Vehicle Motor Cooling Assembly With Turbulence-Generating Insert
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Solution Overview
Problem
Existing cooling solutions for electrical machines in vehicles, such as traction drives, often rely on laminar flow channels that do not provide an optimal cooling effect, leading to inefficient heat dissipation and potential operational issues.
Innovation Solution
A cooling assembly with a cooling channel and an insert featuring a two-part insertion part designed to generate turbulence in the cooling medium, utilizing a deep-drawn first element with elevations and a dimensionally stable second element for enhanced flow guidance and support, converting laminar flow to turbulent flow for improved cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cooling passages are provided in a cast motor housing with laminar flow, then the structure is simple and easy to manufacture, but the cooling effect is insufficient
Solution Approach 1:
The cooling channel is divided into a first cooling channel section and a second cooling channel section, with the insert part positioned between them to generate turbulence. This segmentation allows the cooling system to combine simple laminar flow paths with localized turbulence generation, achieving effective cooling while maintaining manufacturing simplicity
Solution Approach 2:
An insert part is introduced as an intermediary element within the cooling channel to generate turbulence. This insert part acts as a mediator that transforms the laminar flow into turbulent flow locally, improving the cooling effect without requiring complete redesign of the entire cooling channel structure
2Temperature
If an insert with insertion part is added to generate turbulence, then the cooling effect is significantly improved, but the device complexity increases
Solution Approach 1:
The insert part is divided into a first insertion part and a second insertion part that can be separately manufactured and then assembled. This segmentation reduces the manufacturing complexity of each individual component and simplifies the installation process, thereby reducing overall device complexity while maintaining the turbulence-generating function
Solution Approach 2:
The insert part serves multiple functions: it generates turbulence in the cooling medium, provides structural support within the cooling channel, and can be designed to fit standard cooling channel configurations. This multi-functionality reduces the need for additional separate components, thereby reducing device complexity
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 solution achieves a significantly better cooling effect than laminar flow, ensuring efficient heat dissipation and prolonged operation of electrical machines by converting laminar flow to turbulent flow within the cooling channel.
Implementation Method 1
The cooling assembly has an insert with at least one insertion part for generating turbulence (flow vortices) in the cooling medium within the cooling channel. A turbulent flow can be generated from a laminar flow by means of the insertion part.
Data Source
AI summary
A cooling assembly for a drive assembly, which comprises an electrical machine, for a vehicle, for cooling the electrical machine, the cooling assembly comprising a cooling channel, with an inlet and an outlet, for conducting a cooling medium, the cooling channel having a receiving region for receiving the electrical machine, the cooling assembly comprising an insert having at least one insertion part for generating turbulence in the cooling medium, the insert being arranged in a space surrounding the receiving region for the electrical machine within the cooling channel, and the insertion part having a two-part design.