Dual-Motor Vehicle Power Converter With Integrated Liquid Cooling
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Solution Overview
Problem
Existing vehicle systems with high-nominal power electric motors require effective and efficient liquid cooling systems to prevent overheating of electronic power components, while also being compact and cost-effective.
Innovation Solution
A vehicle design featuring two electric motors with a liquid cooling system that utilizes a compact, efficient cooling liquid flow configuration, where each electronic power converter is housed in a cup-shaped container with a chamber for cooling liquid flow, ensuring effective temperature management and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a liquid cooling system is provided for high-nominal power electric motors, then the electronic power components are prevented from overheating, but the system complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the cooling liquid flow chamber with the housing structure of the electronic power converter. The housing itself forms the cooling chamber, eliminating the need for separate cooling system components. This integration reduces device complexity while maintaining effective cooling of the electronic power components.
Solution Approach 2:
The housing structure serves dual functions: it provides mechanical protection for the electronic power components and simultaneously acts as the cooling liquid flow chamber. This multi-functionality reduces the number of separate components needed, simplifying the overall system while ensuring proper temperature management.
2Temperature
If a liquid cooling system is provided for high-nominal power electric motors, then the electronic power components are prevented from overheating, but the manufacturing cost increases
Solution Approach 1:
By integrating the cooling chamber into the housing structure, the patent reduces the total number of parts that need to be manufactured and assembled. This consolidation simplifies the manufacturing process and reduces production costs while still providing effective cooling for the electronic power components.
Solution Approach 2:
The housing structure performs multiple functions simultaneously - mechanical protection and thermal management. This multi-functionality eliminates the need for separate cooling system components, reducing manufacturing complexity and cost while ensuring proper temperature control of the electronic power components.
3Volume of moving object
If a compact cooling system is designed, then the vehicle space is optimized, but the cooling effectiveness may be compromised
Solution Approach 1:
The patent combines the cooling liquid flow chamber with the housing structure, creating a compact integrated unit. This integration eliminates the need for separate cooling system components, significantly reducing the overall volume occupied by the cooling system while maintaining effective thermal management through direct contact between the cooling liquid and electronic power components.
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 system effectively maintains optimal working temperatures for electronic power components, uses a minimal cooling liquid flow rate, and achieves a compact and cost-efficient design.
Implementation Method 1
a liquid cooling system, which is effective, efficient and compact
Implementation Method 2
the cooling system uses a reduced cooling liquid flow rate
Data Source
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AI summary
A vehicle (1) having: two front wheels (2); two rear wheels (2); two electric motors (4), which are connected to the two wheels (2) of a same axle; and an electronic power converter (6) to control both electric motors (4). The electronic power converter (6) has: two groups (11) of power modules (10); at least one capacitor (12), which is connected in parallel to a DC input; a container (9), which houses the two groups (11) of power modules (10) and the capacitor (12) and is provided with a cup-shaped body (13) provided with a lower wall (18); and a cooling system (14) provided with a chamber (15), which is configured to be flown through by a cooling liquid. The chamber (15) of the cooling system (14) is delimited, on one side, by the lower wall (18) of the cup-shaped body (13) of the container (9) and, on the other side, by a containing wall (19), which is arranged at a given distance from the lower wall (18).