Electric Power Controller Cooling Jacket for Motorcycle
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Solution Overview
Problem
Saddle-type electric vehicles, such as sport-type electric motorcycles, face challenges in cooling their electric power controllers due to increased current demand and limited space, making it difficult to achieve efficient cooling without increasing weight or cost.
Innovation Solution
A compact cooling system is designed for the electric power controller, where a dedicated cooling jacket is positioned close to the power module's substrate, using lubricating oil as a coolant, and utilizing traveling wind for additional cooling, while maintaining a reduced size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling system is added to cool the electric power controller, then the cooling capability is improved, but the weight and size of the vehicle increase
Solution Approach 1:
The patent combines the cooling functions for the electric motor and electric power controller into a single integrated cooling system. The cooling jacket is configured to contact both the electric motor housing and the electric power controller housing, allowing one coolant circulation system to cool both heat-generating components simultaneously, thereby avoiding the need for separate cooling systems and reducing overall weight.
Solution Approach 2:
The cooling jacket serves multiple functions: it acts as both the cooling structure for the electric motor and the cooling structure for the electric power controller. By making the cooling jacket multi-functional, the patent eliminates redundant cooling components and reduces the total weight of the cooling system while maintaining adequate cooling capability for both components.
2Temperature
If a cooling system is added to cool the electric power controller, then the cooling capability is improved, but the size of the vehicle increases
Solution Approach 1:
The patent merges the cooling systems for the electric motor and electric power controller into a single integrated unit. The cooling jacket is designed to contact both the electric motor housing and the electric power controller housing, allowing one coolant circulation system to cool both components, thereby reducing the overall volume occupied by cooling systems.
Solution Approach 2:
The cooling jacket is positioned such that it is disposed between the electric motor housing and the electric power controller housing, effectively nesting the cooling function within the existing structural space. This arrangement allows the cooling system to utilize the space between existing components rather than adding external cooling structures, thereby minimizing the increase in vehicle size.
3Device complexity
If air-cooling is used for the electric power controller, then the device complexity is reduced, but the cooling capability is insufficient for high current applications
Solution Approach 1:
The patent employs liquid cooling through a cooling jacket that circulates coolant to remove heat from both the electric motor and the electric power controller. This hydraulic cooling approach provides superior cooling capability compared to air-cooling, enabling the system to handle high current applications while maintaining manageable complexity through the integrated design.
4Temperature
If a dedicated cooling system is provided for the electric power controller, then the cooling capability is improved, but the cost increases
Solution Approach 1:
The patent combines the cooling functions for the electric motor and electric power controller into a single integrated cooling system with one cooling jacket and one coolant circulation system. This merging eliminates the need for separate cooling systems, reducing the number of components, simplifying manufacturing processes, and lowering overall system cost while maintaining adequate cooling capability for both components.
Solution Approach 2:
The cooling jacket serves dual purposes by cooling both the electric motor and the electric power controller simultaneously. This multi-functionality reduces the total number of cooling components required, simplifies the manufacturing process, and lowers the overall cost of the cooling system while ensuring both components receive adequate cooling.
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 configuration ensures effective cooling of the electric power controller, reducing the size and weight of the cooling system, suppressing cost increases, and enhancing cooling capability while utilizing existing wind for additional cooling efficiency.
Implementation Method 1
a cooling jacket which is in contact with at least a portion of the substrate
Implementation Method 2
using lubricating oil as a coolant
Implementation Method 3
utilizing traveling wind for additional cooling
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
In a saddle-type electric vehicle (e.g., electric motorcycle 1) including a driving motor (30) and an electric power control unit (60) for controlling electric power supply to the motor (30), a substrate (61a) of a power module (61) to which a semiconductor element such as IGBT is mounted is accommodated into a case (62) of an electric power control unit (60) such that the substrate (61a) is positioned in close proximity to a wall portion of the case (62), and a cooling jacket is provided such that the coolant contacts the wall portion. A cooler (66) may be mounted such that it closes an opening (62b) provided in the case (62). A desired cooling capability is attained while reducing a size of the cooler (66) to a required size and an amount of the coolant to a required amount and suppressing a weight increase and a cost increase.