Vehicle Drive Module Cooling Layout for Lower Energy Loss
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Solution Overview
Problem
Electric and hybrid vehicles face challenges in effectively cooling electric machines, inverters, and gearboxes, leading to inefficiencies and increased energy consumption due to conventional cooling methods.
Innovation Solution
A thermal system utilizing an external water-ethylene glycol coolant and internal oil coolant, with a variable capacity oil pump and solenoid-controlled valve, to efficiently cool and lubricate electric machines and gearboxes, reducing energy consumption and eliminating the need for external heat exchangers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional cooling methods are used for electric machines, inverters, and gearboxes, then the components can be cooled, but the energy consumption increases and thermal efficiency decreases
Solution Approach 1:
The patent combines the cooling functions for the electric machine, inverter, and gearbox into a single integrated thermal system. The housing members are thermally coupled to multiple components, and a single liquid coolant circulates through all heat exchange surfaces, merging previously separate cooling systems into one unified system that reduces energy consumption and improves thermal efficiency.
Solution Approach 2:
The liquid coolant system serves multiple functions simultaneously: it cools the electric machine through heat exchange surfaces, cools the inverter through thermally coupled housing members, and cools the gearbox through integrated heat exchange surfaces. This multi-functional approach eliminates the need for separate cooling systems for each component.
2Reliability
If separate cooling systems are used for each component, then each component can be cooled independently, but the device complexity increases
Solution Approach 1:
The patent integrates multiple cooling functions into a single unified system where housing members are thermally coupled to the electric machine, inverter, and gearbox. The liquid coolant circulates through all components via a single circulation path, reducing the number of separate cooling systems while maintaining effective cooling for each component.
3Temperature
If external heat exchangers are used for cooling, then heat exchange efficiency can be improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent nests the heat exchange surfaces within the existing housing structure of the electric machine, inverter, and gearbox. The heat exchange surfaces are integrated into the housing members rather than being separate external components, allowing the cooling system to be embedded within the existing mechanical structure and eliminating the need for external heat exchangers.
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 solution enhances thermal efficiency, reduces energy requirements, and extends the electrically powered range of vehicles by optimizing cooling and lubrication processes within the drive module.
Implementation Method 1
a first housing member 50 thermally coupled with the inverter and having a first set of heat exchange surfaces 52, a second housing member 40 thermally coupled with the electric machine and having a second set of heat exchange surfaces 42
Implementation Method 2
a liquid coolant introduced into the interior volume removes heat from both the first and second set of heat exchange surfaces
Implementation Method 3
an oil pump, the oil pump circulating an oil to cool the electric machine
Implementation Method 4
the oil collects in a gravity fed, lower oil sump wherein it supplies the oil pump
Implementation Method 5
a third housing member defining a wall of the lower oil sump and being thermally coupled with the oil collected in the oil sump, the third housing member 55 further including a third set of heat exchange surfaces 56 projecting into the interior space in which the liquid coolant is circulated
Implementation Method 6
the oil collects in a gravity fed, lower oil sump wherein it supplies the oil pump
Data Source
AI summary
A drive module for a vehicle including an electric machine, an inverter, a gearing assembly, and a cooling system. A first housing member thermally coupled with the inverter has a first set of heat exchange surfaces and a second housing member thermally coupled with the electric machine has a second set of heat exchange surfaces. The first and second sets of heat exchange surfaces each project into an interior volume cooled by an externally supplied liquid coolant which thereby defines a heat exchanger. A lower oil sump for collecting oil used to cool the electric machine may also include heat exchange surfaces projecting into the same heat exchanger. The gearbox may include an elevated oil sump which is supplied by the same oil pump circulating oil on the electric machine wherein the elevated oil sump gravity feeds oil onto selected surfaces within the gearbox.