Electric Compressor Cooling Passage Design
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Solution Overview
Problem
Existing compressor systems for internal combustion engines face challenges in achieving high power output, efficiency, and emissions control, particularly with the integration of electric compressors, which often suffer from heat management and lubricant degradation issues.
Innovation Solution
The integration of a coolant passage within the electric compressor assembly, utilizing pins and bridges to enhance heat transfer and manage lubricant flow, combined with a housing design that includes specific materials like Ni-Resist cast iron for improved thermal stability and reduced mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an electric compressor assembly is used to increase power output and efficiency, then engine performance is improved, but heat management and lubricant degradation issues arise
Solution Approach 1:
A coolant passage is introduced as an intermediary element between the electric motor and the compressor wheel. The passage allows coolant to flow through and absorb heat generated by the electric motor, preventing excessive temperature buildup while maintaining the power transmission function. This mediator resolves the contradiction by providing a dedicated heat removal path without interfering with the mechanical power transfer.
Solution Approach 2:
The design changes the thermal parameters of the system by introducing active cooling through the coolant passage. By controlling coolant flow rate and temperature, the system can maintain optimal operating temperatures for both the electric motor and compressor, allowing sustained high power output without thermal degradation.
2Use of energy by moving object
If an electric compressor assembly is used to improve efficiency, then fuel economy is enhanced, but lubricant degradation occurs
Solution Approach 1:
The coolant passage acts as an intermediary that protects the lubricant from excessive heat exposure. By cooling the housing and internal components, the passage prevents lubricant from reaching degradation temperatures, thereby extending lubricant life and maintaining reliability while the system operates efficiently at improved fuel economy.
Solution Approach 2:
The cooling system provides beforehand protection against lubricant degradation by maintaining temperatures below degradation thresholds. This preventive approach ensures that even during high-efficiency operation, the lubricant remains within safe thermal limits, cushioning against potential degradation before it can occur.
3Stability of the object's composition
If housing material is changed to Ni-Resist cast iron for improved thermal stability, then temperature resistance is enhanced, but mass increases
Solution Approach 1:
Instead of making the entire housing from heavy Ni-Resist cast iron, the design applies this material selectively in areas requiring high thermal stability, such as regions near the electric motor and coolant passage. Other areas can use lighter materials, achieving the necessary thermal stability locally without unnecessarily increasing overall mass.
Solution Approach 2:
The housing design may utilize composite construction, combining Ni-Resist cast iron sections for thermal stability with lighter alloy sections for other structural requirements. This composite approach achieves the necessary thermal properties while minimizing overall mass compared to a complete Ni-Resist construction.
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 design enhances the performance and durability of electric compressors by improving heat dissipation and lubricant management, leading to increased efficiency and reduced wear, thus optimizing engine performance and emissions.
Implementation Method 1
a housing that includes a bore wall that seats the stator and an outer wall that includes a coolant inlet and a coolant outlet in fluid communication with a coolant passage defined by and at least in part between the bore wall and the outer wall
Implementation Method 2
at least one pin disposed at least in part in the coolant passage, substantially parallel to the axis, that diminishes flow area within the coolant passage to define multiple flow paths within the coolant passage
Data Source
AI summary
A compressor assembly (300) can include an electric motor (400) that includes a stator (420) and a rotor (440), where the stator defines an axis and where the rotor includes a shaft (460) substantially centered along the axis; a compressor wheel (500) coupled to the shaft; a back disk (600) disposed between the compressor wheel and the electric motor; a housing (700) that includes a bore wall (720) that seats the stator and an outer wall (740) that includes a coolant inlet (752) and a coolant outlet (754) in fluid communication with a coolant passage (760) defined by and at least in part between the bore wall and the outer wall; and at least one pin (810) disposed at least in part in the coolant passage, substantially parallel to the axis, that diminishes flow area within the coolant passage to define multiple flow paths within the coolant passage.