Battery Cooling Control System for EV Charging
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Solution Overview
Problem
Existing battery cooling systems in electric vehicles fail to maintain optimal battery temperature during charging, leading to increased charging times due to rising battery temperatures as State of Charge (SOC) decreases, which affects charging efficiency and user convenience.
Innovation Solution
A battery cooling control system that includes an electric water pump (EWP) and a chiller, controlled by a controller that adjusts cooling modes based on battery temperature, using a cooling map to optimize RPM and determine when to engage or disengage cooling components to maintain optimal charging temperatures, thereby maximizing charging current and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cooling control is performed using existing technology, then battery protection (durability) is improved, but charging time increases due to inability to maintain optimal charging temperature
Solution Approach 1:
The system dynamically switches between first and second cooling control modes based on real-time battery temperature conditions. The controller adjusts cooling strategy dynamically: using EWP alone for moderate cooling needs, and EWP plus chiller for intensive cooling, thereby maintaining optimal charging temperature and reducing charging time while protecting battery durability
Solution Approach 2:
The system performs preliminary cooling action before charging by determining the required cooling level based on predicted charging conditions and current battery temperature. The controller pre-adjusts the cooling system operation to ensure optimal temperature is reached before charging begins, maximizing charging efficiency from the start
2Productivity
If battery temperature is allowed to increase, then charging speed may be optimized in theory, but actual charging time increases due to temperature rise during charging
Solution Approach 1:
The controller continuously monitors battery temperature during charging and uses this feedback to adjust cooling system operation in real-time. Based on the temperature feedback, the controller determines whether to switch between cooling modes or adjust cooling intensity, thereby maintaining battery temperature within the optimal charging range and ensuring sustained high charging speed
Solution Approach 2:
The system changes operating parameters of the cooling system based on battery temperature conditions. The controller adjusts RPM of EWP and activation state of chiller according to temperature thresholds, optimizing the balance between cooling effect and energy consumption to maintain optimal charging temperature
3Temperature
If PTC heater is used to increase battery temperature, then optimal charging temperature can be achieved, but system complexity increases
Solution Approach 1:
Instead of using heating (PTC heater) to achieve optimal charging temperature, the system inverts the approach by using cooling (EWP and chiller) to maintain optimal temperature by removing excess heat. This reverse strategy achieves the same goal of temperature control while avoiding the complexity of adding heating systems
Solution Approach 2:
The cooling system serves multiple functions: it cools the battery during charging, maintains optimal temperature ranges, and eliminates the need for separate heating systems. The EWP and chiller combination provides universal temperature management capability, reducing overall system complexity despite having active cooling components
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 minimizes battery charging time by maintaining optimal temperatures, enhancing charging efficiency and user convenience by dynamically controlling cooling based on battery SOC and temperature, without requiring additional heating systems like PTC heaters.
Implementation Method 1
an electric water pump (EWP) that circulates coolant to cool a battery
Implementation Method 2
a chiller that cools the coolant
Data Source
AI summary
A battery cooling control system includes an electric water pump (EWP) that circulates coolant to cool a battery, a chiller that cools the coolant, and a controller electrically connected with the EWP and the chiller. The controller enters a battery cooling control mode to monitor a current temperature of the battery, when battery charging is scheduled, determines the cooling control mode based on the current temperature of the battery, and controls cooling using at least one of the EWP or the chiller depending on the determined cooling control mode.