EV Powertrain Cooling Structure Without Pump-Driven Oil Circulation
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Solution Overview
Problem
Existing cooling systems for electric vehicle motors, such as air, water, and oil cooling, struggle to efficiently dissipate heat while maintaining cost-effectiveness, especially in high-power density scenarios, with oil cooling systems being costly due to the need for an electric oil pump and heat exchanger.
Innovation Solution
A power assembly design incorporating a shell with integrated heat dissipation, liquid storage, flow diversion, and heat exchange structures that utilize cooling liquid to directly drive flow and exchange without additional pumps or external heat exchangers, enhancing heat dissipation efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery pack is secured to the floor of the vehicle using a conventional battery pack securing device, then the battery pack is fixed in position, but the device requires complex assembly and disassembly procedures requiring two people and multiple tools
Solution Approach 1:
The battery pack is divided into an upper portion and a lower portion that can be separated. The lower portion includes the battery module and cooling plate integrated as one unit, allowing the upper portion to be easily removed without disturbing the lower portion secured to the floor. This segmentation enables single-person operation and simplifies assembly/disassembly procedures.
Solution Approach 2:
The cooling plate is extracted and integrated directly with the lower portion of the battery pack, forming a unified structure. This eliminates the need for separate cooling plate installation and simplifies the securing process, as the entire lower portion can be positioned and secured as a single unit.
2Adaptability or versatility
If the battery pack is designed as a single integrated unit, then the structure is simple, but the battery pack cannot be easily separated into upper and lower portions for maintenance or replacement
Solution Approach 1:
The battery pack is segmented into an upper portion containing battery modules and a lower portion containing the cooling plate and battery module. The upper and lower portions can be independently separated, allowing flexible maintenance and replacement operations while maintaining a relatively simple overall structure.
Solution Approach 2:
The battery pack design allows dynamic reconfiguration where the upper portion can be easily attached to or separated from the lower portion. This dynamic capability enables adaptable maintenance procedures without requiring complete disassembly of the entire battery pack system.
3Productivity
If the cooling plate is separate from the battery module, then each component can be manufactured independently, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The cooling plate is merged with the lower portion of the battery pack to form an integrated unit. This combining reduces the number of separate assembly steps, as the cooling plate and lower portion are positioned and secured together in one operation, significantly reducing assembly time while maintaining the ability to manufacture components independently.
4Strength
If heavy objects are placed on the battery pack during vehicle assembly, then the battery pack is secured firmly, but the battery pack may be damaged due to excessive weight
Solution Approach 1:
The battery pack is segmented into upper and lower portions with the lower portion serving as the primary load-bearing structure secured to the floor. This segmentation allows the upper portion to be handled and positioned without requiring heavy weights for securing, as the lower portion's integration with the floor provides sufficient structural support and stability.
Data Source
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AI summary
The application provides a power assembly, including a shell and a power component disposed in the shell. The shell includes an accommodating structure, a flow diversion structure, a liquid storage structure, a heat dissipation structure, and a heat exchange structure. The accommodating structure is filled with cooling liquid, and the power component is rotatably disposed in the accommodating structure, and can drive the cooling liquid in the accommodating structure to flow during rotation. The flow diversion structure is configured to guide a flow direction of the cooling liquid that is driven by the power component to flow. The liquid storage structure is configured to: store the cooling liquid that is guided by the flow diversion structure to enter the liquid storage structure, and distribute the cooling liquid that enters the liquid storage structure. The heat dissipation structure is communicated with both the liquid storage structure and the accommodating structure, and the heat dissipation structure is configured to: receive the cooling liquid distributed by the liquid storage structure, and transfer the cooling liquid to the power component to cool the power component. The heat exchange structure is configured to perform heat exchange and cooling on the cooling liquid in the accommodating structure. The present invention further provides an electric vehicle.