Integrated Pump Inverter Cooling for EV Drive Assemblies
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Solution Overview
Problem
Existing electric vehicle drive systems face complexity and inefficiency in cooling systems due to separate data and power lines for coolant pumps, making optimization of cooling power difficult and increasing assembly complexity.
Innovation Solution
Integration of the pump inverter into the drive inverter allows for self-controlled cooling of electric motors and inverters, eliminating the need for separate data and power lines by using a centralized data and energy supply, enabling the drive inverter to actuate the coolant pump and optimize cooling based on power demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate data and power lines are used for coolant pumps, then the cooling system can be independently controlled, but the assembly complexity and cabling complexity increase
Solution Approach 1:
The patent combines the pump inverter with the drive inverter into a single integrated unit. This merging eliminates the need for separate data and power lines between the coolant pump and central control device, reducing cabling complexity while maintaining the ability to control cooling independently through the integrated inverter system.
Solution Approach 2:
The drive inverter is designed to perform multiple functions: it controls both the electric motor and the coolant pump through the integrated pump inverter. This multi-functionality allows the single inverter unit to manage both propulsion and thermal management, simplifying the overall system architecture while preserving independent cooling control capabilities.
2Use of energy by moving object
If coolant pumps are actuated as needed based on power requirements, then energy efficiency is improved, but the control system complexity increases
Solution Approach 1:
The integrated pump inverter receives information about the electric motor's power requirements and automatically adjusts the coolant pump's operation accordingly. This feedback mechanism enables the cooling system to respond dynamically to thermal demands, optimizing energy efficiency while the integration simplifies the control architecture by eliminating the need for separate control systems.
Solution Approach 2:
The drive inverter with integrated pump inverter autonomously manages the cooling of the electric motor based on its own operational parameters. The system self-regulates the coolant flow and pump speed according to the motor's thermal needs, eliminating the requirement for external control devices and reducing overall system complexity.
3Ease of manufacture
If the pump inverter is integrated into the drive inverter, then assembly work and cabling are simplified, but the thermal management of multiple components becomes more challenging
Solution Approach 1:
The integrated inverter system incorporates separate cooling channels and thermal management zones for different components (drive inverter and pump inverter). This segmentation allows independent thermal control of each component while maintaining physical integration, simplifying assembly and cabling while effectively managing the thermal requirements of multiple components.
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 reduces energy consumption, simplifies assembly, and enhances the self-protection and service life of drive components by creating a compact, cost-efficient cooling system that can independently manage thermal, electrical, and mechanical control, minimizing cabling complexity and allowing for optimized spatial arrangement and thermal management.
Implementation Method 1
at least one cooling unit with at least one coolant pump, a cooler, at least one pump inverter and with at least one heat exchanger
Data Source
AI summary
A drive device is disclosed, in particular for an electrically driveable vehicle, having at least one electric motor, having at least one drive inverter for actuating the electric motor, having at least one cooling unit with at least one coolant pump, a cooler, at least one pump inverter and with at least one heat exchanger, wherein the heat exchanger is connected in fluid-conducting fashion to the coolant pump and to the cooler via a coolant circuit, wherein at least one pump inverter is integrated into the drive inverter or is arranged adjacent to the drive inverter, wherein the coolant pump can be actuated by the pump inverter.