Header guiding fluid flow to and from cooling channels in a high density motor
A header for an electric machine that include a stator core and one or more windings that include coolant passages formed therein. The header includes an inlet to receive a coolant, an outlet though which the coolant exits the header, an inlet plenum fluidly connected to the inlet, and an outlet plenum fluidly separated from the inlet plenum and fluidly connected to the outlet. The inlet and outlet plenums each have a varying cross section that varies from a top of the header as compared to a bottom of the header.
1 . A header for an electric machine that include a stator core and one or more windings that include coolant passages formed therein, the header comprising:
an inlet to receive a coolant;
an outlet though which the coolant exits the header,
an inlet plenum fluidly connected to the inlet; and
an outlet plenum fluidly separated from the inlet plenum and fluidly connected to the outlet;
wherein the inlet and outlet plenums each have a varying cross section that varies from a top of the header as compared to a bottom of the header;
wherein the inlet is a main inlet and the outlet is a main outlet and the header includes a front side and a back side;
the header further comprising:
a plurality of outlet passages formed on back side of the header and in fluid communication with the inlet plenum so that coolant that enters the main inlet can exit the inlet plenum and the header; and
a plurality of inlet passages formed on a back side of the header and in fluid communication with the outlet plenum so that coolant that exited through the outlet passages and passed through a portion of a motor can enter the outlet plenum;
wherein at least one of the plurality of outlet passages is connected to another one of the plurality of outlet passages by a first crossover section.
2 . The header of claim 1 , wherein the inlet plenum and the outlet plenum are co-planar.
3 . The header of claim 1 , wherein the inlet plenum and the outlet plenum are side by side and spaced parallel to each other.
4 . The header of claim 1 , wherein the inlet plenum includes an orifice plate disposed therein that divides the inlet plenum into a plenum inlet side and a plenum outlet side.
5 . The header of claim 4 , wherein the orifice plate includes a plurality of holes therein.
6 . The header of claim 1 , wherein at least one of the plurality of inlet passages is connected to another one of the plurality of inlet passages second crossover section.
7 . The header of claim 1 , wherein the inlet and outlet are arranged to receive and output coolant along an axial direction of the header.
8 . The header of claim 1 , wherein the inlet and outlet are arranged to receive and output coolant along a direction tangential to the header.
9 . The header of claim 1 , wherein the inlet and outlet are arranged to receive and output coolant along a vertical direction of the header.
10 . A motor comprising:
a rotor;
a stator; and
a header as recited in claim 1 .
11 . A header for an electric machine that include a stator core and one or more windings that include coolant passages formed therein, the header comprising:
an inlet to receive a coolant;
an outlet though which the coolant exits the header,
an inlet plenum fluidly connected to the inlet; and
an outlet plenum fluidly separated from the inlet plenum and fluidly connected to the outlet;
wherein the inlet and outlet plenums each have a varying cross section that varies from a top of the header as compared to a bottom of the header;
wherein the inlet is a main inlet and the outlet is a main outlet and the header includes a front side and a back side;
the header further comprising:
a plurality of outlet passages formed on back side of the header and in fluid communication with the inlet plenum so that coolant that enters the main inlet can exit the inlet plenum and the header; and
a plurality of inlet passages formed on a back side of the header and in fluid communication with the outlet plenum so that coolant that exited through the outlet passages and passed through a portion of a motor can enter the outlet plenum;
wherein the inlet plenum includes an orifice plate disposed therein that divides the inlet plenum into a plenum inlet side and a plenum outlet side;
wherein the orifice plate includes a plurality of holes therein;
wherein the holes vary in size from the top of the header to the bottom of the header.
12 . The header of claim 5 , wherein coolant is received into the inlet plenum in the plenum inlet side, passes through the holes, enters into the plenum outlet side and then exits the header via the outlet passages.
13 . A motor comprising:
a rotor;
a stator; and
a header as recited in claim 11 .
14 . The header of claim 11 , wherein the inlet and outlet are arranged to receive and output coolant along an axial direction of the header.
15 . The header of claim 11 , wherein the inlet and outlet are arranged to receive and output coolant along a direction tangential to the header.
16 . The header of claim 11 , wherein the inlet and outlet are arranged to receive and output coolant along a vertical direction of the header.
17 . A header for an electric machine that include a stator core and one or more windings that include coolant passages formed therein, the header comprising:
an inlet to receive a coolant;
an outlet though which the coolant exits the header,
an inlet plenum fluidly connected to the inlet; and
an outlet plenum fluidly separated from the inlet plenum and fluidly connected to the outlet;
wherein the inlet is a main inlet and the outlet is a main outlet and the header includes a front side and a back side;
the header further comprising:
a plurality of outlet passages formed on back side of the header and in fluid communication with the inlet plenum so that coolant that enters the main inlet can exit the inlet plenum and the header; and
a plurality of inlet passages formed on a back side of the header and in fluid communication with the outlet plenum so that coolant that exited through the outlet passages and passed through a portion of a motor can enter the outlet plenum;
wherein at least one of the plurality of outlet passages is connected to another one of the plurality of outlet passages by a first crossover section.
18 . The header of claim 17 , wherein the inlet plenum and the outlet plenum are co-planar.
19 . The header of claim 17 , wherein the inlet plenum and the outlet plenum are side by side and spaced parallel to each other.
20 . The header of claim 17 , wherein the inlet plenum includes an orifice plate disposed therein that divides the inlet plenum into a plenum inlet side and a plenum outlet side.