Electric Drive Module Cooling Valve for Lower Pump Power
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Solution Overview
Problem
Conventional thermal management systems in battery electric vehicles (BEVs) continuously operate to provide coolant to electric drive modules (EDMs), leading to unnecessary power consumption.
Innovation Solution
A thermal management system for EDMs that includes a fluid circuit with a pump and a valve, where the pump operates at a low flow rate to minimize power consumption when cooling is not required and switches to a higher flow rate when cooling is needed, with the valve selectively opening to supply coolant to the stator only when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the thermal management system continuously operates to provide constant coolant flow to the EDM, then the stator is adequately cooled, but power consumption increases unnecessarily
Solution Approach 1:
The system dynamically adjusts pump operation based on real-time thermal conditions. The controller monitors stator temperature and motor load, operating the pump only when cooling is required rather than maintaining continuous operation, thereby adapting the cooling system's behavior to actual thermal demands
Solution Approach 2:
The system changes the operational parameters of the pump based on thermal conditions. When the stator temperature exceeds a threshold or motor load is high, the pump operates at a higher flow rate; otherwise, it operates at a lower flow rate or remains off, optimizing the balance between cooling effectiveness and energy consumption
2Temperature
If the pump operates at a higher flow rate to ensure adequate cooling, then thermal management is improved, but power consumption increases
Solution Approach 1:
The system applies partial cooling action only when necessary. Instead of maintaining full cooling capacity continuously, the pump operates at reduced flow rates or remains off when thermal conditions are within acceptable ranges, providing just enough cooling to maintain safe operating temperatures while minimizing energy consumption
3Use of energy by moving object
If the valve remains closed to minimize coolant flow, then power consumption is reduced, but cooling capability is compromised when needed
Solution Approach 1:
The system uses feedback from temperature sensors and load monitoring to control the valve and pump operation. When the stator temperature exceeds a predetermined threshold or motor load is high, the controller opens the valve and activates the pump to provide cooling; when conditions are normal, the valve remains closed and the pump operates at minimal consumption, ensuring cooling reliability is maintained only when actually needed
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 approach reduces overall power consumption and minimizes unnecessary coolant supply, optimizing thermal management while conserving energy.
Implementation Method 1
a fluid circuit configured to supply a fluid to the gearbox assembly, the rotor, and the stator
Implementation Method 2
supply fluid to the stator for cooling thereof
Data Source
AI summary
An electric drive module (EDM) configured to generate and transfer drive torque to a driveline for propulsion of an electric vehicle. The EDM includes a gearbox assembly, an electric motor having a rotor and a stator, and a thermal management system. The thermal management system includes a fluid circuit configured to supply a fluid to the gearbox assembly, the rotor, and the stator, and a pump configured to direct the fluid through the fluid circuit. A valve is disposed on the fluid circuit and configured to selectively move between (i) a closed position where the fluid is not supplied to the stator, and (ii) an open position where the fluid is supplied to the stator for cooling thereof.