Electric Machine Cooling Bypass for Coolant Degassing
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Solution Overview
Problem
Existing cooling systems for electric machines in motor vehicles are inefficient in removing gaseous constituents from the coolant, leading to reduced heat dissipation and impaired cooling performance.
Innovation Solution
A cooling system with a supply line, cooling line, and bypass line is implemented, where the bypass line collects and discharges gases at the highest point in the direction of gravity, minimizing thermal resistances and enhancing heat transfer by using a dielectric liquid coolant, while a branch line cools power electronics directly, and a drain removes gases from the coolant circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional cooling system is used without a bypass line, then the cooling system is simpler, but gaseous constituents accumulate in the coolant leading to reduced heat dissipation
Solution Approach 1:
The bypass line extracts gaseous constituents from the coolant by providing a separate discharge path at the highest point of the cooling system. This allows gases to be removed without disrupting the main cooling circuit, thereby improving heat dissipation while adding only minimal structural complexity
Solution Approach 2:
The system changes the physical state separation by utilizing the difference in density between liquid coolant and gaseous constituents. By positioning the bypass line outlet at the highest point, gases naturally rise and are discharged, while the liquid coolant continues its cooling function, optimizing heat transfer efficiency
2Reliability
If the bypass line is positioned at a lower height, then the system is easier to install, but gaseous constituents cannot be effectively collected and discharged
Solution Approach 1:
The bypass line outlet is positioned at the highest point of the cooling system to counteract the natural tendency of gases to settle. This gravitational positioning ensures that gaseous constituents, being lighter than the liquid coolant, naturally rise to the highest point and are effectively discharged through the bypass line, maintaining reliable cooling performance
3Productivity
If thermal resistances are not minimized, then the cooling system is simpler to design, but heat transfer efficiency is reduced
Solution Approach 1:
The bypass line acts as an intermediary element that removes gaseous constituents which would otherwise create thermal resistances in the cooling system. By providing a dedicated gas discharge path, the system maintains optimal thermal contact between the coolant and components being cooled, enhancing heat transfer efficiency without major design modifications
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
The system effectively reduces gaseous constituents in the coolant, improving heat transfer performance and cooling capacity, enabling efficient cooling of electric machines, even under high power demands, suitable for sports cars or race cars.
Implementation Method 1
the bypass line, in order to collect and/or discharge air, exits from the first winding head region at a highest position in the direction of gravity
Implementation Method 2
supply line for supplying a cooled coolant to a first winding head region of the electric machine, at least one cooling line leading from the first winding head region through a stator
Data Source
AI summary
A cooling system for cooling an electric machine of a motor vehicle, including a supply line, at least one cooling line, and a bypass line. The supply line is for supplying a cooled coolant to a first winding head region of the electric machine. The at least one cooling line leads from the first winding head region through a stator of the electric machine up to a second winding head region of the electric machine. The bypass line is guided from the first winding head region to the second winding head region past the stator. The bypass line, to collect and/or discharge air, exits from the first winding head region at a highest position in a direction of gravity and/or opens into the second winding head region at a highest position in the direction of gravity.