Performance enhancement of hvac systems thermally regulated by multi-branch cooling subsystems

Abstract

A system for enhancing the performance of a heating, air conditioning, and ventilation (HVAC) system includes high thermal mass rechargeable energy storage system (RESS) modules, low thermal mass auxiliary module(s), and a cooling subsystem having a main coolant loop with coolant thermal conditioning devices. The HVAC and individual parallel RESS coolant branches in parallel with auxiliary coolant branches are connected to the main coolant loop. An electronic controller determines the temperature of the RESS module(s) and the auxiliary module(s) relative to respective temperature ranges, regulates the coolant in the main loop, and limits the flow of coolant from the main loop into the RESS coolant branches when the temperature of the RESS module(s) is within a first temperature range. The controller also regulates the flow of coolant from the main loop into the auxiliary branches to provide target temperature coolant to the HVAC from the main coolant loop when the auxiliary module temperature is outside a second temperature range.

Description

Technical Field

[0001] This disclosure relates to prioritizing, enhancing, and optimizing the performance of heating, air conditioning, and ventilation (HVAC) systems through thermal regulation of multi-branch cooling subsystems, such as those used in multi-cell rechargeable energy storage systems (RESS). Background Technology

[0002] Typically, a battery system for generating and storing electrical energy comprises one or more battery cells for providing power to a load. Multiple battery cells can be arranged close together to form a battery module, and multiple battery modules can be organized into a battery pack array. Batteries can be broadly classified into primary batteries and secondary batteries. Primary batteries, also known as disposable batteries, are designed to be used until depleted, after which they are simply replaced with new batteries. Secondary batteries, more commonly called rechargeable batteries, employ specific chemistry that allows them to be repeatedly recharged and reused, thus offering advantages in terms of economy, environmental friendliness, and ease of use compared to disposable batteries.

[0003] Rechargeable batteries can power a variety of items, such as toys, consumer electronics, and motor vehicles. The specific chemistry of rechargeable batteries (such as lithium-ion cells), along with external factors, can lead to internal reaction rates that generate significant heat. Prolonged exposure of battery cells to high temperatures can cause them to experience thermal runaway events, where heat buildup in individual cells leads to heat diffusion to neighboring cells in the module and affects the entire battery array. Additionally, extreme temperatures can affect the power generation of battery cells. Therefore, effective thermal management is necessary to optimize battery system performance. Generally, devices such as radiators or cold plates with circulating coolant are used to remove heat from the battery system. Summary of the Invention

[0004] A system for enhancing the performance of a heating, air conditioning, and ventilation (HVAC) system includes a multi-cell rechargeable energy storage system (RESS) with multiple relatively high thermal mass RSS modules. The system also includes auxiliary modules with relatively low thermal mass and a cooling subsystem comprising a main coolant circuit fluidly connected to the HVAC system and configured to circulate coolant. The cooling subsystem additionally includes at least one coolant thermal conditioning device arranged in the main coolant circuit. The cooling subsystem also includes multiple RSS coolant branches arranged in parallel, each RSS coolant branch configured to receive coolant from the main coolant circuit to adjust the temperature of one of the corresponding RSS modules. The cooling subsystem additionally includes auxiliary coolant branches arranged in parallel with the multiple RSS coolant branches and configured to receive coolant from the main coolant circuit to adjust the temperature of the auxiliary modules.

[0005] The system also includes an electronic controller operatively connected to the cooling subsystem and configured to determine when the temperature of at least one of the RESS modules is within a first predetermined temperature range. The electronic controller is additionally configured to determine when the temperature of an auxiliary module is outside a second predetermined temperature range. The electronic controller is additionally configured to thermally regulate the coolant in the main coolant circuit to a target temperature. The electronic controller is additionally configured to limit the flow rate of coolant entering individually from the main coolant circuit into at least one of the RESS coolant branches when the temperature of the corresponding at least one RESS module is within the first predetermined temperature range. The electronic controller is additionally configured to regulate the flow rate of coolant from the main coolant circuit into the auxiliary coolant branch when the temperature of the auxiliary module is outside the second predetermined temperature range. Regulating the flow rate of coolant into the auxiliary coolant branch under these conditions aims to maintain the target coolant temperature in the main coolant circuit and supply this coolant to the HVAC system, thereby enhancing the performance of the HVAC system.

[0006] The flow rate of coolant entering the auxiliary coolant branch can be adjusted to additionally provide at least a predetermined minimum coolant flow rate through the cooling subsystem for the necessary performance of the HVAC system.

[0007] A relatively high thermal mass RESS module may include individual battery modules with multiple battery cells.

[0008] The cooling subsystem may additionally include at least one RESS flow valve, which is operatively connected to an electronic controller and configured to regulate and distribute coolant received from the main coolant circuit on the plurality of RESS coolant branches.

[0009] One or more RESS flow valves may be configured as multi-way valve assemblies arranged at the junction between the main coolant circuit and the plurality of RESS coolant branches, and configured to control the flow rate of coolant entering each of the RESS coolant branches.

[0010] One or more RSS flow valves may be configured as multiple individual throttle valves, each arranged in one of the multiple RSS coolant branches upstream of the corresponding RSS module, and configured to control the flow rate of coolant entering the main RSS coolant branch.

[0011] Each RESS coolant branch may include a one-way valve configured to control the flow rate of coolant exiting the main RESS coolant branch.

[0012] The cooling subsystem may also include a bypass flow valve, which is operatively connected to the electronic controller and configured to regulate the coolant in the auxiliary coolant branch.

[0013] The cooling subsystem may additionally include a check valve configured to control the flow rate of coolant exiting the auxiliary coolant branch.

[0014] The cooling subsystem may also include a fluid pump configured to circulate coolant through the main coolant circuit.

