger, to dissipate a heat absorbed by the oil into the surrounding environment.
[00012] The method further includes configuring, a flow sensor, to monitor the flow in the BLDC motor system. The method further includes configuring, a temperature sensor, to monitor a temperature inside the BLDC motor system. The oil flow and temperature are adjusted if the oil flow falls below a first predefined value and the temperature exceeds a second predefined value. The method further includes pumping, a heat-laden oil, through a cooling passages or an oil channels around the BLDC motor core components to maximize the heat removal efficiency.
[00013] According to some embodiments herein, the oil comprises a high-performance dielectric fluid, or mineral oil.
[00014] According to some embodiments herein, the Oil Cooler or Heat Exchanger comprises a radiator or a heatsink.
[00015] According to some embodiments herein, the method further comprises configuring, an oil filter, to remove contaminants from the oil before the oil is returned to the BLDC motor.
[00016] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[00017] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[00018] FIG. 1A illustrates a motor housing and cooling channel layout, according to some embodiments herein;
[00019] FIG. 1B illustrates an oil flow path, according to some embodiments herein;
[00020] FIG. 1C illustrates an oil cooler/heat exchanger, according to some embodiments herein;
[00021] FIG. 1D illustrates an oil filtration system, according to some embodiments herein; and
[00022] FIG. 2 illustrates a flow chart showing a method for providing a cooling system for Brushless Direct Current (BLDC) motor, according to some embodiments herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[00023] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed 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.
[00024] As mentioned, there remains a need for a cooling system for Brushless Direct Current (BLDC) motor and method thereof. Referring now to the drawings, and more particularly to FIGS. 1A through 2, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[00025] Refereeing to FIGs. 1A-1D, the system (100A, 100B, 100C, and 100D) includes a motor housing 102, stator/rotor 104, windings 106, bearings 108, an oil circulation 110, a oil cooling channel 112, an oil reservoir 114, an oil pump 116, an oil cooler/heat exchanger 118, a cooled oil return path 120, fins/tubes 122, air flow 124, a radiator 126, oil filter 128, a magnetic filter 130.
[00026] The oil reservoir 114 is configured to store oil. The oil circulates within the BLDC motor system. The oil pump 116 is configured to pump the oil throughout the BLDC motor system. The motor housing 102 is configured with oil cooling channel 112. The oil flows through the oil cooling channel in order to cool BLDC motor core components.
[00027] Further the oil cooler or heat exchanger 118 is configured to dissipate a heat absorbed by the oil into the surrounding environment. The flow sensor is configured to monitor the flow in the BLDC motor system. The temperature sensor is configured to monitor a temperature inside the BLDC motor system. The oil flow and temperature are adjusted if the oil flow falls below a first predefined value and the temperature exceeds a second predefined value. The heat-laden oil is pumped through a cooling passages or an oil channels around the BLDC motor core components to maximize the heat removal efficiency. In a non-limiting example, optimum temperature range for BLDC Motor is 25°C to 75°C. The cooling system is activated when the temperature reaches 75°C.
[00028] The oil includes a high-performance dielectric fluid, or mineral oil. The Oil cooler or heat exchanger 118 includes a radiator or a heatsink. The cooling system 100 further includes an oil filter 128 that is configured to remove contaminants from the oil before the oil is returned to the BLDC motor.
[00029] The motor housing 102 contains internal channels where oil circulates around the Rotor and Stator. Oil absorption and heat transfer happen through these channels. The oil is pumped from the oil reservoir 114, circulates through the motor housing 102, absorbs heat, and then passes through the oil cooler/heat exchanger 118 to dissipate the heat. This component dissipates the heat absorbed by the oil. The cooler may use either air cooling or liquid cooling (e.g., a radiator or a heat exchanger) to transfer heat from the oil to the environment. To maintain cooling efficiency, the oil filtration system removes contaminants from the oil before it returns to the motor housing.
[00030] The oil cooling method for BLDC motors is designed to effectively manage the thermal load of the motor components, such as the stator and rotor, by using oil to absorb and dissipate heat.
[00031] The BLDC motor starts its operation, and the electrical energy from the power source (typically DC) is converted into rotational motion by the interaction of the rotor and stator. During this process, the motor generates heat due to resistive losses in the windings, friction in bearings, and other electrical losses. As the motor operates, heat is generated from copper losses, Iron losses, Frictional losses. The copper loss is in the motor windings (I²R losses). Iron losses are from the alternating magnetic fields. Frictional losses are from the rotor and bearings. The heat accumulates in the motor components, which can raise the temperature of critical parts such as the rotor, stator windings, and bearings.
[00032] The motor is integrated with an oil reservoir and a pump that circulates oil around the motor’s core components. The oil can either flow in an immersed system (where the motor is submerged in oil) or in a closed-loop system where oil flows through the oil cooling channel around the motor.
[00033] The oil is typically a high-performance dielectric fluid or mineral oil that has excellent heat transfer properties.
[00034] As the oil flows through the motor, it comes into contact with the motor's components (stator, rotor, and bearing housing) and absorbs heat generated during operation. The oil's thermal conductivity helps transfer the heat from the motor components to the oil.
[00035] The circulating oil carries the absorbed heat away from the motor's internal components. It moves through oil channels, or a heat exchanger system designed to increase the contact area for heat transfer.
[00036] The heat-laden oil is pumped through cooling passages or oil channels around the stator windings, rotor shaft, and bearings. This maximizes the heat removal efficiency.
