Integrated Drive Train Cooling Unit for Lower Assembly Complexity
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Solution Overview
Problem
Existing drive train cooling systems for electric vehicles are complex and costly, requiring numerous individual components and extensive assembly efforts, which increase procurement costs and reduce system efficiency.
Innovation Solution
Integration of multiple main components of the coolant circuit, including a coolant valve, drive train coolant pump, coolant expansion tank, and sensor, into a single, self-contained drive train cooling unit, which reduces the number of components and simplifies assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple cooling components are assembled as individual components in the vehicle, then the system allows for flexible installation and maintenance, but the assembly complexity and procurement costs increase significantly
Solution Approach 1:
The patent combines the radiator, condenser, and fan into a single integrated drive train cooling unit (CRFM). This merging of previously separate components reduces the number of individual parts that need to be procured and assembled, directly addressing the contradiction by lowering procurement costs and assembly complexity while maintaining the cooling functionality.
Solution Approach 2:
The integrated cooling unit serves multiple functions: it acts as both a radiator for the coolant circuit and a condenser for the refrigerant circuit, while the fan provides airflow for both functions. This multi-functionality reduces the overall component count and simplifies the system architecture, resolving the contradiction between manufacturing ease and device complexity.
2Ease of repair
If multiple cooling components are assembled as individual components in the vehicle, then the system allows for independent replacement and maintenance of each component, but the assembly effort and time increase
Solution Approach 1:
By integrating the radiator, condenser, and fan into a single modular unit, the patent reduces the number of assembly steps required during vehicle assembly. The entire cooling unit can be installed as one component rather than assembling multiple separate components, significantly reducing assembly time while maintaining ease of repair at the unit level.
3Device complexity
If cooling components are integrated into a single unit, then procurement costs and assembly complexity are reduced, but the risk of thermal losses and pressure drops increases due to internal flow paths
Solution Approach 1:
The integration of the coolant circuit and refrigerant circuit into a single housing creates internal flow paths that are optimized for thermal efficiency. The close proximity of the radiator and condenser within the same unit allows for efficient heat transfer and minimized thermal losses, while the integrated design reduces the number of external connections and potential leak points.
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 integration leads to significant cost reductions, improved system efficiency due to reduced pressure and thermal losses, and a lower risk of leaks, while maintaining effective heat dissipation for the drive train.
Implementation Method 1
a fan (13) for generating a cooling air flow (3)
Implementation Method 2
a condenser (11) for the refrigerant circuit of the vehicle
Implementation Method 3
a radiator (12) for a coolant circuit of the vehicle
Data Source
AI summary
The invention relates to a drive train cooling unit (10) for a partially electrically or fully electrically driven vehicle, with a fan (13), a condenser (11) for a refrigerant circuit (1) of the vehicle, and a radiator (12) for a coolant circuit (2) of the vehicle, wherein, in an air flow direction which can be caused by the fan (13), the fan (13) itself, the condenser (11), and the radiator (12) are connected together sequentially in series to form a cooling unit for a drive train of the vehicle, wherein, apart from the radiator (12) as main component (12) of the coolant circuit (2), a further main component (14, 15, 16, 17) of the coolant circuit (2) of the vehicle is integrated into the drive train cooling unit (10).