Traction Battery Zone Cooling Circuits for Temperature Uniformity
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Solution Overview
Problem
Current thermal management systems for traction batteries in vehicles often fail to maintain optimal temperature uniformity across different zones, leading to hot and cold spots that can affect battery performance and lifespan.
Innovation Solution
A thermal management system with distinct circuits for each cooling zone, equipped with temperature sensors and valves that control coolant flow rates, allowing for individual heating or cooling of each zone to maintain optimal temperatures, and a controller that adjusts valve openings based on temperature readings to prioritize cooling or heating as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single thermal management circuit is used for the entire battery, then the system complexity is reduced, but temperature uniformity across different zones deteriorates
Solution Approach 1:
The battery pack is divided into multiple thermal zones (first thermal zone, second thermal zone, etc.), each with its own thermal management circuit. This segmentation allows independent temperature control for each zone, resolving the contradiction by maintaining temperature uniformity without requiring a single complex system to manage the entire battery.
Solution Approach 2:
Each thermal zone is equipped with its own temperature sensor and control circuit, enabling localized temperature monitoring and adjustment. This local quality approach allows the system to address temperature variations in specific zones without affecting other zones, thereby maintaining overall temperature uniformity.
2Manufacturing precision
If multiple distinct thermal management circuits are used for different zones, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The thermal management system uses a unified coolant circulation architecture where the same coolant flows through multiple thermal zones via separate circuits. This multi-functionality allows a single coolant system to serve multiple zones with different temperature requirements, achieving precise temperature control without proportionally increasing system complexity.
Solution Approach 2:
Each thermal zone has dynamically adjustable flow control mechanisms that can independently regulate coolant flow rates based on real-time temperature conditions. This dynamic control enables precise temperature management while the system adapts to changing thermal loads in different zones.
3Temperature
If coolant flow rate is increased to cool hot zones, then cooling effectiveness is improved, but energy consumption increases
Solution Approach 1:
The system applies cooling selectively to only those thermal zones that require it, rather than cooling the entire battery uniformly. By directing coolant flow and adjusting flow rates locally in hot zones, the system achieves effective cooling while minimizing energy consumption in zones that are already at optimal temperature.
Solution Approach 2:
The thermal management system dynamically adjusts coolant flow rates, temperatures, and circulation patterns based on real-time temperature sensor data from each zone. This parameter optimization allows the system to achieve maximum cooling effectiveness with minimum energy input by adapting to actual thermal conditions.
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
This solution ensures temperature homogeneity across the battery, enhancing performance and extending battery life by actively managing temperature differentials between zones.
Implementation Method 1
conduit configured to circulate coolant therethrough
Implementation Method 2
a pump, and valves each connected between the pump and a corresponding one of the circuits
Implementation Method 3
valves each connected between the pump and a corresponding one of the circuits such that flow rates of the coolant through each of the circuits are individually controlled by the valves
Data Source
AI summary
A vehicle includes a traction battery having a plurality of cells arranged in arrays and grouped into a plurality of cooling zones. A thermal management system includes a plurality of distinct circuits each associated with one of the zones. The thermal management system is configured to provide individual heating or cooling to each of the circuits to independently control temperatures of the zones. A controller is programmed to, in response to one of the zones exceeding a first threshold temperature and another of the zones being less a second threshold temperature, command the thermal management system to provide cooling to the circuit associated with the one of the zones and command the thermal management system to provide heating to the circuit associated with the another of the zones.