Electric Drive Connector Cooling via Integrated Coolant Distribution
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Solution Overview
Problem
Existing electric drive systems in automobiles struggle to efficiently cool electrical connectors, as most cooling systems cannot directly contact these components, leading to suboptimal cooling efficiency.
Innovation Solution
The electric drive system incorporates a cooling system with a coolant distribution assembly that includes specific holes and protrusions to directly supply coolant to electrical connectors, enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a dedicated cooling system with multiple spray pipes is provided to cool the electric motor, then the cooling capability is improved, but the device complexity increases and the structure becomes more complicated
Solution Approach 1:
The patent combines the cooling functions for the electric motor and electrical connectors into a single integrated cooling system. The housing serves as a common cooling structure with cooling channels that distribute coolant to multiple components, eliminating the need for separate cooling systems and reducing overall structural complexity while maintaining effective cooling capability.
Solution Approach 2:
The housing is designed to serve multiple functions: it provides structural support, contains cooling channels for coolant flow, and acts as a mounting structure for electrical connectors. This multi-functional design reduces the need for additional dedicated cooling components, thereby simplifying the overall device structure while maintaining cooling effectiveness.
2Temperature
If multiple spray pipes are arranged on the outer face of the stator to directly spray cooling oil, then the cooling efficiency is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent integrates the spray pipe functions directly into the housing structure. Instead of providing separate spray pipes for each component, the housing incorporates cooling channels that distribute coolant to both the electric motor and electrical connectors through a unified structure, reducing manufacturing complexity while maintaining direct cooling efficiency.
Solution Approach 2:
The housing itself serves as the cooling distribution structure, utilizing its own structure to provide cooling channels and spray pathways. This self-service approach eliminates the need for additional dedicated spray pipe components, simplifying manufacturing while maintaining the ability to directly cool critical components.
3Temperature
If the cooling system is designed to cool the electrical connector, then the cooling efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent merges the cooling of electrical connectors into the existing housing-based cooling system. The housing contains cooling channels that extend to and cool the electrical connectors, eliminating the need for separate dedicated cooling systems for connectors and reducing overall system complexity while achieving effective cooling.
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 design allows for direct cooling of electrical connectors, significantly improving cooling efficiency and maintaining a compact, integrated, and cost-effective system structure.
Implementation Method 1
coolant flows through the at least one first hole toward the first electrical connector... coolant flows through the at least one second hole toward the second electrical connector... directly cool the electrical connectors
Data Source
AI summary
An electric drive system includes a housing, which is internally provided with an electric motor, a controller and a transmission, wherein the electric motor includes a stator and a rotor. A first electrical connector, which is arranged in the housing and is located at an outlet terminal of the stator, is connected electrically to the controller, and a second electrical connector, which is arranged in the housing and is located at the outlet terminal of the stator is connected electrically to the stator. A cooling system includes a cooling channel arranged on the housing and a coolant distribution assembly connected to the cooling channel and having at least one first hole provided thereon. The first hole permits coolant flow through first hole toward the first electrical connector. At least one second hole permits coolant flow through the at least one second hole toward the second electrical connector.