Vehicle Grid Cooling Control for Post-Power Heat Soak
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Solution Overview
Problem
Large vehicle grid assemblies face heat soak issues after power cessation, leading to excessive wear and reduced lifespan due to inadequate cooling of resistive elements and substrates, as the blower system stops operating once electrical power is no longer received, allowing retained heat to dissipate into the board.
Innovation Solution
A controller is coupled with blower drives to continue operating fan blowers after electrical power is no longer received by resistive elements, varying speed based on operational parameters to ensure continued cooling of both resistive elements and substrates, using models or feedback to determine the duration and intensity of cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the blower system stops operating once electrical power is no longer received by the resistive elements, then energy is conserved within the system, but heat soak causes the substrate temperature to increase above its designed thermal rating, leading to unnecessary wear and reduced lifespan
Solution Approach 1:
The controller initiates extended cooling operation before the substrate temperature actually exceeds its thermal rating. By predicting temperature rise based on resistive element temperature and thermal coupling characteristics, the system activates cooling preemptively, preventing heat soak damage before it occurs while maintaining energy efficiency
Solution Approach 2:
The system uses temperature sensors on both the resistive elements and substrate to provide real-time feedback to the controller. This feedback loop enables the controller to dynamically adjust blower operation based on actual thermal conditions, extending cooling only when and where needed to prevent substrate overheating while conserving energy during normal operation
2Reliability
If the blower system continues operating after electrical power cessation to prevent heat soak, then substrate temperature is controlled and component lifespan is extended, but additional energy is consumed
Solution Approach 1:
The system applies partial cooling action by operating the blower at reduced capacity or for limited duration after power cessation, rather than maintaining full cooling. This partial action is sufficient to prevent substrate overheating while consuming significantly less energy than continuous full-capacity cooling would require
Solution Approach 2:
The controller dynamically changes operational parameters including blower speed, cooling duration, and activation threshold based on real-time temperature measurements and operational history. This parameter optimization allows the system to achieve adequate cooling with minimal energy expenditure by adapting to actual thermal conditions
3Loss of energy
If the blower speed is varied based on operational parameters, then cooling effectiveness is optimized and energy use is reduced, but control system complexity increases
Solution Approach 1:
The system transitions from static blower operation to dynamic speed control based on real-time temperature feedback. The controller continuously adjusts blower speed to match actual cooling requirements, optimizing energy efficiency while managing complexity through proven control algorithms and sensor integration
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 approach extends the lifespan of grid assembly components by maintaining effective cooling post-power cessation, reducing wear and temperature fluctuations, and optimizing energy use by adjusting blower operation based on operational conditions.
Implementation Method 1
a blower system is utilized to convey cooling air across the resistive elements on the board to supplement and enhance cooling of the grid
Implementation Method 2
resistive elements that dissipate electrical power as heat
Data Source
AI summary
An assembly may be provided that includes a controller configured to be coupled with at least one blower drive that operates a blower motor to cool resistive elements that dissipate electrical power as heat. The controller may be configured to determine whether the electrical power is no longer received by the resistive elements and operate the at least one blower drive to operate the blower motor to cool the resistive elements responsive to the electrical power no longer being received by the resistive elements.