Vehicle Cooling Circuit Mixing for Stable Battery and Motor Temperatures
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Solution Overview
Problem
Current thermal management systems in vehicles face challenges in efficiently controlling the temperature of both electric motors and batteries, particularly during transient journeys where sudden changes in temperature and pressure occur when switching between series and parallel connection modes, leading to inefficient heat dissipation and potential overheating.
Innovation Solution
A thermal management system that utilizes a multi-way valve to connect the battery and electric motor cooling circuits in series, parallel, or a needs-based mixing mode, allowing for incremental or continuous adjustment of valve positions to smoothly mix coolant flows and bypass radiators, thereby optimizing temperature control and reducing sudden transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the multi-way valve switches between series connection mode and parallel connection mode to control temperature, then temperature control capability is improved, but sudden changes in temperature and pressure occur causing system instability
Solution Approach 1:
The multi-way valve is designed to be adjustable between series connection mode, parallel connection mode, and intermediate mixing modes, allowing dynamic adjustment of the cooling circuit configuration. This dynamic capability enables smooth transition between different cooling strategies, preventing sudden temperature and pressure changes while maintaining system stability.
Solution Approach 2:
The intermediate valve position acts as an intermediary state between series and parallel connection modes. In this intermediate position, coolant flows from both cooling circuits are mixed in a controlled manner, serving as a transition state that prevents abrupt changes in system parameters while maintaining temperature control capability.
2Speed
If frequent switching between series and parallel modes is performed during transient journeys, then temperature control responsiveness is improved, but system reliability deteriorates due to sudden transitions and potential overheating
Solution Approach 1:
The intermediate mixing mode enables continuous and smooth adjustment of coolant flow distribution between the two cooling circuits. This continuous adjustment capability eliminates abrupt transitions during transient journeys, maintaining system reliability while preserving temperature control responsiveness through gradual adaptation to changing thermal conditions.
3Device complexity
If the multi-way valve provides only binary switching between series and parallel modes, then device complexity is reduced, but temperature control precision deteriorates due to inability to perform needs-based mixing
Solution Approach 1:
The multi-way valve incorporates intermediate positions between the binary series and parallel modes, enabling continuous adjustment of coolant flow distribution. This dynamic positioning capability allows needs-based mixing of coolant flows from both cooling circuits, achieving precise temperature control without significantly increasing device complexity.
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 improves temperature control for both electric motor and battery cooling circuits by preventing sudden temperature and pressure changes, allowing for efficient heat dissipation and precise temperature management, reducing the risk of overheating and enhancing overall thermal management efficiency.
Implementation Method 1
the coolant flows of the two cooling circuits are mixed with each other as needed... waste heat or heat loss from the electric motor cooling circuit can advantageously be dissipated to the battery cooling circuit
Data Source
AI summary
A thermal management system for use in a vehicle includes a first cooling circuit for cooling a battery; and a second cooling circuit for cooling an electric motor configured to drive the vehicle. The first and second cooling circuits are connected to each other: (a) in series by a multi-way valve in a first mode of the thermal management system and in a first valve position of the multi-way valve, or (b) in parallel in a second mode of the thermal management system and in a second valve position of the multi-way valve. In a third mode of the thermal management system and in a third valve position, the multi-way valve is configured to take up an intermediate position in which coolant flows of the first and second cooling circuits are mixed with each other as needed.