[0015] At least one coolant thermal conditioning device may include a coolant heater and / or a coolant-air heat exchanger, the coolant heater being configured to add heat energy to the coolant in the main coolant circuit, and the coolant-air heat exchanger being configured to remove heat energy from the coolant in the main coolant circuit.

[0016] The paper also discloses motor vehicles employing the aforementioned system and methods for enhancing the performance of HVAC systems.

[0017] Option 1. A system for enhancing the performance capabilities of heating, air conditioning, and ventilation (HVAC) systems, comprising:

[0018] A multi-unit rechargeable energy storage system (RESS) having multiple relatively high thermal mass RESS modules;

[0019] An auxiliary module having a relatively low thermal mass;

[0020] Cooling subsystem, the cooling subsystem comprising:

[0021] A main coolant circuit, which is fluidly connected to the HVAC system and configured to circulate coolant;

[0022] At least one coolant thermal regulation device is arranged in the main coolant circuit;

[0023] Multiple RSS coolant branches, arranged in parallel, wherein each RSS coolant branch is configured to receive coolant from the main coolant circuit to adjust the temperature of one of the corresponding RSS modules; and

[0024] An auxiliary coolant branch, arranged in parallel with the plurality of RESS coolant branches, and configured to receive coolant from the main coolant circuit to adjust the temperature of the auxiliary module; and

[0025] An electronic controller, which is operatively connected to and configured to:

[0026] Determine when the temperature of at least one of the RESS modules is within a first predetermined temperature range;

[0027] Determine when the temperature of the auxiliary module is outside the second predetermined temperature range;

[0028] Adjust the coolant temperature in the main coolant circuit to the target temperature;

[0029] When the temperature of at least one corresponding RESS module is within a first predetermined temperature range, the flow rate of coolant entering at least one of the RESS coolant branches individually from the main coolant circuit is limited; and

[0030] When the temperature of the auxiliary module is outside the second predetermined temperature range, the flow rate of coolant from the main coolant circuit into the auxiliary coolant branch is regulated to provide coolant at the target temperature from the main coolant circuit to the HVAC system.

[0031] Option 2. The system according to Option 1, wherein the relatively high thermal mass RESS module includes individual battery modules having multiple battery cells.

[0032] Option 3. The system according to Option 1, wherein the cooling subsystem additionally includes at least one RESS flow valve, the at least one RESS flow valve being operatively connected to an electronic controller and configured to regulate and distribute coolant received from the main coolant circuit on the plurality of RESS coolant branches.

[0033] Option 4. The system according to Option 3, wherein at least one RESS flow valve is a multi-way valve assembly arranged at the junction between the main coolant circuit and the plurality of RESS coolant branches, and configured to control the flow rate of coolant entering each of the RESS coolant branches.

[0034] Option 5. The system according to Option 3, wherein the at least one RESS flow valve is a plurality of separate throttle valves, each throttle valve being arranged in one of the plurality of RESS coolant branches upstream of the corresponding RESS module and configured to control the flow rate of coolant entering the main RESS coolant branch.

[0035] Option 6. The system according to Option 1, wherein each RESS coolant branch includes a one-way valve configured to control the flow rate of coolant flowing out of the main RESS coolant branch.

[0036] Option 7. The system according to Option 1, wherein the cooling subsystem additionally includes a bypass flow valve and a check valve, the bypass flow valve being operatively connected to an electronic controller and configured to regulate the coolant in the auxiliary coolant branch, and the check valve being configured to control the flow rate of coolant flowing out of the auxiliary coolant branch.

[0037] Option 8. The system according to Option 1, wherein the cooling subsystem additionally includes a one-way valve configured to control the flow rate of coolant flowing out of the auxiliary coolant branch.

[0038] Option 9. The system according to Option 1, wherein the cooling subsystem additionally includes a fluid pump configured to circulate coolant through the main coolant circuit.

[0039] Option 10. The system according to Option 1, wherein at least one coolant thermal conditioning device includes a coolant heater and / or a coolant-air heat exchanger, the coolant heater being configured to add thermal energy to the coolant in the main coolant circuit, and the coolant-air heat exchanger being configured to remove thermal energy from the coolant in the main coolant circuit.

[0040] Option 11. A motor vehicle, comprising:

[0041] An electric motor-generator configured to generate torque;

[0042] Heating, air conditioning, and ventilation (HVAC) systems;

[0043] A multi-unit rechargeable energy storage system (RESS) configured to supply electrical energy to an electric generator and having multiple RESS modules with relatively high thermal mass;

[0044] An auxiliary module having a relatively low thermal mass;

[0045] Cooling subsystem, the cooling subsystem comprising:

[0046] A main coolant circuit, wherein the main coolant circuit is configured to circulate coolant;

[0047] At least one coolant thermal regulation device is arranged in the main coolant circuit;

[0048] Multiple RSS coolant branches, arranged in parallel, wherein each RSS coolant branch is configured to receive coolant from the main coolant circuit to adjust the temperature of one of the corresponding RSS modules; and

[0049] An auxiliary coolant branch, the auxiliary coolant branch being arranged in parallel with the plurality of RESS coolant branches and configured to receive coolant from the main coolant circuit; and

[0050] An electronic controller, which is operatively connected to and configured to:

[0051] Determine when the temperature of at least one of the RESS modules is within a first predetermined temperature range;

[0052] Determine when the temperature of the auxiliary module is outside the second predetermined temperature range;

[0053] Adjust the coolant temperature in the main coolant circuit to the target temperature;

[0054] When the temperature of at least one corresponding RESS module is within a first predetermined temperature range, the flow rate of coolant entering at least one of the RESS coolant branches individually from the main coolant circuit is limited; and

[0055] When the temperature of the auxiliary module is outside the second predetermined temperature range, the flow rate of coolant from the main coolant circuit into the auxiliary coolant branch is regulated to provide coolant at the target temperature from the main coolant circuit to the HVAC system.

