Motor and Controller Cooling with Oil-Water Heat Exchange
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing new energy vehicle drive motors require an effective cooling system to manage increased power density, as current independent water and oil cooling systems are insufficient for continuous high power and high torque output.
Innovation Solution
A combined cooling system integrating a water cooling assembly, an oil cooling assembly, and an oil-water heat exchanger, with intelligent control of pumps and fans, is designed to optimize cooling efficiency by leveraging the lower operating temperature of the motor controller and enhancing energy consumption reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If independent water cooling system is used, then cooling coverage is comprehensive, but cooling efficiency is insufficient for high power density motors
Solution Approach 1:
The patent combines water cooling and oil cooling systems into a hybrid cooling system. The water cooling assembly cools the motor controller and transfers heat to the oil cooling system via a heat exchanger, while the oil cooling assembly directly cools the motor. This merging of two independent cooling methods resolves the contradiction by achieving both comprehensive cooling coverage and high cooling efficiency for high power density motors.
2Productivity
If independent oil cooling system is used, then cooling efficiency is high, but cooling coverage is limited
Solution Approach 1:
The oil cooling system serves multiple functions: it directly cools the motor through the oil cooling assembly and simultaneously acts as a heat transfer medium in the heat exchanger to cool the motor controller via water circulation. This multi-functionality expands the cooling coverage beyond what a standalone oil cooling system could achieve, while maintaining high cooling efficiency.
3Productivity
If both water cooling and oil cooling systems are combined, then cooling efficiency is improved, but system complexity increases
Solution Approach 1:
The heat exchanger serves as an intermediary component that couples the water cooling assembly and oil cooling assembly. It enables heat transfer between the two cooling circuits without requiring direct mixing of coolant systems, thereby simplifying the overall system architecture while achieving efficient combined cooling. The controller acts as another intermediary that coordinates the operation of water pump, oil pump, and fan based on temperature feedback.
Solution Approach 2:
The system incorporates temperature sensors and a controller that monitor cooling temperatures and adjust the operation of water pump, oil pump, and fan accordingly. This feedback mechanism automates the coordination between the two cooling systems, reducing the complexity of manual control while optimizing cooling efficiency under different operating conditions.
4Power
If high power density motor is used, then motor performance is improved, but heat generation increases requiring more effective cooling
Solution Approach 1:
The cooling system is segmented into specialized subsystems: water cooling assembly for controller cooling, oil cooling assembly for direct motor cooling, and a heat exchanger for thermal energy transfer between them. This segmentation allows each subsystem to be optimized for its specific function, enabling effective heat management for high power density motors without compromising performance.
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 combined cooling system improves cooling efficiency, reduces energy consumption, and enhances environmental adaptability by balancing energy saving and cooling performance through linked control of water and oil pumps and fans.
Implementation Method 1
an cooling water outlet of the motor controller is connected to a water inlet of an oil-water heat exchanger, and a water outlet of the oil-water heat exchanger is connected to a cooling water inlet of the motor; one end of the oil cooling assembly is connected to a cooling oil outlet of the motor, the other end of the oil cooling assembly is connected to an oil inlet of the oil-water heat exchanger, and an oil outlet of the oil-water heat exchanger is connected to a cooling oil inlet of the motor
Implementation Method 2
the water cooling assembly comprises a radiator, a fan, a first water pump, and a water pipe
Implementation Method 3
the fan is used for cooling the radiator
Data Source
AI summary
The present disclosure discloses a combined cooling system for a motor and a motor controller, which comprises a water cooling assembly, an oil cooling assembly, and an oil-water heat exchanger; one end of the water cooling assembly is connected to an cooling water outlet of the motor, the other end is connected to an cooling water inlet of the motor controller and/or a water inlet of the oil-water heat exchanger; one end of the oil cooling assembly is connected to a cooling oil outlet of the motor, the other end of the oil cooling assembly is connected to an oil inlet of the oil-water heat exchanger, and an oil outlet of the oil-water heat exchanger is connected to a cooling oil inlet of the motor. The above technical solution utilizes the temperature characteristics of the motor and the motor controller, and achieves the objects of saving energy in cooling, and improving high power output performance and environmental adaptability of the motor through the cooperation and intelligent control of the water pump, oil pump and fan in the combined cooling system.