E-Charger Dual Cooling Circuit Layout for Compact Thermal Control
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Solution Overview
Problem
Conventional cooling systems for e-chargers face challenges in providing effective cooling, particularly due to space constraints and limited cooling circuit design, which affects operating efficiency and manufacturability.
Innovation Solution
A compact e-charger cooling system with a dual cooling circuit design, where a bearing cooling circuit and a motor cooling circuit are connected in-series via a manifold passage, allowing for efficient coolant distribution and tailored coolant flow to specific areas of the motor assembly, enhancing cooling performance and manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional cooling system is used for the e-charger, then the structure is simple, but the cooling effect is insufficient and operating efficiency deteriorates
Solution Approach 1:
The cooling system is segmented into multiple independent cooling circuits: a first cooling circuit for the motor assembly and a second cooling circuit for the bearing assembly. Each circuit has its own coolant flow path, allowing targeted cooling of different components with optimized coolant distribution, thereby improving overall cooling effectiveness without excessive complexity.
Solution Approach 2:
Different regions of the e-charger receive customized cooling based on their specific thermal requirements. The motor assembly and bearing assembly are cooled through separate circuits with tailored coolant flow rates and paths, ensuring that each component receives appropriate cooling quality rather than a uniform cooling approach.
2Temperature
If the cooling circuit is extended to improve cooling coverage, then the cooling effect improves, but space constraints are violated
Solution Approach 1:
The cooling circuits are nested within the existing structural spaces of the e-charger housing. The coolant flow passages are integrated into the housing structure itself, utilizing available void spaces and structural features rather than adding external cooling components, thereby achieving extended cooling coverage without increasing overall device volume.
3Temperature
If multiple cooling circuits are added to improve cooling performance, then the cooling effect improves, but manufacturing complexity increases
Solution Approach 1:
Multiple cooling circuits are merged into a single integrated housing structure. The housing serves as a common platform that contains and routes multiple coolant flow paths, reducing the number of separate manufactured components. This integration simplifies assembly and manufacturing while maintaining the benefits of multiple targeted cooling circuits.
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 dual cooling circuit design improves cooling efficiency, maintains high operating performance across various conditions, and simplifies manufacturing due to its compact and modular layout, reducing pressure loss and interface complexity.
Implementation Method 1
The manifold passage is configured to distribute a flow of the coolant between the first motor cooling circuit and the second motor cooling circuit
Implementation Method 2
a cooling system may be provided that directs flow of a coolant through the device to maintain operating temperatures within a predetermined range
Implementation Method 3
The electric motor may be cooled, for example, to improve operating efficiency of the motor
Data Source
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AI summary
An e-charger includes an outer housing and a rotor supported for rotation within the outer housing. A motor assembly is housed within the outer housing and includes an electric motor and a motor case. The electric motor is encased within the motor case. The electric motor is configured to drivingly rotate the rotor within the outer housing. Furthermore, the e-charger includes a cooling system configured to receive a coolant. The cooling system includes a manifold passage defined in the outer housing. The cooling system includes a first motor cooling circuit and a second motor cooling circuit that are cooperatively defined by the outer housing and the motor case. The first motor cooling circuit and the second motor cooling circuit are fluidly connected to the manifold passage. The manifold passage is configured to distribute a flow of the coolant between the first motor cooling circuit and the second motor cooling circuit.