Plug-in Connection Element for a Cooler of a High-Voltage Accumulator
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Solution Overview
Problem
The existing connection methods for cooler elements in high-voltage accumulators require a high structural spatial requirement, result in additional costs, and are prone to assembly errors and leaks due to the use of multiple pipe pieces and complex sealing locations, making disassembly difficult for leak testing.
Innovation Solution
A connection element with congruent interface contours for the coolant guide, allowing multiple identical elements to be inserted and sealed without additional pipe pieces, enabling a more compact and simpler assembly with reduced error potential, using a design where one interface is male and the other female, with circumferential seals for reliable sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If opening with a mandrel is used to assemble pipe pieces and connection elements, then a common rail can be formed, but the structural spatial requirement increases axially
Solution Approach 1:
The connection element merges the functions of multiple separate components (pipe pieces and connection elements) into a single integrated component. The coolant guide is formed directly as part of the connection element body, eliminating the need for separate pipe pieces and reducing the axial length required for assembly.
2Ease of manufacture
If opening with a mandrel is used with alternately arranged pipe pieces and connection elements, then a common rail can be assembled, but the number of sealing locations increases
Solution Approach 1:
By integrating the coolant guide directly into the connection element, the number of separate sealing locations is reduced. The single integrated structure eliminates multiple interface points where sealing could fail, thereby improving reliability.
3Ease of manufacture
If multiple separate pipe pieces and connection elements are used, then a common rail can be formed, but the number of assembly errors and leakages increases
Solution Approach 1:
The integration of the coolant guide into the connection element reduces the total number of components and assembly steps. Fewer components mean fewer potential assembly errors and fewer possible leakage points, directly improving system reliability.
4Ease of manufacture
If opening with a mandrel is used with multiple separate components, then a common rail can be assembled, but disassembly for leak testing becomes difficult
Solution Approach 1:
The connection element is designed as a modular component that can be easily separated from the heat exchange element. This segmentation allows for simple disassembly and reassembly, facilitating leak testing and maintenance without requiring complex disassembly procedures.
5Reliability
If a large number of connection elements are required for cooler elements, then cooling coverage is improved, but the complexity of assembly increases
Solution Approach 1:
The connection element is designed as a universal component that can be used in multiple positions and configurations within the cooler assembly. The congruent interface contours allow identical elements to be assembled in series, reducing the variety of unique components needed and simplifying the overall assembly process while maintaining adequate cooling coverage.
Data Source
AI summary
The present subject matter relates to a connection element for a cooler of a high-voltage accumulator. A coolant supply system extends between a supply interface and a discharge interface. A connection interface connects a heat exchange element of the cooler to the coolant supply system. The supply interface and the discharge interface have congruent interface contours. A cooler element and a cooler for a high-voltage accumulator are also provided.