[0056] Option 12. The motor vehicle according to Option 11, wherein the relatively high thermal mass RESS module includes individual battery modules having multiple battery cells.

[0057] Option 13. The motor vehicle according to Option 11, wherein the cooling subsystem additionally includes at least one RESS flow valve, the at least one RESS flow valve being operatively connected to an electronic controller and configured to regulate and distribute coolant received from the main coolant circuit on the plurality of RESS coolant branches.

[0058] Option 14. The motor vehicle according to Option 13, wherein the at least one RESS flow valve is a multi-way valve assembly arranged at the junction between the main coolant circuit and the plurality of RESS coolant branches, and configured to control the flow rate of coolant entering each of the RESS coolant branches.

[0059] Option 15. The motor vehicle according to Option 13, wherein the at least one RESS flow valve is a plurality of individual throttle valves, each throttle valve being arranged in one of the plurality of RESS coolant branches upstream of the corresponding RESS module and configured to control the flow rate of coolant entering the main RESS coolant branch.

[0060] Option 16. The motor vehicle according to Option 11, wherein each RESS coolant branch includes a one-way valve configured to control the flow rate of coolant flowing out of the main RESS coolant branch.

[0061] Option 17. The motor vehicle according to Option 11, wherein the cooling subsystem additionally includes a bypass flow valve and a one-way valve, the bypass flow valve being operatively connected to an electronic controller and configured to regulate the coolant in an auxiliary coolant branch, and the one-way valve being configured to control the flow rate of coolant flowing out of the auxiliary coolant branch.

[0062] Option 18. The motor vehicle according to Option 11, wherein the cooling subsystem additionally includes a one-way valve configured to control the flow rate of coolant flowing out of the auxiliary coolant branch.

[0063] Option 19. The motor vehicle according to Option 11, wherein the at least one coolant thermal regulation device includes a coolant heater and / or a coolant-air heat exchanger, the coolant heater being configured to add heat energy to the coolant in the main coolant circuit, and the coolant-air heat exchanger being configured to remove heat energy from the coolant in the main coolant circuit.

[0064] Option 20. A system for enhancing the performance capabilities of heating, air conditioning, and ventilation (HVAC) systems, comprising:

[0065] A multi-cell rechargeable energy storage system (RESS) having multiple battery cells arranged in individual battery modules with relatively high thermal mass;

[0066] An auxiliary module having a relatively low thermal mass;

[0067] Cooling subsystem, the cooling subsystem comprising:

[0068] A main coolant circuit, which is fluidly connected to the HVAC system and configured to circulate coolant;

[0069] At least one coolant thermal regulation device is arranged in the main coolant circuit;

[0070] Multiple RSS coolant branches are arranged in parallel, wherein each RSS coolant branch is configured to receive coolant from the main coolant circuit to adjust the temperature of one of the corresponding RSS modules;

[0071] At least one RESS flow valve configured to regulate and distribute coolant received from the main coolant circuit on the plurality of RESS coolant branches; an auxiliary coolant branch arranged in parallel with the plurality of RESS coolant branches and configured to receive coolant from the main coolant circuit to adjust the temperature of the auxiliary module; and

[0072] Bypass flow valve, the bypass flow valve being configured to regulate the coolant in the auxiliary coolant branch; and

[0073] An electronic controller, which is operatively connected to and configured to:

[0074] Determine when the temperature of at least one of the battery modules is within a first predetermined temperature range;

[0075] Determine when the temperature of the auxiliary module is outside the second predetermined temperature range;

[0076] The coolant in the main coolant circuit is thermally regulated to the target temperature via the at least one coolant thermal regulation device;

[0077] When the temperature of at least one corresponding RESS module is within a first predetermined temperature range, the flow rate of coolant entering at least one of the RESS coolant branches individually from the main coolant circuit is limited via at least one RESS flow valve; and

[0078] When the temperature of the auxiliary module is outside the second predetermined temperature range, the flow rate of coolant entering the auxiliary coolant branch from the main coolant circuit is regulated via the bypass flow valve, and a minimum predetermined coolant flow rate is provided through the cooling subsystem to provide coolant at the target temperature from the main coolant circuit to the HVAC system.

[0079] The foregoing features and advantages, as well as other features and advantages of this disclosure, will become apparent from the following detailed description of one or more embodiments and one or more preferred modes for carrying out this disclosure, when taken in conjunction with the accompanying drawings and claims. Attached Figure Description

[0080] Figure 1 This is a schematic top view of an embodiment of a motor vehicle according to the present disclosure, the motor vehicle employing multiple power sources, heating, air conditioning and ventilation (HVAC), a multi-unit rechargeable energy storage system (RESS), auxiliary modules and systems for enhancing the performance of the HVAC system, the multi-unit rechargeable energy storage system having various modules and configured to generate and store electrical energy used by the vehicle system.

[0081] Figure 2 It is based on this disclosure for enhancing Figure 1 The schematic diagram of the performance capabilities of the HVAC system shown includes an embodiment of a cooling subsystem having a main coolant loop and multiple parallel coolant branches for adjusting the temperature in the individual battery modules and auxiliary modules.

[0082] Figure 3 It is based on this disclosure for enhancing Figure 1The schematic diagram of the performance capabilities of the HVAC system shown includes another embodiment of a cooling subsystem having a main coolant loop and multiple parallel coolant branches for adjusting the temperature in the individual battery modules and auxiliary modules.

