Drive Axle Battery Thermal Control Across Charge, Park, and Drive

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Solution Overview

Problem

Existing vehicle drive axle systems with electric powertrains face inefficiencies in thermal management, particularly when transitioning between different operating modes such as charge, park, and drive modes, leading to energy wastage and potential performance issues.

Innovation Solution

A method of controlling the drive axle system that dynamically adjusts the thermal management of the first electric power source based on the current operating mode, using the thermal management subsystem to either cool or heat the power source as necessary to maintain optimal temperatures within defined limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the thermal management subsystem continuously operates to maintain optimal temperature, then the reliability of the electric power source is improved, but the energy consumption increases

Engineering Contradiction:

Improvereliability of electric power sourceVSAvoidenergy consumption of thermal management subsystem

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The thermal management subsystem operates periodically rather than continuously. The controller monitors temperature and activates cooling only when the temperature exceeds the upper threshold or heating when below the lower threshold, allowing the system to rest in between operations, thus reducing energy consumption while maintaining reliability

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system dynamically adjusts thermal management parameters (cooling/heating activation) based on temperature thresholds. By changing the operational state of the thermal management subsystem according to temperature parameters, the system maintains reliability only when necessary while minimizing energy consumption during normal operating conditions

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the thermal management subsystem actively cools or heats the electric power source, then the temperature control precision is improved, but the energy wastage increases

Engineering Contradiction:

Improvetemperature control precisionVSAvoidenergy wastage in thermal management

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The controller continuously monitors the temperature of the electric power source and uses this feedback to determine when cooling or heating is necessary. By comparing the monitored temperature against predefined thresholds, the system activates thermal management only when needed, achieving precise temperature control without continuous energy wastage

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The electric power source inherently generates heat during operation, and the system leverages this self-heating effect during drive modes. The thermal management subsystem supplements this by providing heating only when necessary (below lower threshold) or cooling when excessive (above upper threshold), reducing overall energy wastage while maintaining temperature precision

Inventive Principle:

Principle #25Self-service

3Quantity of substance

If the system transfers electrical energy from the first electric power source to the second electric power source, then the state of charge of the second power source is improved, but the available energy for propulsion decreases

Engineering Contradiction:

Improvestate of charge of second electric power sourceVSAvoidavailable energy for vehicle propulsion

Core Design Contradiction:

Quantity of substanceVSUse of energy by moving object

Solution Approach 1:

The system performs partial energy transfer from the first to the second electric power source rather than complete transfer. The controller manages the charging of the second power source (auxiliary battery) to maintain its state of charge within acceptable limits while preserving sufficient energy in the first power source (traction battery) for propulsion needs, balancing both requirements through controlled partial action

Inventive Principle:

Principle #16Partial or excessive action

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 approach enhances energy efficiency by tailoring thermal management actions to the specific operating mode, preventing energy wastage and improving the performance and reliability of the electric powertrain.

Implementation Method 1

The thermal management subsystem may circulate a fluid to remove heat from the first electric power source

Methodology Applied

Scientific EffectHeat transfer: Convection

Implementation Method 2

The thermal management subsystem may circulate a fluid to provide heat to the first electric power source

Methodology Applied

Scientific EffectHeat transfer: Convection

Data Source

PatentUS12221013B2Vehicle drive axle system and method of control

Publication Date: 2025.02.11 ARVINMERITOR TECHNOLOGY LLC

AI summary

A method of controlling a drive axle system of a vehicle. The temperature of a first electric power source that is configured to store electrical energy and provide electrical energy to an electric motor to provide propulsion torque may be reduced when an upper temperature limit is exceeded. The temperature of the first electric power source may be increased when the temperature is below a lower temperature limit.