Vehicle Power Module Radiator Pillar Layout for Heat-Pressure Balance
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Solution Overview
Problem
The existing design methods for vehicle power module radiators lack a systematic approach, relying on empirical trial-and-error, leading to long design cycles and high costs due to the need for extensive testing and simulation to optimize pillar arrangements for efficient heat exchange and fluid flow.
Innovation Solution
A design method using the response surface method to determine optimal pillar dimensions (D1, D2, R) through simulation and multi-objective optimization, minimizing temperature rise and pressure drop, with explicit functions fitted via central composite design, and utilizing finite element simulation for accuracy.
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 (pitch, row spacing, number of pillars) to find the optimal configuration that balances heat exchange capacity with acceptable pressure drop. Through simulation and experimentation, specific parameter ranges are identified that maximize thermal performance while maintaining fluid flow characteristics within acceptable limits.
2Manufacturing precision
If empirical trial-and-error method is used for pillar arrangement design, then various arrangement modes can be tested, but the design period is long and cost is high
Solution Approach 1:
The patent applies preliminary action by conducting simulation calculations and theoretical analysis before actual manufacturing and testing. The optimal pillar arrangement is determined through computational modeling and simulation experiments, allowing the design to be optimized virtually before physical implementation, thereby avoiding extensive trial-and-error testing and reducing both time and cost.
Solution Approach 2:
The patent uses simulation models as virtual copies of the actual radiator system to test and optimize pillar arrangements. Instead of physically manufacturing and testing multiple prototypes, the design is refined through computational simulations that replicate thermal and fluid flow behavior, significantly reducing the number of physical iterations needed.
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 design time and cost by providing a systematic methodology for radiator optimization, ensuring efficient heat exchange and fluid flow, thus improving thermal management in vehicle power modules.
Implementation Method 1
the cooling liquid is provided with a liquid inlet for an inflow of the cooling liquid and a liquid outlet for an outflow of the cooling liquid
Implementation Method 2
a heat dissipation substrate having a first surface in proximity to the vehicle power module, and a second surface distant from the vehicle power module
Data Source
Figure 1a~1b
Figure 2~3
Figure 4
AI summary
This invention provides a design method for a radiator of a vehicle power module. The design method comprises: 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.