[0083] Figure 4 The illustration is based on the adoption of this disclosure. Figures 1 to 3 The method shown is to enhance the performance of an HVAC system using a coolant subsystem. Detailed Implementation

[0084] The embodiments of this disclosure as described herein are intended to be illustrative. Other embodiments may take various and alternative forms. Additionally, the drawings are generally schematic and not necessarily drawn to scale. Some features may be enlarged or reduced to show details of particular components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to employ this disclosure in various ways.

[0085] Certain terms used in the following description may be for illustrative purposes only and are not intended to be limiting. For example, terms such as “above” and “below” refer to orientation in the referenced figures. Terms such as “front,” “rear,” “before,” “after,” “left,” “right,” “rear,” “side,” “upward,” “downward,” “top,” and “bottom” describe the orientation and / or position of portions of a part or element within a consistent but arbitrary frame of reference, as will become clear from the text describing the part or element in question and the associated figures.

[0086] Furthermore, terms such as "first," "second," and "third" may be used to describe individual components. Such terms may include the words specifically mentioned above, their derivatives, and words with similar meanings, and are used to describe the accompanying drawings, but do not imply a limitation on the scope of this disclosure as defined by the appended claims. Moreover, the teachings may be described according to functional and / or logical block components and / or various processing steps. It should be appreciated that such block components may be implemented by multiple hardware, software, and / or firmware components configured to perform the specified functions.

[0087] Referring to the accompanying drawings, similar reference numerals refer to similar parts. Figure 1A schematic diagram of a motor vehicle 10 having a vehicle operator / passenger cabin 10A and a powertrain 12 is shown. Vehicle 10 may include, but is not limited to, commercial vehicles, industrial vehicles, passenger vehicles, aircraft, boats, trains, etc. It is also contemplated that vehicle 10 may include mobile platforms such as aircraft, all-terrain vehicles (ATVs), boats, personal mobile devices, robots, etc., to achieve the purposes of this disclosure. The powertrain 12 includes a power source 14 configured to generate a power source torque T (in... Figure 1 (As shown in the diagram), it is used to propel the vehicle 10 relative to the road surface 18 via the drive wheels 16. The power source 14 is depicted as an electric motor-generator.

[0088] like Figure 1 As shown, the powertrain 12 may include an additional power source 20, such as an internal combustion engine. Power sources 14 and 20 may work together to provide power to vehicle 10. Vehicle 10 additionally includes a central processing unit (CPU) 22 and a multi-cell rechargeable energy storage system (RESS) 24, which is configured to generate and store electrical energy through a heated electrochemical reaction to supply electrical energy to power sources 14 and 20. Vehicle 10 also includes a high-voltage data bus or BUS 25 for transmitting electrical signals between various vehicle systems. Vehicle 10 also includes a vehicle heating, air conditioning, and ventilation (HVAC) system 26, which is configured to regulate the temperature in the vehicle cabin 10A. CPU 22 regulates various systems of vehicle 10, including the powertrain 12 for generating a predetermined amount of power source torque T and HVAC 26. RESS 24 may be connected to power sources 14 and 20, to the electronic CPU 22, and to other vehicle systems, such as HVAC 26, via BUS 25.

[0089] like Figures 1 to 3 As shown, RESS 24 includes multiple battery cells 28, such as lithium-ion rechargeable cells, arranged in various battery modules (such as first module 30-1, second module 30-2, and third module 30-3). The main modules 30-1, 30-2, and 30-3 can be arranged in series or in parallel. Within each module (e.g., 30-1, 30-2, 30-3), different battery cells 28 can be connected in series or in parallel and assembled into cell groups. Such cell groups are then connected in series and assembled into individual modules. Although three separate battery modules are specifically shown, it is intended that RESS 24 includes at least two corresponding modules, and multiple modules can be organized into a battery pack.

[0090] The remainder of this description will focus on the RESS 24 configuration having three battery modules 30-1, 30-2, and 30-3, each battery module having a desired number of battery cells 28. (See also...) Figure 2 and Figure 3 As shown, each battery module 30-1, 30-2, 30-3 includes a corresponding battery module housing 32-1, 32-2, 32-3, which is connected to the chassis ground and configured to house and support the corresponding battery cell 28. The RESS24 may also include a battery pack housing 33, which is surrounded by an environment 34 and configured to house and support the battery modules 30-1, 30-2, 30-3 (e.g., ...). Figure 1 (as shown in the image).

[0091] like Figure 2 and Figure 3 As shown, RESS 24 also includes a cooling subsystem 36 configured to remove heat from various temperature-sensitive components of the RESS. Cooling subsystem 36 includes a main coolant circuit 38 configured to circulate coolant 40 through RESS 24 and HVAC system 26. As shown, cooling subsystem 36 also includes a fluid pump 42 configured to circulate coolant 40 through the main coolant circuit 38. Cooling subsystem 36 also includes multiple coolant branches in fluid communication with the main coolant circuit 38, shown as a first branch 44-1, a second branch 44-2, and a third branch 44-3. Each of the coolant branches 44-1, 44-2, and 44-3 extends adjacent to and along the constituent battery cell 28 through a corresponding battery module 30-1, 30-2, 30-3.

[0092] Furthermore, each coolant branch 44-1, 44-2, 44-3 is configured to receive a portion 38 of coolant 40 from the main coolant circuit. Coolant branches 44-1, 44-2, 44-3 are arranged in parallel to receive their respective portions of coolant 40. Coolant branches 44-1, 44-2, 44-3 are thus configured to independently circulate their respective portions of coolant 40 and adjust the temperature of their corresponding battery modules 30-1, 30-2, 30-3 (by removing or adding heat). Therefore, each coolant branch 44-1, 44-2, 44-3 passes through one of the battery module housings 32-1, 32-2, 32-3. As shown, the main coolant circuit 38 is connected to one or more auxiliary coolant branches (such as…) Figure 2 and Figure 3 The branch 44-4 shown is in fluid communication with the auxiliary coolant branch, which is arranged in parallel with the coolant branches 44-1, 44-2, and 44-3.

