Novel adjustable backflow structure in electric coolant pump for balancing hydraulic performance and reducing temperature rise

Abstract

An electric coolant pump serves as the source for coolant circulation in the thermal management of electric vehicles. To address the thermal issues for the printed circuit board integrated within the electric coolant pump, a novel backflow structure with an adjustable orifice diameter is designed from the impeller outlet to the printed circuit board to promote convective heat dissipation. Eventually, this flow returns to the impeller inlet, thereby altering the hydraulic performance of pump. The balance between hydraulic performance and temperature rise is achieved by adjusting the orifice diameter. Considering the variations in coolant properties with respect to temperature, numerical simulations of the electric coolant pump are performed using the unsteady compressible Reynolds-Averaged Navier-Stokes Equations. There is good agreement between experimental and numerical simulations results in both cases with and without an orifice. On an average, by increasing the orifice diameter by 1.5 mm which results in a 1.11 % decrease in efficiency, a 0.008 decrease in pressure coefficient, and a reduction of temperature by 2.98 K on printed circuit board. As the orifice diameter increases, leakage losses in the rear side chamber increases with the improvement of heat dissipation. The clash between the backflow jet and the inflow from the suction pipe results in significant entropy generation, forming jet vortices and increasing in pressure fluctuation. However, when the orifice diameter exceeds 3 mm, the cooling advantages no longer justify the trade-off in hydraulic performance. Thus, 3 mm orifice diameter is an optimal compromise between hydraulic performance and temperature control.