Motor Drive Cooling Layout for Lower Refrigerant Pressure Loss
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Solution Overview
Problem
Conventional cooling systems for electric vehicles and hybrid vehicles face inefficiencies due to increased pressure loss and pump size in refrigerant channels, necessitating a more efficient refrigerant channel design to cool motors and batteries effectively.
Innovation Solution
A drive apparatus with a refrigerant channel configuration that includes a first flow passage connecting a refrigerant pool and a pump suction port, a second flow passage connecting the pump discharge port and a cooler inflow port, and a third flow passage extending to the motor housing portion, with the cooler and pump fixed to the housing in a manner that minimizes channel length and overlap with the gear accommodation portion, allowing for efficient refrigerant distribution and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the refrigerant channel length is increased to accommodate all components, then the cooling coverage is improved, but the pressure loss increases and pump power consumption increases
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional spatial configuration by positioning the cooler vertically above the motor and using vertical flow passages. This dimensional change allows the refrigerant to reach the motor efficiently without requiring long horizontal passages, thereby reducing pressure loss while maintaining adequate cooling coverage.
Solution Approach 2:
The housing structure serves multiple functions: it contains the motor, accommodates the power transmission mechanism in a separate gear accommodation portion, and provides mounting surfaces for the cooler and pump. This multi-functionality allows compact integration of components without requiring additional space or extending the refrigerant channel length.
2Temperature
If the refrigerant channel length is increased to connect all components, then the cooling coverage is improved, but the pump size increases
Solution Approach 1:
By arranging the cooler vertically above the motor and using vertical flow passages, the patent reduces the horizontal refrigerant channel length. This dimensional rearrangement decreases the total refrigerant volume that must be circulated, allowing for a more compact pump design while still providing adequate cooling coverage to the motor.
Solution Approach 2:
The patent integrates the cooler and pump into the housing structure, with the cooler mounted on the outer side face and the pump positioned to minimize passage length. This merging of components into a compact arrangement reduces the overall system volume and allows for a smaller pump while maintaining effective cooling coverage.
3Volume of moving object
If the cooler is positioned away from the motor to avoid overlapping with the gear accommodation portion, then the power transmission space is preserved, but the refrigerant channel length increases
Solution Approach 1:
The patent resolves the spatial conflict by positioning the cooler in the vertical dimension above the motor, rather than horizontally adjacent to it. This vertical placement allows the cooler to overlap with the gear accommodation portion in the radial direction without interfering with the power transmission mechanism, while the vertical flow passages provide efficient refrigerant delivery with minimal length.
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 configuration reduces pressure loss and enhances cooling efficiency by shortening flow passages, ensuring effective temperature management of the motor and reducing the risk of excessive temperature increases, thereby improving the reliability of the drive apparatus.
Implementation Method 1
a cooler (9) that cools the refrigerant
Implementation Method 2
a pump (8) that pumps the refrigerant
Implementation Method 3
supplying the refrigerant to the motor (2)
Data Source
AI summary
A drive apparatus includes: a motor having a motor shaft rotatable about a motor axis; a power transmission connected to the motor shaft from one side in an axial direction; a housing having a motor housing portion accommodating the motor and a gear accommodation portion accommodating the power transmission; a channel through which a refrigerant circulates; a cooler; and a pump. The channel includes a first passage connecting a refrigerant pool in the housing and a suction port of the pump, a second passage connecting a discharge port of the pump and an inflow port of the cooler, and a third passage extending from an outflow port of the cooler to the inside of the motor housing portion. The cooler is fixed to an outside of the housing to overlap at least partially the gear accommodation portion in the radial direction above the horizontal plane including the motor axis.