Fan Module Cooling Air Guide for Motor Thermal Management
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Solution Overview
Problem
Existing fan modules for motor vehicle ventilation systems face challenges in efficiently cooling electric motors while minimizing acoustic noise and maintaining high cooling efficiency, especially when dealing with large temperature ranges and high electrical power conversion.
Innovation Solution
The fan module utilizes a pressure drop between the outlet and inlet sides to guide cooling air past the electric motor, mixing heated cooling air with incoming air to maintain efficiency and reduce noise, with a cooling air duct design that includes a guide element to direct cooling air axially through the motor and brushes, ensuring effective heat absorption and distribution without significant airflow slowdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling air duct is provided to cool the electric motor, then the cooling efficiency is improved, but the acoustic load increases
Solution Approach 1:
The cooling air duct is segmented into multiple paths: one path directs cooling air to the brushes, another path directs cooling air through the electric motor, and a third path allows mixing with inlet air. This segmentation enables targeted cooling of different components while managing noise levels in each path independently.
Solution Approach 2:
Different regions of the cooling air duct system are assigned different functions: the first region (outlet to brushes) provides intense cooling where thermal load is highest, the second region (through motor) provides distributed cooling, and the third region (mixing zone) balances temperature and noise. This local differentiation optimizes both cooling efficiency and noise control.
2Productivity
If cooling air flow is increased to improve cooling efficiency, then the thermal management is improved, but the noise pollution increases
Solution Approach 1:
The system changes the parameters of cooling air by mixing it with inlet air in a controlled manner. The mixing ratio and location are optimized to reduce the temperature and velocity of cooling air before it enters noise-sensitive areas, thereby reducing noise while maintaining adequate cooling capacity.
Solution Approach 2:
The inlet air acts as an intermediary substance that mixes with the hot cooling air from the outlet. This mixing process serves as a mediator to reduce the temperature and kinetic energy of the cooling air stream, thereby reducing noise generation while preserving cooling effectiveness.
3Temperature
If the cooling air duct runs directly to the brushes, then the brush cooling is improved, but the device complexity increases
Solution Approach 1:
The cooling air duct system is designed to serve multiple functions simultaneously: it cools the brushes, cools the electric motor, and mixes with inlet air to control noise. This multi-functionality is achieved through a unified duct structure that branches to different components, reducing overall system complexity compared to separate cooling systems for each component.
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 maintains high cooling efficiency of the electric motor while minimizing noise pollution and preventing thermal overloading of brushes, ensuring reliable operation and extended service life by targeted cooling of individual components.
Implementation Method 1
The passing air can absorb thermal energy and cool the electric motor
Implementation Method 2
a pressure drop between the outlet side and the inlet side of the fan module is used to guide the cooling air past the electric motor
Implementation Method 3
The heated cooling air is mixed with air that flows into the fan wheel on the inlet side and transported together with this in the direction of the outlet side
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
The invention relates to a fan module, comprising a fan impeller having an axial inlet side and a radial outlet side, an electric motor for coaxially driving the fan impeller, and a cooling air guide that leads from the outlet side to the electric motor. From the electric motor, the cooling air guide further leads to the fan impeller, wherein the fan impeller has, in a region close to the axis, a cut-out for the passage of cooling air to the inlet side.