[0093] For example, each additional coolant branch 44-4 may be configured to receive coolant 40 from the main coolant circuit 38 and circulate coolant through an auxiliary module or device, generally identified by numeral 45. Such an auxiliary module or device may be, for example, an auxiliary power module (APM), a battery disconnect unit (BDU) including various electrical switches and relays, a DC / DC converter for supplying 12V / 48V power to the vehicle 10, an optional heat-insulated coolant bypass, etc., each with specific temperature requirements and / or heat absorption / dissipation characteristics. Additionally, the main coolant circuit 38 is fluidly connected to the HVAC system 26 to provide its thermal regulation. For example, the cooling subsystem 36 may thermally regulate the HVAC system 26 via a dedicated bidirectional heat pump that operates through two HVAC heat exchangers, one interacting with cabin air (not shown) and the other (identified by numeral 56-1) interacting with the main coolant circuit 38.

[0094] Therefore, at least some of the coolant branches 44-1, 44-2, and 44-3 are configured to receive corresponding portions of coolant 40 from the main coolant circuit 38 to adjust the temperature of the respective battery modules 30-1, 30-2, and 30-3. Similarly, one or more corresponding branches 44-4 are configured to receive one or more portions of coolant 40 from the main coolant circuit 38 to adjust the temperature of one or more corresponding auxiliary modules 45. Each of the battery modules 30-1, 30-2, and 30-3 and each of the auxiliary modules 45 can generate, transfer, and / or dissipate heat energy. Additionally, each of the battery modules 30-1, 30-2, and 30-3 and each of the auxiliary modules 45 is characterized by a mass that is critical for the absorption and dissipation of heat energy, which is defined herein as “thermal mass”. As understood, a higher thermal mass is capable of absorbing or dissipating a greater amount of heat energy from or to its surroundings by conduction, convection, or radiation than a lower thermal mass. In the context of this disclosure, each of the battery modules 30-1, 30-2, and 30-3 is defined by a relatively high thermal mass, while each individual auxiliary module 45 is defined by a relatively low thermal mass.

[0095] Continue to refer to Figure 2 and Figure 3The RESS 24 may also include an inlet manifold 46 and an outlet manifold 48, the inlet manifold 46 being configured to connect the main coolant circuit 38 to coolant branches 44-1, 44-2, 44-3, and the outlet manifold 48 being configured to connect the coolant branches back to the main coolant circuit. Thus, the inlet and outlet manifolds 46, 48 are configured together to maintain the circulation of coolant 40 through the cooling subsystem 36. The cooling subsystem 36 additionally includes at least one RESS flow valve 50. One or more RESS flow valves 50 are configured to regulate and distribute coolant 40 at each of the coolant branches 44-1, 44-2, 44-3, the coolant 40 circulating through and received from the main coolant circuit 38. In other words, one or more RESS flow valves 50 are specifically structured and operated to provide independent regulation of the coolant flow into each individual coolant branch 44-1, 44-2, 44-3.

[0096] like Figure 2 As shown, the RESS flow valve 50 may be a multi-way valve assembly disposed in a junction (such as an inlet manifold 46) between the main coolant circuit 38 and the plurality of coolant branches 44-1, 44-2, 44-3 upstream of each battery module 30-1, 30-2, 30-3. An embodiment of the multi-way valve assembly of the RESS flow valve 50 may be configured to control the flow rate of coolant 40 entering each of the coolant branches 44-1, 44-2, 44-3. Figure 3 As shown, one or more RESS flow valves 50 may be multiple individual throttle valves 50-1, 50-2, 50-3. Each main throttle valve 50-1, 50-2, 50-3 may be arranged in one of multiple coolant branches 44-1, 44-2, 44-3 upstream of the corresponding battery module 30-1, 30-2, 30-3 and configured to control the flow rate of coolant 40 entering the main coolant branch.

[0097] like Figure 2 and Figure 3 As shown, each coolant branch 44-1, 44-2, 44-3 may include a corresponding check valve 52-1, 52-2, 52-3. Check valves 52-1, 52-2, 52-3 are configured to prevent coolant 40 from flowing back into the corresponding coolant branch 44-1, 44-2, 44-3. Each of the check valves 52-1, 52-2, 52-3 is arranged downstream of one or more RESS flow valves 50 and downstream of the corresponding battery modules 30-1, 30-2, 30-3. Therefore, each check valve 52-1, 52-2, 52-3 is configured to control the flow rate of coolant 40 through and out of the corresponding portion of the main coolant branch 44-1, 44-2, 44-3.

[0098] The cooling subsystem 36 may further include a bypass flow valve 54 configured to regulate the flow rate of coolant received from the main coolant circuit 38 in the auxiliary coolant branch 44-4. Additionally, the cooling subsystem 36 may include a one-way valve 52-4 configured to control the flow rate of coolant 40 exiting the auxiliary coolant branch 44-4. The cooling subsystem 36 may also include one or more coolant thermal conditioning devices arranged in the main coolant circuit 38. Specifically, as... Figure 2 and Figure 3 As shown, the coolant thermal conditioning device may include a coolant-air heat exchanger 56-2 and / or a coolant heater 56-3. The coolant-air heat exchanger 56-2 is configured to remove heat from the coolant 40 in the main coolant circuit 38 downstream of the RESS and auxiliary modules, and the coolant heater 56-3 is configured to add heat to the main circuit coolant. For example, embodiments of the coolant-air heat exchanger 56-2 may dissipate heat to the surrounding environment 34, while the coolant heater 56-3 may use a resistor to correspondingly thermally condition the coolant 40. The coolant-air heat exchanger 56-2 may be placed directly in the same line as the main coolant circuit 38, or, although not shown, may be thermally connected to the main coolant circuit via a coolant-coolant heat exchanger or valve body assembly for mixing coolant through a separate coolant circuit.

