Vehicle Thermal Management Using Brake Heat for Battery Warming
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Solution Overview
Problem
Current thermal management systems for electric, hybrid, and hydrogen vehicles are inefficient in managing heat distribution and temperature regulation across various components, leading to potential damage and power losses, especially during cold starts and braking processes.
Innovation Solution
A thermal management system that integrates a cooling medium circuit with a pump, a heating medium circuit with a pump, and a heat transfer device, along with a control unit that manages temperature thresholds to optimize heat transfer between components, allowing for efficient heating and cooling of the battery, interior, and brake systems during braking and idling processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate heating elements (PTC heating elements) are used to heat the interior and regulate battery temperature, then the temperature control function is achieved, but the device complexity and energy consumption increase
Solution Approach 1:
The patent merges the braking system and thermal management system by using the brake as a heat source and the battery as a heat receiver. The braking process, which generates heat, is integrated with the battery heating function, eliminating the need for separate PTC heating elements. This is achieved through a thermal management control unit that coordinates brake actuation with battery temperature requirements.
Solution Approach 2:
The patent converts the harmful effect of heat generated during braking (which typically requires dissipation) into a beneficial resource for heating the battery. Instead of treating brake heat as waste that needs to be removed, the system recovers and transfers this heat to the battery, improving overall system efficiency and reducing the need for additional heating components.
2Reliability
If brake heat is dissipated during braking, then the brake temperature is controlled, but energy is wasted and the battery may not receive needed heat
Solution Approach 1:
The system transforms the previously harmful heat generation during braking into a useful resource. The brake heat, which would normally be wasted energy requiring dissipation, is now captured and transferred to the battery for thermal management. This resolves the contradiction by making the energy loss beneficial rather than harmful.
Solution Approach 2:
The patent introduces a thermal management control unit as an intermediary that coordinates between the braking system and battery thermal management. This control unit monitors both brake temperature and battery temperature, and intelligently manages heat transfer timing and magnitude, ensuring both brake cooling and battery heating requirements are met simultaneously.
3Reliability
If the battery temperature is below the threshold value, then heating is required for reliable operation, but additional heating components increase device complexity
Solution Approach 1:
The system enables the braking process to serve dual purposes: vehicle deceleration and battery heating. When the battery temperature is below the threshold, the control unit activates the brake not only for braking but also as a heat source for the battery. This self-service approach eliminates the need for dedicated battery heating components.
Solution Approach 2:
The brake system is given multiple functions: it serves both as a vehicle braking device and as a heating device for the battery. This multi-functionality reduces the overall system complexity by eliminating redundant components, as the same hardware (brake) performs both mechanical braking and thermal management functions.
4Reliability
If multiple separate heating elements are installed for interior heating and battery temperature regulation, then temperature control is achieved, but the energy expenditure increases
Solution Approach 1:
The system recovers energy that would otherwise be wasted (brake heat) and repurposes it for battery heating. This energy recovery approach reduces the total energy expenditure of the vehicle by converting mechanical energy loss during braking into useful thermal energy for battery maintenance, eliminating the need for additional heating energy input.
Solution Approach 2:
The system recovers thermal energy from the braking process that would normally be discarded as waste heat. By capturing and redirecting this energy to heat the battery, the system improves overall energy efficiency and reduces the energy burden on the vehicle's powertrain.
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 system effectively dissipates heat generated during braking and uses it to heat the battery and interior, reducing energy expenditure and preventing overheating, while maintaining optimal temperature ranges for reliable operation.
Implementation Method 1
a heat transfer device for exchanging heat between the cooling medium in the cooling medium circuit and the heating medium in the heating medium circuit
Implementation Method 2
a cooling medium pump for delivering a cooling medium, such as oil, in the cooling medium circuit for cooling a brake, such as a multiple-disk brake and/or a component, for instance a rotor, of an electric drive motor
Implementation Method 3
a heating medium pump for delivering a heating medium, such as water, in the heating medium circuit for cooling and/or heating a battery and/or power electronics and/or a charging device and/or another component
Data Source
AI summary
A thermal management system for a vehicle has: a cooling medium circuit with a cooling medium pump for delivering a cooling medium in the cooling medium circuit for cooling a brake and/or a component of an electric drive motor of the vehicle and/or a transmission, a heating medium circuit with at least one heating medium pump for delivering a heating medium in the heating medium circuit for cooling and/or heating a battery and/or power electronics and/or a charging device and/or another component of the electric drive motor of the vehicle and/or an interior of the vehicle, and a heat transfer device for exchanging heat between the cooling medium in the cooling medium circuit and the heating medium in the heating medium circuit.