Brief
CUTTING E-MOTOR COOLANT
TEMPERATURE BY 40%
A leading global supplier of innovative engines and technology-driven marine propulsion systems for recreational sailboats and powerboats, contacted Thermex to help develop a ‘unique integrated cooling system’ for their eagerly anticipated first step into electric propulsion.
The emissions-free Electronic Sail Drive is to be built on an existing footprint and offered as a drop-in replacement for existing combustion engines. The new E Sail Drive units will make the switch to 100% electric boating easier and quicker.
Demonstrating a commitment to a more sustainable future, this zero-emission sail drive propulsion system offers an innovative solution to growing market demand. Incorporating a unique integrated cooling system, it is designed to support the same high engineering standard as combustion engines.
Analysis
COOLING SYSTEM
ANALYSIS
The brief involved designing a cooling pack with 2 primary objectives:
Optimised thermal management of E-Motor Coolant via available sea water
Thermal management of the Motor Controller Invertor via conduction
Other major design factors were also stipulated:
Stringent, predetermined space constraints
Minimal impact on weight
Easy access for servicing & maintenance
Based on initial thermal data, prototyping and testing, there was a requirement to dramatically reduce operating temperatures with very stringent, predetermined, space constraints.
Solution
OPTIMAL DESIGN
SOLUTION
After taking time to clearly understand the performance criteria and to review the submitted thermal data for the new E Sail Drive, our team of experienced engineers worked closely with the customers’ R&D department – with both teams working on data and CAD models simultaneously.
Utilising custom configurator software and careful consideration of complex interactions of various disciplines such as thermal dynamics, metallurgy, pressure boundary calculations and structural analysis concurrently a bespoke ‘Hybrid’ Heat Sink Plate Cooler Solution was designed to incorporate both water cooling and convection technology.
Thermex’s Technical Manager explained “We investigated a number of traditional design routes but with very tight space constraints in place it was a challenge to achieve the required thermal performance for the 2 electronic components.”
With a various design options dismissed early on, the final ‘Hybrid’ design resulted in ‘Proof of Concept’ approval within a very short 3-week time frame with extensive prototype testing showing a 40% reduction in coolant temperature. This, in turn, will reduce the E-Sail Drive’s draw on the available Lithium-ion battery pack, improving both range and performance.
Read more about Thermex’s EV & Hybrid Cooling options here.