[0099] like Figures 1 to 3 As shown, the multi-unit RESS 24 may additionally include an electronic controller 58, which may be electronically connected to the CPU 22 or a portion thereof. The electronic controller 58 is operatively connected to the cooling subsystem 36, i.e., configured or programmed to regulate the operation of the cooling subsystem, and may be structured to manage the operation of the RESS 24 and auxiliary modules 45. As shown, the electronic controller 58 is operatively connected to the fluid pump 42, one or more RESS flow valves 50, bypass flow valve 54, HVAC heat exchanger 56-1, and coolant heater 56-3. To support the necessary management of the RESS 24 and / or cooling subsystem 36, the electronic controller 58 specifically includes a processor and tangible, non-transitory memory containing the necessary instructions programmed therein. The controller's memory may be a suitable recordable medium involved in providing computer-readable data or process instructions. Such a recordable medium may take various forms, including but not limited to non-volatile and volatile media.

[0100] Non-volatile media used for the electronic controller 58 may include, for example, optical discs or magnetic disks and other persistent storage. Volatile media may include, for example, dynamic random access memory (DRAM), which may constitute the main memory. These instructions programmed into the controller 58 may be transmitted by one or more transmission media or via a wireless connection, including coaxial cables, copper wires, and optical fibers, including lines containing a system bus connected to a computer processor. The memory of the electronic controller 58 may also include floppy disks, hard disks, magnetic tapes, other magnetic media, CD-ROMs, DVDs, other optical media, etc. The electronic controller 58 may be configured or equipped with other necessary computer hardware, such as a high-speed clock, necessary analog-to-digital (A / D) and / or digital-to-analog (D / A) circuitry, input / output circuitry and devices (I / O), and appropriate signal conditioning and / or buffering circuitry.

[0101] Electronic controller 58 can be configured to regulate the flow rate of coolant 40 entering the respective battery modules 30-1, 30-2, 30-3 via fluid pump 42 and one or more RSS flow valves 50. Similarly, electronic controller 58 can be configured to regulate the flow rate of coolant 40 from the main coolant circuit 38 into the auxiliary module 45 via coolant branch 44-4. One or more algorithms (generally indicated via digit 60) required by or accessible to electronic controller 58 can be stored in the controller's memory and executed automatically to facilitate the operation of RSS 24 and / or cooling subsystem 36. The function of cooling subsystem 36 can be regulated by electronic controller 58, both under normal operating conditions and for the purpose of enhancing (or optimizing) its performance capabilities by prioritizing the thermal regulation of the respective RSS modules 30-1, 30-2, 30-3 and auxiliary module 45.

[0102] Generally, during normal operation of RESS 24, coolant flow through coolant branches 44-1, 44-2, and 44-3 is used to absorb the heat released by the battery cells 28 in the individual battery modules 30-1, 30-2, and 30-3, and to stabilize RESS operation. During various extreme and / or transient conditions, the RESS 24 module and auxiliary systems and module 45 can benefit from thermal regulation via controlling the temperature of the coolant 40. However, under certain conditions, the physical and thermal characteristics of the RESS modules 30-1, 30-2, and 30-3 may interfere with the operational requirements of the HVAC system 26.

[0103] For example, during the cold start and warm-up of vehicle 10, the RESS 24 module can benefit from additional thermal energy to generate the power output required for vehicle propulsion. Simultaneously, the HVAC system 26 can be requested to provide heat to the vehicle cabin 10A. To meet these requirements, heaters 56-3 can be directed to add thermal energy to the coolant 40. However, under these conditions, the optimal temperature ranges for the two systems may differ. Since both RESS 24 and HVAC system 26 receive thermal conditioning from the same coolant body 40, the RESS module with a higher thermal mass than the auxiliary modules 45 will continue to absorb thermal energy from the coolant 40 beyond the point where one or more RESS modules are within an acceptable temperature range.

[0104] Therefore, one or more RSS modules will absorb energy that is more beneficial to the HVAC system 26, thus delaying cabin preheating. Similarly, when the vehicle 10 is operating in a hot environment, the coolant-air heat exchanger 56-2 can be directed to remove heat from the coolant 40. Even if one or more modules are within their acceptable temperature range, the RSS modules will continue to discharge heat into the coolant 40. Because each RSS module has a higher thermal mass than at least one of the auxiliary modules 45, if the RSS 24 and the HVAC system 26 continue to receive coolant from the main circuit 38, the HVAC system will be able to discharge less heat into the coolant 40 due to the heat competitively discharged by the RSS modules, thus delaying cabin cooling.

[0105] like Figure 1 As shown, vehicle 10 also includes system 62 for prioritizing, enhancing, and optimizing the performance of associated RESS and auxiliary modules by prioritizing thermal regulation of the RESS and auxiliary modules. Electronic controller 58 is programmed with one or more specific algorithms 60 to operate the main system. Specifically, the algorithms 60 include stock modes configured to monitor the temperatures of RESS modules 30-1, 30-2, 30-3 and auxiliary modules 45, such as via one or more corresponding RESS temperature sensors 64-1, 64-2, 64-3 and auxiliary temperature sensor 64-4. Electronic controller 58 is programmed to determine when the temperature of at least one of the RESS modules 30-1, 30-2, 30-3 is within a first predetermined temperature range 66-1. The first predetermined temperature range 66-1 for the battery may be from -20 to +50 degrees Celsius.

