Motor Controller Coolant Layout for High-Heat Power Device Cooling
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Solution Overview
Problem
Existing motor controllers face challenges in guaranteeing cooling effects, particularly for the additional fourth leg used to enhance heating in low-temperature environments, due to inadequate cooling solutions.
Innovation Solution
A motor controller design that incorporates a liquid coolant flow channel with a first power device having larger heating power disposed near the liquid inlet and multiple second power devices with smaller heating power disposed near the liquid outlet, allowing for efficient heat exchange and improved cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a fourth leg is added to the motor controller to enhance heating effect in low-temperature environments, then the heating capability is improved, but the cooling requirement increases and existing cooling solutions cannot meet the cooling requirements
Solution Approach 1:
The patent applies local quality by differentiating the cooling requirements of different power devices based on their heating power. The first power device with larger heating power is positioned near the liquid inlet to receive cooler coolant, while second power devices with smaller heating power are positioned near the liquid outlet to receive warmer coolant. This localized differentiation of cooling conditions resolves the contradiction by matching cooling intensity to actual heating needs of each component.
Solution Approach 2:
The patent segments the power devices into two groups: first power devices with larger heating power and second power devices with smaller heating power. This segmentation allows the cooling system to be optimized for each group's specific thermal requirements, enabling the fourth leg to provide enhanced heating while the segmented cooling approach manages the increased thermal load effectively.
2Productivity
If the first power device with larger heating power is disposed near the liquid inlet, then the cooling efficiency for high-heat-generating components is improved, but the system complexity increases
Solution Approach 1:
The patent merges the cooling function into the existing liquid coolant flow channel structure, combining thermal management with the motor controller's housing. By integrating the cooling channels directly into the box structure and positioning power devices according to their thermal needs, the system achieves high cooling efficiency without proportionally increasing system complexity. The liquid coolant flow channel serves dual purposes: structural support and thermal management.
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 proposed design effectively enhances the cooling effect for the motor controller, ensuring it can operate reliably across various conditions by leveraging the temperature difference between the liquid coolant and the power devices.
Implementation Method 1
a liquid coolant in the liquid coolant flow channel is capable of separately exchanging heat with the first power device and the plurality of second power devices
Data Source
AI summary
This application discloses a motor controller, a power system, and an electric apparatus. The motor controller includes a box, a first power device, and a plurality of second power devices. The box is provided with a liquid coolant flow channel, and a liquid inlet and a liquid outlet that are in communication with the liquid coolant flow channel. The first power device is disposed in the box and on a side close to the liquid inlet. The plurality of second power devices are disposed in the box and on a side close to the liquid outlet. The second power devices have a smaller heating power than the first power device. A liquid coolant in the liquid coolant flow channel is capable of separately exchanging heat with the first power device and the plurality of second power devices.