Cooling Module Air Guide to Reduce Bypass in Fuel Cell Trucks
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Solution Overview
Problem
The cooling performance of fuel cell stacks in hydrogen electric trucks is compromised due to air bypassing and re-circulation, leading to increased air flow resistance and reduced efficiency, especially with high-output stacks, where insufficient space and complex hydraulic components hinder optimal air flow and cooling performance.
Innovation Solution
An air guide system comprising first and second guide members is installed between the radiator grille and cooling module to optimize air flow, minimizing bypass and re-introduction, and using a motor-driven fan to replace hydraulic components, improving air flow resistance and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional cooling system with hydraulic components is used in high-output fuel cell stacks, then cooling capacity is increased, but air flow resistance increases and cooling performance deteriorates
Solution Approach 1:
The patent removes complex hydraulic components (oil tank, hoses, cooler) from the cooling system and replaces them with a simplified electric water pump system. This extraction of unnecessary components eliminates the air flow resistance problems caused by hydraulic parts while maintaining adequate cooling capacity through optimized pump control and radiator design.
Solution Approach 2:
The patent replaces the hydraulic mechanical system with an electrically-controlled water pump system. The electric water pump provides more precise flow control and eliminates the air flow resistance issues associated with hydraulic components, while the motor-driven cooling fan replaces hydraulic fan drives to further reduce air flow resistance.
2Power
If the number of cooling modules is increased to meet high cooling demands, then cooling performance is improved, but available space is insufficient
Solution Approach 1:
The patent combines multiple cooling functions into a single integrated cooling module. By merging the water pump, radiator, and cooling fan into one compact unit with optimized internal air flow paths, the system achieves high cooling performance while minimizing the space required, thus resolving the contradiction between cooling capacity and available space.
Solution Approach 2:
The patent optimizes the three-dimensional arrangement of components within the cooling module, utilizing vertical space and optimizing flow paths to maximize cooling efficiency within a compact footprint. The radiator is designed with optimized fin arrangements and the air flow paths are configured to utilize available space more effectively, achieving high cooling performance without increasing overall volume.
3Ease of manufacture
If air flow paths are simplified to reduce complexity, then manufacturing ease is improved, but air bypass and re-circulation increase
Solution Approach 1:
The patent introduces air guides as intermediary components that direct air flow between the radiator grille and cooling module. These air guides ensure that air flows through the intended path without bypassing or re-circulating, while maintaining a relatively simple overall system structure that is easy to manufacture. The air guides are strategically positioned to control flow without adding significant complexity.
4Object-affected harmful factors
If motor-driven fans are used to replace hydraulic components, then air flow resistance is reduced, but device complexity changes
Solution Approach 1:
The patent replaces hydraulic fan drives with electrically-controlled cooling fans, eliminating the need for hydraulic motors, oil lines, and associated components. This substitution reduces air flow resistance by removing hydraulic components from the air path while consolidating control systems, ultimately simplifying the overall device complexity despite the initial change in system configuration.
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 air guide system enhances cooling performance by maximizing fresh air inflow and minimizing air flow resistance, eliminating the need for additional radiators and hydraulic components, thus improving stack outlet temperature and overall cooling efficiency.
Implementation Method 1
an air guide disposed in a space between a radiator grille and a cooling module in a front end portion of a vehicle body to guide air introduced through the radiator grille to flow to a radiator of the cooling module
Implementation Method 2
a radiator for cooling a fuel cell stack, which radiates heat from the coolant cooling the fuel cell stack
Implementation Method 3
together with a cooling fan... the radiator for cooling the fuel cell stack and components of the cooling system in the plurality of PMCs are connected to each other via a coolant line (pipe) so that the coolant may be circulated
Data Source
AI summary
An embodiment vehicle includes a vehicle body and an air guide disposed in a space between a radiator grille and a cooling module in a front end portion of the vehicle body, the air guide being configured to guide air introduced through the radiator grille to flow to a radiator of the cooling module, wherein the air guide includes a first guide member fixed to a grille side structure of a front surface portion of the vehicle in which the radiator grille is positioned in the front end portion of the vehicle body and a second guide member installed in a cooling module side structure and spaced apart from the first guide member at an interval.