Reducer Housing Liquid Cooling for High-Torque Heat Dissipation
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Solution Overview
Problem
The existing cooling methods for reducers in new energy vehicles, which rely on stirring lubricating oil with a gear, are insufficient to meet the demands of high power, high torque, and extended service life due to increased rotational speeds and varying road conditions.
Innovation Solution
A liquid cooled heat dissipation structure is integrated into the reducer housing, featuring a coolant tank with alternating convex and concave wavy surfaces and flow guiding plates, enhancing heat exchange with lubricating oil through an S-shaped passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If gear stirring cooling method is used, then the structure is simple, but the heat dissipation performance is insufficient for high power applications
Solution Approach 1:
A coolant tank is introduced as an intermediary component between the gear and the external cooling system. The tank receives hot lubricating oil from the gear, transfers heat to circulating coolant, and returns cooled oil to the gear, effectively mediating the heat transfer process and enhancing overall cooling performance
Solution Approach 2:
The invention utilizes hydraulic principles by implementing a liquid coolant circulation system. Coolant flows through the coolant tank, absorbing heat from lubricating oil via convection and conduction, then dissipates heat externally through the side wall, creating an efficient liquid-based thermal management system
2Temperature
If coolant tank with wavy bottom is used, then the heat exchange area is increased, but the manufacturing complexity increases
Solution Approach 1:
The bottom of the coolant tank is designed with a wavy curved surface instead of a flat plane. This curvature increases the surface area in contact with lubricating oil, enhancing heat exchange efficiency. The curved geometry also promotes better fluid circulation and heat distribution within the tank
3Temperature
If flow guiding plates are added, then the coolant flow path is optimized, but the device complexity increases
Solution Approach 1:
The coolant tank interior is segmented by flow guiding plates into multiple flow channels. These plates divide the single large cavity into several smaller pathways, directing coolant flow more uniformly across the heat exchange surface and preventing dead zones, thereby optimizing thermal efficiency
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 improved heat dissipation performance extends the service life of the reducer and ensures reliable operation under high-power, high-torque, and high-speed conditions, balancing temperature rise and service life requirements.
Implementation Method 1
the heat exchange between the coolant in the cooling tank and the lubricating oil can be achieved, thereby quickly removing the heat inside the reducer housing
Implementation Method 2
increasing a contact area between the coolant tank and the lubricating oil inside the reducer housing
Implementation Method 3
the flow guiding plates cooperate with the convex structures to form a continuous S-shaped passage for the coolant to flow through
Data Source
AI summary
A reducer housing and an electric drive assembly are disclosed. A liquid cooled heat dissipation structure is provided at a bottom of the reducer housing and/or on a side wall thereof through which lubricating oil flows. The heat dissipation structure includes a coolant tank and a cover plate that seals the coolant tank. Two ends of the coolant tank are respectively provided with a liquid inlet and a liquid outlet. Convex structures and concave structures are alternately provided on the bottom of coolant tank so that inner and outer sides of the bottom of the coolant tank are in a wavy shape to increase a contact area between the coolant tank and the lubricating oil inside the reducer housing.