Equalizing Tank Inlet Line Geometry for Air Entrainment Prevention
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Solution Overview
Problem
Existing cooling circuits in electric vehicles face challenges in preventing air inclusion due to pressure differences caused by varying flow rates, leading to costly deaeration valves and additional electrical components for control.
Innovation Solution
An equalizing tank design where the inlet line is configured as a separate structural unit from the tank top piece, with an outlet opening at the tank bottom piece, allowing for adjustable flow rates and preventing air entrainment by ensuring the outlet is always below the coolant level, eliminating the need for costly venting valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deaeration valves are used to prevent air inclusions in the cooling circuit, then air entrainment is prevented, but the system becomes costly and requires additional electrical components for control
Solution Approach 1:
The harmful element (deaeration valve and its control system) is extracted and replaced by a passive geometric solution. The inlet line is repositioned to extend below the minimum coolant level, eliminating the need for active air removal mechanisms while maintaining reliable operation.
Solution Approach 2:
The cooling circuit becomes self-regulating through proper inlet line positioning. The geometry of the inlet line below the minimum coolant level automatically prevents air entrainment through flow dynamics, without requiring external control systems or additional components.
2Ease of manufacture
If the inlet line is integrated into the tank top piece, then the structure is simplified, but the flow rate cannot be adapted to match the outlet line, causing air entrainment
Solution Approach 1:
The inlet line is segmented from the tank top piece into a separate, adjustable component. This allows the inlet line to be independently dimensioned and positioned to match the outlet line's flow characteristics, preventing air entrainment while maintaining manufacturing simplicity through modular assembly.
3Ease of operation
If the inlet line outlet opening is positioned above the minimum coolant level, then installation is easier, but air is entrained into the cooling circuit
Solution Approach 1:
The inlet line is pre-positioned below the minimum coolant level during design and installation. This preliminary positioning ensures that under all operating conditions, the inlet line remains submerged in coolant, preventing air entrainment before it can occur during system operation.
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 prevents air from entering the cooling circuit, reduces production and fabrication costs, and allows for adaptable configurations to different motor models using a single tank top piece with model-specific inlet lines, enhancing the efficiency and cost-effectiveness of the cooling system.
Implementation Method 1
the outlet opening of the inlet line for the coolant is situated in the region of the tank bottom piece, so that this is situated always below the minimum level of coolant inside the equalizing tank, in order to prevent in this way an additional entrainment of gas, especially air, in the coolant
Implementation Method 2
Thanks to the separate configuration of the inlet line from the tank top piece, it is consequently possible to very easily regulate the flow rate of coolant in the area of the inlet line and to adapt it by suitable dimensioning, in particular, to the passage of coolant in the area of the outlet line such that the flow rates may be adapted to each other
Data Source
AI summary
An equalizing tank for a cooling circuit of a motor of a motor vehicle has a tank top piece, on which an inlet line for a coolant is arranged, and a tank bottom piece, on which an outlet line for the coolant is arranged. The inlet line for the coolant is configured as a separate structural unit from the tank top piece, having an outlet opening situated in the region of the tank bottom piece.