Electric Vehicle Cooling System Leakage Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric vehicles face significant cooling function decline due to coolant leakage, which can lead to premature shutdown of critical components like traction electric motors and inverters, and there is a need to maintain operational capability even after such leaks occur.
Innovation Solution
The implementation of a cooling system with liquid leakage detection sensors and valves in the coolant passage, allowing for the isolation of leakage points and continued coolant circulation using a controller that manages valve closure and pump operation to redirect coolant to a reserve tank, ensuring maximum cooling capability is maintained.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coolant leakage detection and valve closure is implemented, then cooling function reliability is improved, but device complexity increases
Solution Approach 1:
The coolant passage is segmented into multiple sections with individual valves (first valve, second valve, third valve, fourth valve) that can be independently controlled. When leakage is detected by liquid leakage detection sensors, only the specific segment containing the leakage point is isolated by closing the relevant valves, rather than shutting down the entire cooling system. This segmentation enables localized fault containment while maintaining cooling functionality in other areas.
Solution Approach 2:
A controller acts as an intermediary between the liquid leakage detection sensors and the valves. The controller receives signals from the sensors, determines the leakage location, and automatically actuates the appropriate valves to isolate the affected section. This automated intermediary system enables rapid response to leakage events without requiring manual intervention, thereby maintaining system reliability while managing the complexity of coordinating multiple sensors and valves.
2Duration of action of moving object
If coolant circulation is maintained after leakage, then operational capability is improved, but cooling efficiency deteriorates
Solution Approach 1:
By segmenting the coolant passage into isolatable sections using multiple valves, the system can maintain coolant circulation in healthy segments even when one segment experiences leakage. The controller closes only the valves surrounding the leakage point, allowing coolant to continue circulating through other components such as the inverter or electric motor that are not affected by the leakage. This enables the vehicle to maintain operational capability with reduced but sufficient cooling efficiency.
Solution Approach 2:
The system applies partial action by maintaining coolant circulation at reduced flow rates or in reduced areas after leakage detection. Instead of completely shutting down the cooling system, the controller continues to pump coolant through the non-leaking portions of the system, providing sufficient cooling for critical components while accepting some degradation in overall cooling efficiency. This partial operation extends the vehicle's operational capability until the leakage can be addressed.
3Stability of the object's composition
If multiple valves are closed to isolate leakage, then cooling function stability is improved, but device complexity increases
Solution Approach 1:
The coolant passage is divided into multiple segments with dedicated valves (first valve, second valve, third valve, fourth valve) at strategic locations. When liquid leakage detection sensors identify a leakage point, the controller closes the two valves that bound the affected segment, isolating the instability caused by leakage to only that specific segment. This segmentation strategy stabilizes the overall cooling function by containing the leakage effect while maintaining proper coolant flow and pressure in the remaining healthy segments.
Solution Approach 2:
The valves are pre-positioned at strategic locations along the coolant passage, and the controller is pre-programmed with the logic to close the appropriate pair of valves based on which liquid leakage detection sensor triggers first. This preliminary arrangement of components and control logic enables rapid stabilization of the cooling function when leakage occurs, as the correct valves can be closed immediately without requiring complex real-time calculations or manual intervention.
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 solution effectively minimizes the impact of coolant leakage by isolating the leakage point and maintaining cooling functions for the inverter and electric motor, allowing the vehicle to continue operating and manage electrical discharge during collisions by concentrating coolant to the appropriate components.
Implementation Method 1
A controller for the cooling system is configured to close valves provided at two locations, between which a portion where liquid leakage has been detected by the liquid leakage detection sensors is located
Implementation Method 2
A coolant passage that is configured to circulate the coolant through the electric motor, the inverter and the radiator. The coolant passage is provided with a plurality of liquid leakage detection sensors and a plurality of valves. A controller for the cooling system is configured to close valves provided at two locations, between which a portion where liquid leakage has been detected by the liquid leakage detection sensors is located
Implementation Method 3
a radiator that cools a coolant
Implementation Method 4
a coolant circulation pump provided on the coolant passage
Data Source
AI summary
An electric vehicle includes an electric motor, an inverter that supplies electric power to the electric motor, a radiator that cools a coolant, a coolant passage that is configured to circulate the coolant through the electric motor, the inverter and the radiator, a plurality of liquid leakage detection sensors (flow sensors) provided in the coolant passage, a plurality of valves provide in the coolant passage, and a controller. The controller is configured to close valves provided at two locations, between which a portion where leakage of the coolant is detected by the liquid leakage detection sensors is located.