[00037] The heated oil is then transported through an external oil cooler (e.g., heat exchanger), where it releases the absorbed heat into the environment. This could involve air cooling or another heat exchange mechanism.
[00038] In some systems, the oil may pass through a radiator or heatsink, where forced air or coolant fluid absorbs the heat from the oil.
[00039] After the oil cools down, it returns to the motor housing 102, either through gravity or by being pumped back into the system. The pumped back of the oil creates a continuous cycle of oil cooling, which helps maintain a stable operating temperature for the motor during prolonged or high-load operation. Over time, the oil may accumulate contaminants such as metal particles, moisture, or other by-products of the motor’s operation. Some systems integrate an oil filtration system that removes these contaminants before the oil is returned to the motor. The oil can be filtered through magnetic filters or other filtration devices to maintain its cooling performance.
[00040] When the motor stops or enters a low-load condition, the oil pump may continue circulating for a short time to dissipate residual heat from the motor before the system is turned off completely.
[00041] FIG. 2 illustrates a flow chart showing a method 200 for providing a cooling system for Brushless Direct Current (BLDC) motor, according to some embodiments herein. At step 202, the method 200 includes configuring, an oil reservoir, to store oil. The oil circulates within a BLDC motor system. At step 204, the method 200 includes configuring, an oil pump, to pump the oil throughout the BLDC motor system. At step 206, the method 200 includes configuring, a motor housing, with the oil cooling channel, wherein the oil flows through the oil cooling channel in order to cool BLDC motor core components. At step 208, the method 200 includes configuring, an oil cooler or heat exchanger, to dissipate a heat absorbed by the oil into the surrounding environment.
[00042] At step 210, the method 200 includes configuring, a flow sensor, to monitor the flow in the BLDC motor system. At step 212, the method 200 includes configuring, a temperature sensor, to monitor a temperature inside the BLDC motor system. The oil flow and temperature are adjusted if the oil flow falls below a first predefined value and the temperature exceeds a second predefined value. At step 214, the method 200 includes pumping, a heat-laden oil, through a cooling passages or an oil channels around the BLDC motor core components to maximize the heat removal efficiency.
[00043] An advantage of the embodiments herein is that the oil cooling system and method in BLDC motors improves motor efficiency by maintaining optimal temperature levels throughout the operation, effectively dissipating heat from critical components, and minimizing losses. By using oil’s superior thermal properties, the system ensures that the motor performs consistently at high efficiency levels, reduces wear and tear, and enhances the motor's overall lifespan.
[00044] The foregoing description of the specific embodiments will 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 practised with modification within the scope of the appended claims.
, C , Claims:We claim:
1. A cooling system (100) for Brushless Direct Current (BLDC) motor, the system (100) comprising:
an oil reservoir (114) that is configured to store oil, wherein the oil circulates within a BLDC motor system;
an oil pump (116( that is configured to pump the oil throughout the BLDC motor system;
a motor housing 102 that is configured with an oil cooling channel 112, wherein the oil flows through the oil cooling channel in order to cool BLDC motor core components;
an oil cooler or heat exchanger (118) that is configured to dissipate a heat absorbed by the oil into the surrounding environment;
a flow sensor that is configured to monitor the flow in the BLDC motor system;
a temperature sensor that is configured to monitor a temperature inside the BLDC motor system, wherein the oil flow and temperature is adjusted if the oil flow falls below a first predefined value and the temperature exceeds a second predefined value; and
a heat-laden oil is pumped through a cooling passages or an oil channels around the BLDC motor core components to maximize the heat removal efficiency.
2. The cooling system (100) as claimed in claim 1, wherein the oil comprises a high-performance dielectric fluid, or mineral oil.
3. The cooling (100) system as claimed in claim 1, wherein the oil cooler or heat exchanger (118) comprises a radiator or a heatsink.
4. The cooling (100) system as claimed in claim 1, wherein the cooling system (100) further comprises an oil filter (128) that is configured to remove contaminants from the oil before the oil is returned to the BLDC motor.
5. A method (200) for providing a cooling system for Brushless Direct Current (BLDC) motor, the method comprising:
configuring (202), an oil reservoir, to store oil, wherein the oil circulates within a BLDC motor system;
configuring (204), an oil pump, to pump the oil throughout the BLDC motor system;
configuring (206), a motor housing, with an oil cooling channel, wherein the oil flows through the oil cooling channel in order to cool BLDC motor core components;
configuring (208), an oil cooler or heat exchanger, to dissipate a heat absorbed by the oil into the surrounding environment;
configuring (210), a flow sensor, to monitor the flow in the BLDC motor system;
configuring (212), a temperature sensor, to monitor a temperature inside the BLDC motor system,
wherein the oil flow and temperature are adjusted if the oil flow falls below a first predefined value and the temperature exceeds a second predefined value; and
pumping (214), a heat-laden oil, through a cooling passages or an oil channels around the BLDC motor core components to maximize the heat removal efficiency.
6. The method (200) as claimed in claim 5, wherein the oil comprises a high-performance dielectric fluid, or mineral oil.
7. The method (200) as claimed in claim 5, wherein the Oil Cooler or Heat Exchanger comprises a radiator or a heatsink.
8. The method (200) as claimed in claim 5, wherein the method further comprises configuring, an oil filter, to remove contaminants from the oil before the oil is returned to the BLDC motor.