[0106] The electronic controller 58 is also programmed to determine when the temperature of a particular auxiliary module 45 (such as a BDU, APM, OBCM, or coolant bypass) falls outside a second predetermined temperature range 66-2. The second predetermined temperature range 66-2 for the BDU, APM, or OBCM auxiliary modules can be from -35 to +70 degrees Celsius. For cold environment operation (e.g., ambient environment 34 at -10 degrees Celsius), coolant 40 can pass through a coolant heater 56-3 to increase the coolant temperature by up to 5 degrees Celsius for the heating mode of the HVAC system 26. For hot operation (e.g., ambient environment 34 at 35 degrees Celsius), coolant 40 can pass through a coolant-air heat exchanger 56-2 to decrease the coolant temperature by up to 40 degrees Celsius for the cooling mode of the HVAC system 26. The electronic controller 58 is also programmed to thermally regulate (increase or decrease its temperature) the coolant 40 in the main coolant circuit 38 to a target temperature 68 using appropriate coolant thermal conditioning devices 56-2 or 56-3.

[0107] The electronic controller 58 is additionally programmed to limit (i.e., throttle or cut off) the flow rate of coolant 40 from the main coolant circuit 38 into at least one of the RESS coolant branches 44-1, 44-2, and 44-3 (via one or more appropriate RESS flow valves 50) when the temperature of the corresponding RESS module(s) is within a first predetermined temperature range 66-1. This limitation of the flow rate of coolant 40 through the corresponding RESS modules 30-1, 30-2, and 30-3 will maintain a larger volumetric flow rate of coolant through the auxiliary modules 45 and limit the influence of the main RESS modules(s) on the temperature of the coolant in the cooling subsystem 36. The electronic controller 58 is also programmed to regulate the flow rate of coolant 40 from the main coolant circuit 38 into the auxiliary coolant branch 44-4 when the temperature of the auxiliary module 45 (e.g., HVAC) is outside a second predetermined temperature range 66-2.

[0108] By limiting the flow through one or more RESS modules 30-1, 30-2, and 30-3, more coolant 40 will be directed through one or more auxiliary modules 45. By allowing a greater volumetric flow through the auxiliary coolant branch 44-4, the flow rate of coolant 40 can be regulated to at least a predetermined minimum volumetric flow rate for the necessary HVAC 26 performance. Additionally, if the auxiliary modules are outside a second predetermined temperature range 66-2, the coolant flow rate through the auxiliary modules 45 can be further increased. After the coolant 40 has passed through the auxiliary branch 44-4, the electronic controller 58 can regulate the coolant flow through the HVAC heat exchanger 56-1 to supply coolant at a target temperature from the main coolant circuit to the HVAC, thereby thermally regulating the HVAC system 26 to heat or cool the cabin 10A. The end result of this prioritized thermal regulation is enhanced performance of the HVAC system 26, such as increasing HVAC heat output during cold starts of the vehicle 10 or reducing heat penetration into cooler cabin air during hot ambient conditions.

[0109] Figure 4 Methods 100 for prioritizing, enhancing, and optimizing the performance of HVAC system 26 through thermal regulation via multi-branch cooling subsystem 36 are shown below, and references are made below. Figures 1 to 3 The structure shown in Figure 102 is described below. Method 100 begins in Figure 102 with monitoring the temperature of RESS modules 30-1, 30-2, 30-3 and(one or more) auxiliary modules 45 via electronic controller 58, such as via corresponding RESS temperature sensors 64-1, 64-2, 64-3 and auxiliary temperature sensor 64-4, and may also monitor the temperature in the vehicle cabin 10A and the surrounding environment 34. In Figure 102, the method may additionally include detecting, via electronic controller 58, an operator's request to start the vehicle 10, such as a key start mode of powertrain 12, to cause RESS 24 to begin discharging. Following Figure 102, the method proceeds to Figure 104.

[0110] In frame 104, the method includes determining, via electronic controller 58, when the temperatures of one or more RESS modules 30-1, 30-2, 30-3 are within a first predetermined temperature range 66-1. Following frame 104, the method proceeds to frame 106. In frame 106, the method includes determining, via electronic controller 58, when the temperature of a particular auxiliary module 45 is outside a second predetermined temperature range 66-2. After completing frame 106, the method proceeds to frame 108. In frame 108, the method includes thermally conditioning the coolant in the main coolant circuit 38 to a target temperature 68 via electronic controller 58 (using coolant-air heat exchanger 56-2 or heater 56-3). This thermal conditioning may, for example, include increasing the temperature of coolant 40 above the predetermined value 68 for heating the vehicle cabin 10A via HVAC system 26 after a cold start. Following frame 108, the method proceeds to frame 110.

[0111] In block 110, the method includes limiting the flow rate of coolant 40 entering at least one of the RESS coolant branches 30-1, 30-2, 30-3 individually from the main coolant circuit 38 (via one or more RESS flow valves 50) via an electronic controller 58 when the temperature of the corresponding RESS module(s) is within a first predetermined temperature range 66-1. This limitation on the flow rate of coolant 40 entering the RESS coolant branches 30-1, 30-2, 30-3 aims to maintain a large volumetric flow rate of coolant through the auxiliary modules(s) 45 and limit the influence of the main RESS modules(s) on the temperature of the coolant in the cooling subsystem 36. Following block 110, the method proceeds to block 112. In block 112, the method includes regulating the flow rate of coolant 40 entering a specific auxiliary coolant branch 44-4 from the main coolant circuit 38 via an electronic controller 58 when the temperature of the corresponding auxiliary module 45 is outside a second predetermined temperature range 66-2.

