Distributed Inverter Cooling Layout for Multi-Cart Electric Vehicles
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Solution Overview
Problem
Conventional electric vehicle drive systems face challenges in efficiently cooling multiple inverters due to the proximity of coolers, leading to increased size and manufacturing costs, especially when space is limited, such as under the vehicle floor.
Innovation Solution
The system disperses control devices with their associated inverters and coolers near the front and rear of the vehicle, ensuring sufficient separation between windward and leeward coolers, reducing the size of each housing and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If two coolers are placed close to each other in series along the forward direction, then the windward cooler can efficiently cool the inverter, but the leeward cooler experiences reduced cooling efficiency due to air flow blockage and heat interference
Solution Approach 1:
The patent divides the cooling function into separate modular coolers, each capable of independent operation. By segmenting the cooling system, each cooler can be optimally positioned and sized without being constrained by the presence of another cooler, thus resolving the air flow interference issue between windward and leeward coolers.
Solution Approach 2:
The patent transitions from a one-dimensional linear arrangement of coolers to a two-dimensional or three-dimensional dispersed layout. Control devices are positioned at different locations including side surfaces and end surfaces of the vehicle body, allowing coolers to be arranged in multiple spatial dimensions to avoid air flow blockage and heat interference.
2Temperature
If high-performance coolers using heat pipes or large-sized coolers are applied to achieve sufficient cooling on the leeward side, then cooling performance improves, but the size and manufacturing cost of the control device increase
Solution Approach 1:
Instead of using a single large cooler or high-performance heat pipe cooler, the patent segments the cooling function across multiple standard-sized coolers distributed at different locations. This allows each cooler to be smaller and more cost-effective while collectively providing sufficient cooling coverage.
Solution Approach 2:
The patent uses multiple copies of standard cooler components rather than a single specialized high-performance cooler. By replicating simpler, more cost-effective cooler units at multiple locations, the system achieves the required cooling performance without the high cost and large size associated with advanced heat pipe technology.
3Volume of stationary object
If control devices are installed under the floor of the electric vehicle, then space utilization is improved, but the limited space under the floor restricts the size and configuration of the housing
Solution Approach 1:
The patent expands the installation space from the limited under-floor area to include side surfaces and end surfaces of the vehicle body. By utilizing three-dimensional space in multiple dimensions, the system accommodates control devices and coolers without being constrained by the limited under-floor volume, thereby maintaining housing configuration flexibility.
Solution Approach 2:
The patent divides the control devices into multiple smaller units that can be distributed across different locations (under floor, side surfaces, end surfaces). This segmentation allows each housing to be appropriately sized for its specific location, providing flexibility in configuration while effectively utilizing the total available space throughout the vehicle.
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 allows for efficient cooling of inverters while avoiding increases in device size and cost, enabling flexible placement within limited vehicle spaces.
Implementation Method 1
a cooler that cools the inverter using a relative air flow generated by traveling of the electric vehicle
Data Source
AI summary
An electric vehicle drive system includes a first control device that controls electric motors that drive axles of a first cart of an electric vehicle, and a second control device that controls electric motors that drive axles of a second cart. The control devices each include an inverter and a controller that controls the inverter. The first control device is housed in a first housing, and the second control device is housed in a second housing. Coolers that perform cooling using a relative air flow are attached to the housings, respectively. The control devices are dispersedly disposed near the first cart and near the second cart.