Electric Device Cooling System with Bypass Valve Flow Control
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Solution Overview
Problem
Conventional cooling systems for electric vehicles and systems with batteries experience increased pressure loss and reduced circulating pump lifetime due to unnecessary cooling fluid flow to devices that do not require cooling, leading to higher operation loads and reduced efficiency.
Innovation Solution
A cooling system design that restricts refrigerant flow through a bypass channel when electric devices are in operation, forming a circulation channel that bypasses non-operational components, thereby reducing pressure loss and improving circulating pump efficiency and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cooling fluid flows through all devices in the first cooling fluid channel including the charger, then the cooling system can cool all components, but the operation load on the circulating pump increases and pressure loss increases
Solution Approach 1:
The cooling system is segmented into multiple channels: a first cooling fluid channel for devices requiring cooling during operation (motor, inverter), a second cooling fluid channel for the charger, and a bypass channel. The circulation pump is divided into a first pump for the first channel and a second pump for the second channel, allowing independent control of cooling fluid flow to different components based on their actual cooling needs.
Solution Approach 2:
The system dynamically adjusts the cooling fluid flow paths using valves (first valve and second valve) that switch between different channels based on operational conditions. When the motor and inverter are operating, the first valve directs cooling fluid through the first channel; when the charger is operating, the second valve directs cooling fluid through the second channel, optimizing the system's response to changing thermal requirements.
2Reliability
If the circulating pump operates at high load to cool all devices, then all components can be cooled, but the lifetime of the circulating pump is reduced
Solution Approach 1:
The cooling system is segmented into multiple channels: a first cooling fluid channel for devices requiring cooling during operation (motor, inverter), a second cooling fluid channel for the charger, and a bypass channel. The circulation pump is divided into a first pump for the first channel and a second pump for the second channel, allowing independent control of cooling fluid flow to different components based on their actual cooling needs.
Solution Approach 2:
The system applies partial cooling action by directing cooling fluid only to components that actually require cooling at any given time. The bypass channel allows cooling fluid to skip the charger when it is not operating, and the valve system ensures that only the necessary components receive cooling fluid flow, avoiding excessive pumping load and extending pump lifetime.
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 solution effectively reduces pressure loss and enhances the operational efficiency and lifespan of the circulating pump by selectively routing the refrigerant flow, minimizing unnecessary heat dissipation and pressure loss across non-operational components.
Implementation Method 1
The radiator 101 dissipates heat of a cooling fluid to outside to cool the cooling fluid
Implementation Method 2
The circulating pump 102 applies a pressure for causing the cooling fluid to flow, to the cooling fluid
Data Source
AI summary
The cooling system includes a heat exchanger, the circulating pump, a first refrigerant channel in which an electric device and the circulating pump are provided, a second refrigerant channel connected to the first refrigerant channel so as to form a circulation channel of the refrigerant, in which the heat exchanger is provided, a bypass channel connected to the first refrigerant channel in parallel to the second refrigerant channel, in which a charger is provided, and a valve provided at a position where the first refrigerant channel and the bypass channel are connected to each other, for forming a circulation channel of the refrigerant, the circulation channel including the first refrigerant channel and the second refrigerant channel, to restrict a flow of the refrigerant through the bypass channel when the electric device is in operation.