Electric Drive Vehicle Cooling System Bubble Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing cooling systems for electric drive vehicles experience reduced cooling performance due to bubbles in the coolant circuit, which can lead to increased flow resistance and inefficient pump operation, as bubbles are not effectively delivered to the degas tank, causing them to remain in the circuit.
Innovation Solution
A cooling system design where the coolant circuit connects the electric motor, electrical equipment, pump, and degas tank in series, with the degas tank positioned at an upper stage, ensuring bubbles are collected and separated, allowing the coolant to flow freely and maintaining high pump efficiency regardless of pump placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the coolant circuit is arranged in parallel with multiple circuits, then the coolant flow path is increased and cooling coverage is improved, but bubbles accumulate in the circuits and cooling performance deteriorates
Solution Approach 1:
The coolant circuit is divided into multiple independent circuits (first coolant circuit and second coolant circuit) that operate in parallel. Each circuit has its own pump and coolant flow path, allowing bubbles to be contained in one circuit while the other maintains effective cooling. This segmentation prevents bubble accumulation from affecting the entire cooling system.
Solution Approach 2:
Bubbles are extracted and removed from the coolant through the reservoir tank connected to each circuit. Thedegasfunction separates bubbles from the coolant, preventing their accumulation and maintaining cooling performance in the affected circuit.
2Productivity
If the pump is arranged immediately downstream of the reservoir tank, then pump efficiency is maintained by preventing bubble suction, but the system layout flexibility is reduced
Solution Approach 1:
The system is segmented into independent circuits where each pump is positioned according to spatial requirements rather than a fixed rule. The first pump and second pump can be located at different positions relative to their respective reservoir tanks, providing layout flexibility while maintaining efficiency through proper circuit design.
Solution Approach 2:
The reservoir tank acts as an intermediary between the coolant circuit and the pump, ensuring that only deaerated coolant reaches the pump regardless of its position. This intermediary function protects pump efficiency while allowing flexible system layout.
3Reliability
If bubbles remain in the coolant circuit, then flow resistance increases and cooling efficiency decreases, but removing bubbles requires complex degas systems
Solution Approach 1:
The coolant circuit incorporates self-degasing functionality through the reservoir tank with its specific structure (communicating with the atmosphere or vacuum source). The system automatically separates and removes bubbles during normal operation without requiring external intervention or complex active degasification equipment.
Solution Approach 2:
Bubbles are continuously extracted from the coolant through the reservoir tank's degas function, preventing their accumulation and the associated increase in flow resistance. This simple extraction mechanism maintains cooling efficiency without adding system complexity.
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 configuration effectively prevents bubble accumulation in the coolant circuit, enhancing cooling performance, reducing pump vibration, and allowing for a more compact and lightweight system with reduced flow resistance and increased travel distance for electric drive vehicles.
Implementation Method 1
the degas tank separates bubbles from the coolant
Implementation Method 2
a pump that is connected to the coolant circuit and feeds the coolant
Implementation Method 3
a coolant for cooling the electric motor and the electrical equipment circulates
Implementation Method 4
the radiator releases heat of the coolant
Data Source
AI summary
A cooling system includes: a coolant circuit through which a coolant for cooling an electric motor and electrical equipment circulates; a pump that feeds the coolant; and a degas tank that separates the bubbles from the coolant. The coolant circuit connects the devices in series. The degas tank is disposed at an upper stage, a first device as at least one of the electric motor, the electrical equipment, and the pump is disposed at a lower stage, and a remaining second device is disposed at a position that is above the lower stage and is as high as the degas tank or lower than the degas tank. The coolant circuit connects the degas tank, the second device, and the first device in this order, and the coolant flows in this order.