Air-Cooled Energy Dissipation Layout for Motor and Power Electronics
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Solution Overview
Problem
Electric vehicles face challenges in auxiliary braking due to the energy dissipation and cooling capacity limitations, particularly when the battery is fully charged, as conventional cooling systems are inadequate and may expose components to high temperatures.
Innovation Solution
An energy dissipation system comprising an air compressor driven by an electric motor, with power electronics and a unique air flow channel design using thermally conductive elongated tubes to cool both the motor and power electronics, reducing the need for conventional coolant and debris protection, and incorporating an air cooled resistor for additional energy dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling systems are used for electric motors and power electronics, then the system can operate, but the cooling capacity is insufficient and components are exposed to high temperatures
Solution Approach 1:
The patent combines the cooling functions for the electric motor and power electronics into a single integrated air flow channel system. The air flow channel is configured to cool both components simultaneously, merging what would traditionally be separate cooling systems into one unified structure, thereby improving cooling capacity while maintaining system reliability
Solution Approach 2:
The air flow channel serves multiple functions: it cools the electric motor, cools the power electronics, and protects both components from debris contamination. This multi-functional design addresses the cooling capacity limitation while enhancing system reliability through a single versatile cooling structure
2Quantity of substance
If the battery is fully charged (state-of-charge above threshold), then energy storage is maximized, but auxiliary braking functionality is limited due to inability to dissipate excess electric energy
Solution Approach 1:
The patent converts the harmful excess electric energy that cannot be stored in a fully charged battery into a useful resource by using it to drive the air compressor through the electric motor. This allows the system to maintain braking functionality even when the battery is full, as the excess energy is productively utilized rather than causing system limitations
3Device complexity
If air flow channel is used for cooling, then conventional coolant and separate cooling systems are reduced, but debris contamination risk to motor and electronics must be addressed
Solution Approach 1:
The patent uses the air flow channel as a protective enclosure that acts as a barrier between the ambient environment and the sensitive components. The channel walls function as a protective shell that prevents debris contamination while allowing heat transfer, thus simplifying the cooling system without compromising component protection
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides a compact, high-cooling-capacity system that effectively dissipates electric energy without using conventional engine coolant, reducing the risk of debris contamination and enhancing the cooling efficiency of electric motors and power electronics, thus addressing the limitations of existing systems.
Implementation Method 1
the air flow channel being formed by an inner elongated tube member and an outer elongated tube member, wherein the outer elongated tube member is radially spaced apart from the inner elongated tube member, the inner elongated tube member comprising a first inner surface and a first outer surface, and the outer elongated tube member comprises a second inner surface and a second outer surface, the first outer surface and the second inner surface facing each other, wherein the electric motor is housed within the inner elongated tube member and attached to the first inner surface, and wherein the power electronics housing is attached to the second outer surface
Data Source
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AI summary
An energy transformation system comprising an air compressor, an electric motor, power electronics and cooling by ambient air. Compressor comprises a compressor shaft and a compressor inlet configured to receive ambient air. The electric motor comprises a rotor including a rotor shaft connected to the compressor shaft. Power electronics are arranged in a electronics housing and being connected electrically to the electric motor in order to feed electric power to the electric motor. An air flow channel for said ambient air is formed by an inner elongated tube member and an outer elongated tube member before reaching the compressor inlet. The electric motor is housed within the inner elongated tube member and attached to a first inner surface. The electronics housing is attached to a second outer surface of said outer elongated tube.