EV Battery Coolant Heater With Feedback Overheat Protection
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Solution Overview
Problem
Electric vehicle batteries are sensitive to temperature, with maximum charge and discharge currents varying based on battery temperature, and existing heaters are not suited for high voltage electric vehicle battery packs, posing challenges in maintaining optimal operating temperatures.
Innovation Solution
A temperature control system for electric vehicle batteries using a coolant heater and chiller, with a thermistor to monitor coolant temperature and a controller to energize the heating element when the temperature is below a predetermined limit, and to discontinue power if the temperature increase rate exceeds a threshold, ensuring safe and efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If existing engine block heaters are used for electric vehicle battery packs, then heating function is provided, but the heater is not suited for high voltage power supply and may cause overheating
Solution Approach 1:
The heating element's electrical parameters (voltage, current, resistance) are specifically designed for high voltage power supply compatibility. The controller adjusts power delivery parameters based on real-time temperature feedback to prevent overheating, transforming the heater into a high-voltage optimized device with controlled power output.
Solution Approach 2:
A temperature sensor continuously monitors the battery temperature and feeds this information back to the controller. The controller uses this feedback to dynamically adjust the heating element's power output, discontinuing heating when the temperature reaches the predetermined threshold, thus preventing overheating while maintaining heating efficiency.
2Temperature
If heating element is continuously energized to maintain battery temperature, then temperature control is improved, but energy consumption increases and overheating risk increases
Solution Approach 1:
The temperature sensor provides continuous feedback to the controller, which intelligently controls the heating element's operation. The controller energizes the heating element only when the temperature falls below the predetermined threshold and discontinues power supply when the threshold is reached, optimizing energy consumption while maintaining temperature control.
Solution Approach 2:
Instead of continuous heating, the system employs periodic heating cycles controlled by temperature thresholds. The heating element is intermittently energized based on real-time temperature conditions, reducing overall energy consumption while effectively maintaining the battery within the desired temperature range.
3Speed
If high power heating element is used for rapid temperature increase, then heating speed is improved, but overheating control becomes more difficult
Solution Approach 1:
The temperature sensor and controller form a closed-loop control system that continuously monitors battery temperature and adjusts heating power accordingly. This feedback mechanism enables the use of high-power heating elements for rapid temperature increase while automatically preventing overheating by discontinuing power supply when the predetermined threshold is reached, simplifying control despite the high power involved.
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 system effectively maintains the electric vehicle battery within a desired temperature range, optimizing charging and discharging efficiency while preventing overheating, thus ensuring reliable battery performance.
Implementation Method 1
A heating element is positioned within the housing in a heat transfer relationship with coolant for transferring heat to an electric vehicle battery
Implementation Method 2
A thermistor is positioned in the housing to output a signal indicative of a temperature of the battery coolant
Implementation Method 3
A heating element is positioned within the housing in a heat transfer relationship with coolant for transferring heat
Data Source
AI summary
An electric vehicle battery heater includes a housing having a coolant inlet and a coolant outlet. A heating element is positioned within the housing in a heat transfer relationship with coolant for transferring heat to an electric vehicle battery. A thermistor is positioned in the housing to output a signal indicative of a temperature of the battery coolant. A controller energizes the heating element when the signal represents that the coolant temperature is less than a predetermined lower limit.