Vehicle Power Module Radiator Pillar Layout for Low Pressure Drop
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Solution Overview
Problem
The existing design methods for vehicle power module radiators lack methodology guidance, relying on empirical trial-and-error, leading to long design periods and high costs, and inefficient thermal management due to suboptimal pillar array arrangements in liquid cooling systems.
Innovation Solution
A design method using the response surface method to optimize the pillar array arrangement by determining specific values for pillar distances and radii through simulation calculations, fitting explicit functions, and performing multi-objective optimization to minimize temperature rise and pressure drop, thereby improving the radiator's heat exchange efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a denser arrangement of pillars is used, then the heat exchange capacity of the radiator is increased, but the flow channel resistance and pressure drop of the cooling liquid increase
Solution Approach 1:
The patent applies parameter changes by systematically varying the pillar arrangement parameters (spacing, row pitch, pillar diameter) to find the optimal configuration. Through response surface methodology, the patent identifies specific parameter values that maximize heat exchange capacity while keeping pressure drop within acceptable limits, thus resolving the contradiction between heat exchange performance and flow resistance.
2Reliability
If the empirical trial-and-error method is used for pillar arrangement optimization, then various arrangement modes can be tested, but the design period is extended and cost increases
Solution Approach 1:
The patent replaces the empirical trial-and-error mechanical design process with a computational optimization system based on response surface methodology and genetic algorithms. This substitution allows for automated, systematic exploration of the design space, significantly reducing design time and cost while maintaining or improving optimization quality compared to traditional empirical methods.
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 approach reduces the design speed and cost of radiators, enhances thermal management, and achieves a more efficient heat exchange process by optimizing the pillar array arrangement, resulting in a reduced temperature rise and pressure drop.
Implementation Method 1
a cooling tank, which is located on a side of the second surface distant from the vehicle power module, wherein the cooling tank is provided with an interface in proximity to the second surface... the plurality of pillars extend into the cooling tank through the interface... a side wall of the cooling tank is provided with a liquid inlet for an inflow of a cooling liquid and a liquid outlet for an outflow of the cooling liquid
Data Source
AI summary
This disclosure provides a design method for a radiator of a vehicle power module. The design method includes: selecting a plurality of specific values from the possible value ranges of the first distance D1, the second distance D2 and the radius R, respectively, to form different combinations of the plurality of specific values, performing simulation calculations on the different combinations, and obtaining a temperature rise ΔTj and a pressure drop ΔPf corresponding to each combination to form a plurality of samples; through a response surface method, fitting explicit functions of the temperature rise ΔTj and the pressure drop ΔPf with the first distance D1, the second distance D2 and the radius R as dependent variables; and through a multi-objective optimization, determining the first distance D1, the second distance D2 and the radius R with an optimization objective that the temperature rise ΔTj and the pressure drop ΔPf are simultaneously minimized.