Multi-Fan ECU Assembly With Plenum Cooling in Limited Housing Space
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Solution Overview
Problem
The challenge of integrating multiple electronic control units (ECUs) into a vehicle's limited space while ensuring each ECU receives adequate cooling air for temperature regulation, as conventional assemblies often require increased housing size to accommodate additional ECUs.
Innovation Solution
A multi-ECU assembly design that includes a housing with compartments separated by a plenum, where ECUs are arranged side by side, with air ducts guiding cooling air through the plenum to each ECU, allowing for temperature monitoring and fan activation to regulate internal temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple ECUs are added to the assembly, then the computing capability and vehicle control functions are improved, but the housing size and space requirements increase
Solution Approach 1:
The housing is divided into multiple compartments, with each compartment capable of housing one or more ECUs. The plenum is segmented into multiple plenum compartments, each serving specific ECUs. This segmentation allows multiple ECUs to be accommodated in an organized manner within the same housing volume, improving computing capability without proportionally increasing housing size.
Solution Approach 2:
The plenum compartments are nested within the housing structure, and air ducts are nested within the plenum compartments. This nested arrangement allows the cooling system components to be integrated within the existing housing volume, accommodating multiple ECUs without requiring additional external space.
2Volume of stationary object
If multiple ECUs are positioned in the same compartment, then the space utilization is improved, but the airflow distribution and cooling effectiveness deteriorate
Solution Approach 1:
The plenum is divided into multiple plenum compartments, with each compartment serving one or more ECUs. This segmentation ensures that cooling air is distributed to each ECU through dedicated air ducts, maintaining effective cooling even when multiple ECUs are positioned in the same housing compartment.
Solution Approach 2:
The plenum compartments act as intermediaries between the air ducts and the ECUs. Each plenum compartment receives cooling air through dedicated air ducts and distributes it to the ECUs within its compartment, ensuring proper airflow distribution and cooling effectiveness for multiple ECUs.
3Adaptability or versatility
If the housing size is increased to accommodate additional ECUs, then the ECU capacity is improved, but the vehicle space constraints are violated
Solution Approach 1:
The housing is segmented into multiple compartments that can accommodate ECUs in a space-efficient arrangement. The plenum is also segmented into multiple compartments, allowing for optimized space utilization. This segmentation enables the housing to accommodate multiple ECUs without requiring a proportional increase in overall housing dimensions.
Solution Approach 2:
The compartments and plenum compartments are arranged in a three-dimensional configuration within the housing. This multi-dimensional arrangement allows maximum ECU capacity within the constrained housing volume, accommodating additional ECUs without increasing the external housing dimensions.
4Temperature
If air ducts are added to provide cooling air to each ECU, then the cooling coverage is improved, but the device complexity increases
Solution Approach 1:
The air duct system is segmented into multiple air ducts, with each duct serving one or more specific ECUs. This segmentation allows for targeted cooling delivery to each ECU while maintaining a manageable level of complexity through modular configuration.
Solution Approach 2:
The plenum compartments serve multiple functions: they act as air distribution chambers, structural dividers between ECUs, and pathways for air duct routing. This multi-functionality reduces the need for separate dedicated components, thereby managing device complexity while providing comprehensive cooling coverage.
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 effectively cools multiple ECUs within a compact housing, minimizing space requirements and maintaining ECU functionality by ensuring each unit receives cooling air without increasing the assembly's size.
Implementation Method 1
The assembly can include a fan unit comprising a fan motor and fan blades. The fan unit can be arranged to face the first ECU and the second ECU. The fan motor can be arranged to rotate the fan blades, thereby moving air from outside the housing and through the inlet of the first ECU and through the inlet of the second ECU.
Data Source
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AI summary
An assembly is described. An assembly can include a housing comprising a first compartment and a plurality of vents letting air flow into and out. The assembly can further include a first ECU positioned within the first compartment, the first ECU comprising a first inlet letting air flow into the first ECU. The assembly can further include a second ECU positioned within the first compartment, the second ECU comprising a second inlet letting air flow into the second ECU. The assembly can further include a first plenum positioned between the first ECU and the second ECU and comprising a second compartment. The assembly can further include a first air duct forming a first channel letting air from a first vent of the plurality of vents into the second compartment, wherein the first plenum further comprises a second vent positioned to align with the first inlet of the first ECU.