Dual Loop Liquid Cooling for Electric Drivetrain Heat Management
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Solution Overview
Problem
Existing electric drivetrain systems in vehicles face challenges in cooling high-power components due to limitations of single coolant types, such as water or oil, which can lead to overheating, corrosion, and inadequate heat removal, especially in compact and integrated designs.
Innovation Solution
A dual loop cooling system using both ethylene glycol and water (EGW) and oil based coolants, with separate loops and a heat exchanger to transfer heat from the oil coolant loop to the EGW coolant loop, allowing for effective heat dissipation through a vehicle cooling system and radiator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single coolant type (water or oil) is used in the cooling system, then the system structure is simple, but the cooling effectiveness is insufficient and corrosion may occur
Solution Approach 1:
The cooling system is divided into two separate loops: an oil-based coolant loop for cooling motor and inverter components, and a water-based coolant loop for cooling the radiator and heat exchanger. This segmentation allows each coolant type to be optimized for its specific function, improving overall cooling effectiveness while managing system complexity through modular design
Solution Approach 2:
A heat exchanger is introduced as an intermediary component that transfers heat from the oil-based coolant loop to the water-based coolant loop. This mediator enables the two different coolant systems to work together efficiently, allowing the oil coolant to cool high-temperature components while the water coolant handles heat dissipation at the radiator
2Power
If high-power components are used in the drivetrain system, then the power output is increased, but heat generation increases leading to overheating risks
Solution Approach 1:
The cooling system is designed to proactively remove heat from high-power components before overheating occurs. The oil-based coolant circulates through the motor and inverter, absorbing heat at the source, while the water-based coolant system prepares to transfer this heat to the radiator for dissipation, preventing temperature buildup that would compromise component performance or safety
3Volume of moving object
If compact and integrated drivetrain designs are used, then the vehicle space efficiency is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The cooling system employs a nested configuration where the oil-based coolant loop is integrated within the compact drivetrain to cool motor and inverter components directly, while the water-based coolant loop is nested around this inner loop, with the heat exchanger transferring heat from the inner oil loop to the outer water loop, which then dissipates heat through the radiator. This nested arrangement maximizes heat dissipation efficiency within the constrained space of a compact drivetrain
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 dual loop cooling system enhances the cooling effectiveness of electric drivetrain components by mitigating the limitations of single coolant types, ensuring efficient heat removal and maintaining component temperatures within operational ranges, thereby preventing overheating and corrosion.
Implementation Method 1
A heat exchanger to remove heat from the oil coolant loop to the EGW coolant loop, away from the electric drivetrain
Implementation Method 2
The radiator can transfer heat to an exterior of the electric vehicle via ambient cooling
Data Source
AI summary
Provided herein are systems and methods for cooling an electric drivetrain of an electric vehicle. The electric drivetrain can include an inverter, a gearbox and a motor. A first cooling system can use ethylene glycol and water (EGW) based coolant, and can include an EGW coolant loop to distribute the EGW based coolant to remove heat from a cold plate of the inverter, a housing of the gearbox, and a housing of the motor. A second cooling system can use an oil based coolant, and can include an oil coolant loop to distribute the oil based coolant to remove heat from internal components and the housing of the gearbox, and to remove heat from internal components and the housing of the motor. The second cooling system can include an oil coolant pump to control a flow of the oil based coolant through the oil coolant loop.