Integrated Coolant Circuit for Compact Electric Drive Assemblies
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Solution Overview
Problem
Existing electric motors and their components, such as motor controllers, often require external cooling lines, which can be cumbersome and inefficient, and lack integrated cooling solutions that effectively manage heat dissipation.
Innovation Solution
A coolant circuit is integrated within the electric motor and its components, allowing shared fluid flow for cooling, with separate heat sinks for the motor and controller, minimizing external lines and enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external cooling lines are used for motor and controller cooling, then cooling function is provided, but system complexity and installation difficulty increase
Solution Approach 1:
The patent combines the cooling functions of the motor and controller into a single integrated coolant circuit. The coolant flows through both the motor and controller components within the same housing, eliminating the need for separate external cooling lines for each component. This merging approach reduces system complexity while maintaining reliable cooling for both heat-generating components.
2Reliability
If separate cooling systems are used for motor and controller, then each component is cooled independently, but the overall system size and external connections increase
Solution Approach 1:
The motor and controller are housed together with a shared coolant circuit that provides independent cooling channels for each component. This integration allows both components to be cooled effectively within a single housing volume, reducing the overall system size compared to separate cooling systems while maintaining independent heat dissipation capability.
Solution Approach 2:
The single coolant circuit serves multiple functions by cooling both the motor and controller components. The coolant flow path is designed to distribute cooled fluid to different heat-generating components within the housing, providing universal cooling coverage across multiple subsystems without requiring separate dedicated cooling systems for each.
3Device complexity
If integrated coolant circuit is used, then external lines are minimized, but internal cooling passage design becomes more complex
Solution Approach 1:
The cooling passages for both motor and controller are integrated into the housing structure as unified internal channels. This design consolidates multiple cooling paths into the housing itself, eliminating external piping while the passages are formed through standard manufacturing processes such as injection molding or CNC machining, keeping manufacturing complexity manageable.
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 integrated cooling system provides efficient heat dissipation for both the electric motor and its components, reducing the need for external cooling lines and improving the compactness and flexibility of drive assemblies.
Implementation Method 1
a coolant circuit where the related components are cooled by the same fluid flow that cools the electric motor
Implementation Method 2
providing separate heat sinks for the electric motor and, for example, a motor controller assembly
Data Source
AI summary
A liquid-cooled electric motor assembly is disclosed having a coolant circuit used to cool both an electric motor and a motor controller of the electric motor assembly. The compact coolant circuit minimizes the need for external lines between the electric motor and controller, while providing separate heat sinks for the electric motor and motor controller assembly. The liquid-cooled electric motor may engage and power a variety of reduction output assemblies to form drive assemblies. The coolant circuit of the electric motor assembly may cooperate with an external coolant circuit to form a cooling system. The external circuit may include a radiator (e.g., heat exchanger or oil cooler) and an electric pump for the coolant which may cool one or more drive assemblies of a vehicle drive system.