[0112] Additionally, in figure 112, by allowing a greater volumetric flow rate through the auxiliary coolant branches 44-4, the flow rate of coolant 40 through the HVAC heat exchanger 56-1 can be regulated to provide at least a predetermined minimum volumetric flow rate for the necessary HVAC 26 performance. For operation of the cooling system 62, after the coolant 40 has passed through the auxiliary branches 44-4, the electronic controller 58 can regulate the coolant flow through the coolant heater 56-3 and raise the coolant temperature by approximately 5 degrees Celsius for the heating mode of the HVAC system 26. For operation of the heating system 62, after the coolant 40 has passed through the auxiliary branches 44-4, the electronic controller 58 can regulate the coolant flow through the coolant-air heat exchanger 56-2 and lower the coolant temperature by approximately 40 degrees Celsius for the cooling mode of the HVAC system 26. The intended result of regulating the flow rate of coolant 40 into the main auxiliary coolant branches 44-4 is to enhance the performance of the HVAC system 26.

[0113] Following block 112, the method can loop back to block 102 to continue monitoring the respective RESS and auxiliary module temperatures. If the various monitored temperatures have become equal or it is determined that a predetermined steady state or acceptable limit conditions have been reached, the method can terminate in block 114. Alternatively, if powertrain 12 and other vehicle systems, such as auxiliary module(s) 45, have been disconnected and fluid pump 42 has been deactivated, the method can shut off current flow and power generation in RESS 24 and similarly terminate in block 114. In general, method 100 utilizes the flexibility provided by a parallel coolant branch controlled separately by the cooling subsystem 36 to enhance the performance of HVAC system 26 using a coolant supply shared with RESS 24 and (one or more) auxiliary modules 45.

[0114] Detailed description and accompanying drawings or figures support and describe this disclosure, but the scope of this disclosure is defined only by the claims. While the best mode for implementing the claimed disclosure and some other embodiments have been described in detail, various alternative designs and embodiments exist for practicing the disclosure as defined in the appended claims. Furthermore, the embodiments illustrated in the drawings, or features of the various embodiments mentioned in this specification, are not necessarily to be construed as independent embodiments. Rather, it is possible that each feature described in one of the examples of embodiments may be combined with one or more other desired features from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Therefore, these other embodiments fall within the framework and scope of the appended claims.

Claims

1. A system for enhancing the performance capabilities of a heating, air conditioning, and ventilation (HVAC) system, comprising: A multi-unit rechargeable energy storage system (RESS) having multiple relatively high thermal mass RESS modules; An auxiliary module having a relatively low thermal mass; Cooling subsystem, the cooling subsystem comprising: A main coolant circuit, which is fluidly connected to the HVAC system and configured to circulate coolant; At least one coolant thermal regulation device is arranged in the main coolant circuit; Multiple RSS coolant branches, arranged in parallel, wherein each RSS coolant branch is configured to receive coolant from the main coolant circuit to adjust the temperature of one of the corresponding RSS modules; and An auxiliary coolant branch, arranged in parallel with the plurality of RESS coolant branches, and configured to receive coolant from the main coolant circuit to adjust the temperature of the auxiliary module; and An electronic controller, which is operatively connected to and configured to: Determine when the temperature of at least one of the RESS modules is within a first predetermined temperature range; Determine when the temperature of the auxiliary module is outside the second predetermined temperature range; Adjust the coolant temperature in the main coolant circuit to the target temperature; When the temperature of at least one corresponding RESS module is within a first predetermined temperature range, the flow rate of coolant entering at least one of the RESS coolant branches individually from the main coolant circuit is limited; and When the temperature of the auxiliary module is outside the second predetermined temperature range, the flow rate of coolant from the main coolant circuit into the auxiliary coolant branch is regulated to provide coolant at the target temperature from the main coolant circuit to the HVAC system.

2. The system according to claim 1, wherein, The Relative High Thermal Mass (RESS) module comprises individual battery modules with multiple battery cells.

3. The system according to claim 1, wherein, The cooling subsystem additionally includes at least one RESS flow valve, which is operatively connected to an electronic controller and configured to regulate and distribute coolant received from the main coolant circuit on the plurality of RESS coolant branches.

4. The system according to claim 3, wherein, At least one RESS flow valve is a multi-way valve assembly arranged at the junction between the main coolant circuit and the plurality of RESS coolant branches, and configured to control the flow rate of coolant into each of the RESS coolant branches.

5. The system according to claim 3, wherein, The at least one RESS flow valve is a plurality of individual throttle valves, each throttle valve being arranged in one of the plurality of RESS coolant branches upstream of the corresponding RESS module and configured to control the flow rate of coolant entering the main RESS coolant branch.

6. The system according to claim 1, wherein, Each RESS coolant branch includes a one-way valve configured to control the flow rate of coolant exiting the main RESS coolant branch.

7. The system according to claim 1, wherein, The cooling subsystem additionally includes a bypass flow valve and a check valve, the bypass flow valve being operatively connected to an electronic controller and configured to regulate the coolant in the auxiliary coolant branch, and the check valve being configured to control the flow rate of coolant exiting the auxiliary coolant branch.

8. The system according to claim 1, wherein, The cooling subsystem additionally includes a check valve configured to control the flow rate of coolant exiting the auxiliary coolant branch.

9. The system according to claim 1, wherein, The cooling subsystem additionally includes a fluid pump configured to circulate coolant through the main coolant circuit.

10. The system according to claim 1, wherein, At least one coolant thermal conditioning device includes a coolant heater and / or a coolant-air heat exchanger, the coolant heater being configured to add heat energy to the coolant in the main coolant circuit, and the coolant-air heat exchanger being configured to remove heat energy from the coolant in the main coolant circuit.

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