Nested Braking Grid Cooling Fan Assembly
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Solution Overview
Problem
Dynamic braking systems in diesel-electric vehicles face overheating issues due to the large size and power consumption of cooling fans, which occupy significant space in the engine compartment and require efficient and compact heat dissipation solutions.
Innovation Solution
A compact braking grid cooling system featuring a fan with a hub and radially projecting blades that nests with the dynamic braking grid, allowing for a combined height less than the sum of the individual components, and a method of positioning and actuating the fan to rotate and move air through the grid for effective cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a large cooling fan is used to provide sufficient air movement uniformly over the entire area of the resistance element, then the cooling effectiveness is improved, but the device occupies significant space in the engine compartment
Solution Approach 1:
The fan is positioned within the braking grid structure such that the fan housing is received by the grid, creating a nested arrangement. This allows the fan to be integrated into the existing grid volume rather than occupying separate space, reducing the overall space occupation while maintaining sufficient cooling air movement over the resistance elements
Solution Approach 2:
The braking grid is configured with a three-dimensional structure that includes a central opening, allowing the fan to be positioned within the grid's internal volume. This spatial reconfiguration enables the cooling system to achieve effective air distribution across the resistance elements without requiring additional external space in the engine compartment
2Temperature
If a large cooling fan is used to direct cooling air over the resistance elements, then the temperature control is improved, but the device complexity and power consumption increase
Solution Approach 1:
The cooling fan and braking grid are combined into a single integrated assembly where the fan is received by the grid structure. This merging eliminates the need for separate mounting structures and reduces the number of discrete components, thereby reducing device complexity while maintaining effective temperature control of the resistance elements
Solution Approach 2:
The braking grid structure serves multiple functions: it provides the resistive braking function through its resistance elements, provides structural support for the fan assembly, and facilitates the distribution of cooling air. This multi-functionality reduces the need for additional dedicated cooling components, simplifying the overall system
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 system efficiently dissipates heat while being more compact, allowing for increased resistive braking capacity without increasing the overall height, by optimizing air flow and resistor surface area, thus addressing the overheating and space constraints of traditional systems.
Implementation Method 1
Cooling fans typically are employed to direct cooling air over the resistance elements of a dynamic braking grid
Implementation Method 2
The braking grid includes a resistance element or elements made of a metallic material that is conductive, but provides resistance to the current received from the traction motor so that the current is converted to heat
Data Source
AI summary
A braking grid cooling system may include a fan having a hub supporting a rotor and at least partially enclosing a stator, and a plurality of fan blades connected to and projecting radially from the hub; and a dynamic braking grid receiving the fan in a nested relation such that a combined height of the grid and the fan is less than a sum of a height of the grid and a height of the fan.