Air Compressor Braking Layout With Ambient-Air Cooling
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Solution Overview
Problem
Electric vehicles face challenges in achieving effective auxiliary braking and cooling due to the limited cooling capacity of components like fuel cell electric vehicles and battery electric vehicles, which are overwhelmed by the energy dissipation during braking, leading to potential overheating issues.
Innovation Solution
An energy dissipation system utilizing an air compressor driven by an electric motor, where the motor and power electronics are integrated within an air flow channel formed by inner and outer elongated tubes, allowing ambient air to conductively cool both components, eliminating the need for conventional coolant and reducing debris exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional coolant systems are used to cool electric motor and power electronics, then cooling capacity is sufficient for normal operation, but the system becomes complex and heavy with additional coolant loops and components
Solution Approach 1:
The patent combines the air intake system and cooling system into a single integrated structure. The air flow channel serves dual purposes: supplying air to the air compressor and simultaneously cooling the electric motor and power electronics through conductive heat transfer via the inner and outer tube walls, eliminating the need for separate coolant loops
Solution Approach 2:
The air flow channel structure performs multiple functions: it serves as the air intake passage for the compressor, provides conductive cooling for the electric motor, and provides conductive cooling for the power electronics housing, replacing multiple separate systems with a single multi-functional component
2Temperature
If electric motor is directly exposed to ambient air for cooling, then cooling efficiency is improved, but the motor becomes vulnerable to debris and particles
Solution Approach 1:
The inner and outer elongated tube members serve as intermediary cooling surfaces between the ambient air and the electric motor. Heat is conducted through the tube walls from the motor to the flowing air, providing effective cooling while the motor remains protected from direct exposure to debris and particles in the air stream
3Temperature
If cooling capacity is increased to handle braking energy dissipation, then overheating is prevented, but the cooling system requires more components and occupies more space
Solution Approach 1:
The cooling function is merged into the existing air intake structure for the compressor. The air flow channel, which already occupies necessary space for air supply, is designed with inner and outer tube surfaces that provide extensive cooling surface area without requiring additional separate cooling components or occupying extra vehicle space
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
The system provides enhanced cooling capacity and reduces the risk of overheating by using ambient air to cool the electric motor and power electronics, thereby improving the efficiency and reliability of auxiliary braking systems in electric vehicles.
Implementation Method 1
The system provides enhanced cooling capacity and reduces the risk of overheating by using ambient air to cool the electric motor and power electronics
Data Source
AI summary
An energy dissipation system for a vehicle, the energy dissipation system comprising an air compressor comprising a compressor inlet configured to receive ambient air, an electric motor comprising a rotor having a rotor shaft operatively connected to a compressor shaft of the air compressor, power electronics arranged in a power electronics housing, the power electronics being electrically connected to the electric motor and configured to feed electric power to the electric motor, and an air flow channel through which the ambient air is configured to be fed to the compressor inlet, the air flow channel being formed by an inner elongated tube member and an outer elongated tube member, wherein the electric motor is housed within the inner elongated tube member and attached to a first inner surface, and wherein the power electronics housing is attached to a second outer surface.