Cooling Pack Assembly Layout for Low-Noise EV Thermal Management
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Solution Overview
Problem
Vehicle cooling systems face challenges in reducing noise and vibration, particularly in battery-electric vehicles where space is limited and traditional configurations do not effectively improve acoustic performance.
Innovation Solution
A cooling pack assembly is designed with a shroud that supports a fan, a first heat exchanger, and a second heat exchanger, where the fan is positioned between the two heat exchangers, and the heat exchangers have distinct cross-sectional areas, allowing for optimal placement and reduced noise through strategic alignment and offsetting of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional cooling system configurations are used in battery-electric vehicles, then space utilization is poor, but noise and vibration reduction is insufficient
Solution Approach 1:
The cooling system employs a nested arrangement where the first heat exchanger and second heat exchanger are positioned in front of and behind the fan assembly respectively, with both heat exchangers offset from the rotational axis. This nesting configuration allows multiple cooling components to occupy overlapping spatial volumes, achieving effective noise and vibration reduction through strategic component placement while maintaining compact overall dimensions suitable for battery-electric vehicle constraints.
2Productivity
If heat exchangers are positioned close to the fan, then cooling efficiency improves, but noise and vibration increase
Solution Approach 1:
The cooling system utilizes asymmetric positioning of the first heat exchanger and second heat exchanger relative to the fan assembly's rotational axis. The heat exchangers are offset from the axis by different distances, creating an asymmetric configuration that optimizes the balance between cooling efficiency and noise/vibration reduction. This asymmetric arrangement allows heat exchangers to be positioned close enough to the fan for effective heat transfer while maintaining sufficient distance and strategic offset to minimize noise and vibration generation.
3Productivity
If multiple heat exchangers are arranged in series, then cooling performance improves, but space requirements increase
Solution Approach 1:
The cooling system transitions from a traditional linear series arrangement to a multi-dimensional configuration where the first heat exchanger and second heat exchanger are positioned in front of and behind the fan assembly along the rotational axis direction. Both heat exchangers are offset from the rotational axis, creating a three-dimensional arrangement that allows multiple heat exchangers to operate in series for enhanced cooling performance while occupying a more compact spatial footprint suitable for battery-electric vehicle applications.
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 noise and vibration by optimizing the arrangement of heat exchangers and fans, improving acoustic performance and space utilization within the vehicle cooling system.
Implementation Method 1
a fan assembly configured to provide convection cooling of the heat exchangers
Implementation Method 2
The cooling systems may include a plurality of heat exchangers and a fan assembly configured to provide convection cooling of the heat exchangers
Data Source
AI summary
The cooling pack assembly includes, a shroud, a fan, a first heat exchanger, and a second heat exchanger. The shroud has a plurality of sidewalls including a main sidewall. The shroud further defines an aperture. The fan is disposed within the aperture. The fan is configured to rotate about a rotational axis. The rotational axis is normal to a plane defined by the main sidewall. The first heat exchanger is disposed on at least one of the plurality of sidewalls. The first heat exchanger has a first cross-sectional area substantially parallel to the plane. The second heat exchanger is disposed on at least one the plurality of sidewalls. The second heat exchanger has a second cross-sectional area substantially parallel to the plane. The second cross-sectional area is less than the first cross-sectional area, and the first heat exchanger is disposed between the fan and the second heat exchanger.