Motor-Driven Fan Cooling Duct for Electric Drive Thermal Management
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Solution Overview
Problem
Existing cooling systems for electric drive components face limitations due to weight restrictions, electrical conductivity issues, and reduced energy efficiency, particularly in air-cooling methods which require large volumes of air and complex ducting, making them impractical for vehicles with weight and complexity constraints.
Innovation Solution
A cooling system that uses a motor-driven fan to create airflow through a cooling duct, with temperature sensors and an electronic controller to optimize airflow based on temperature differences between components, ensuring maximum airflow is generated to efficiently cool electric drive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If liquid-coolant systems are used to improve cooling capacity, then heat removal effectiveness is improved, but weight increases due to the fluid and cooling system components
Solution Approach 1:
The patent extracts the coolant fluid from the cooling system and replaces it with air as the cooling medium. This eliminates the weight of the coolant and associated fluid handling components while maintaining cooling functionality through direct air cooling of electrical components
Solution Approach 2:
The patent substitutes the liquid-based thermal conduction system with an air-based convective cooling system. This replacement eliminates the need for pumps, radiators, and complex fluid distribution manifolds, significantly reducing system weight and complexity
2Weight of moving object
If air-cooling systems are used to reduce weight, then weight and complexity are reduced, but large volumes of air are required which reduces energy efficiency
Solution Approach 1:
The patent implements localized air cooling zones directly at each electrical component (generators, motors, inverters) rather than using a centralized cooling system. Temperature sensors and airflow controllers are positioned locally to provide targeted cooling only where heat is generated, reducing the total volume of air that needs to be moved and improving energy efficiency
Solution Approach 2:
The patent employs dynamic airflow control where the volume and velocity of air supplied to each component is adjusted in real-time based on temperature sensor feedback. This dynamic adjustment ensures adequate cooling is provided only when and where needed, minimizing energy consumption compared to constant high-volume air flow
3Loss of energy
If air-cooling ducts are extended to multiple components, then cooling coverage is improved, but duct size and routing complexity increase
Solution Approach 1:
The patent divides the cooling system into multiple independent modular units, each serving a specific electrical component. Each module has its own airflow control and temperature sensing, eliminating the need for a single complex centralized duct system and allowing flexible positioning of components without extensive ductwork
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 solution enhances cooling efficiency while reducing weight and complexity, improving energy efficiency by dynamically adjusting airflow according to the thermal needs of electric drive components, thus addressing the limitations of traditional cooling systems.
Implementation Method 1
A motor driven fan creates an airflow within the duct
Implementation Method 2
Cooling systems typically use circulating fluid or coolant to absorb heat from various components of the machine
Implementation Method 3
The circulating fluid absorbs heat from various components thus removing it therefrom as it flows through the cooling system
Data Source
AI summary
A cooling system (500) for an electric drive system includes a cooling duct (502) extending between a first component and a second component. A motor (336) driven fan (510) creates an airflow within the duct. A first temperature sensor measures a first temperature of the first component and a second temperature sensor measures a second temperature of the second component. An electronic controller (540) receives the first temperature and calculates a first temperature difference between the first temperature and the first temperature limit (802) to generate a first command (836) for the motor (336). A second temperature difference between the second temperature and the second temperature limit (802) generates a second command (836) for the motor (336). The controller (540) then selects the greater of the first command (836) and the second command (836) to yield the maximum command (836), and controls the motor (336) based on the maximum command (836).