Dual Coolant Path Control for Peak EV Drive Current
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Solution Overview
Problem
Existing cooling systems for electric vehicles and hybrid vehicles require larger cooling circuits to handle temporary increases in output current, leading to disproportionate costs and space usage.
Innovation Solution
A cooling control device that includes a first coolant passage for a cooling target and a second coolant passage for an electric drive unit, with a connection path and control mechanisms to manage coolant flow based on current requirements, allowing coolant temperature adjustment without increasing the size of the second heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the cooling circuit size is increased to handle temporary increases in output current, then the maximum current capacity is improved, but the device complexity and space usage increase
Solution Approach 1:
The patent implements dynamic coolant flow control by switching between first and second coolant passages based on real-time current requirements. The path control device adjusts the coolant flow path dynamically, directing coolant through the first passage during high current periods and through the second passage during normal operation, thereby providing variable cooling capacity without requiring a permanently oversized cooling circuit.
Solution Approach 2:
The cooling system achieves multi-functionality by enabling a single cooling circuit to serve two distinct cooling needs: cooling the battery (first coolant passage) and cooling the electric drive unit (second coolant passage). The path control device allows the system to switch between these functions based on operational requirements, eliminating the need for separate dedicated cooling circuits for each component.
2Power
If the cooling circuit size is increased to handle temporary increases in output current, then the maximum current capacity is improved, but the cost increases
Solution Approach 1:
The system employs dynamic path control to optimize cooling resource allocation. During temporary high current situations, the path control device redirects coolant flow through the first coolant passage to provide enhanced cooling capacity. During normal operation, it uses the second coolant passage, thereby avoiding the need to permanently size the cooling circuit for peak conditions, which reduces overall system cost.
Solution Approach 2:
The cooling system utilizes waste heat from the electric drive unit (when operating) to preheat coolant for battery thermal management. This self-service approach recovers energy that would otherwise be lost, reducing the overall thermal management burden and allowing for a more compact, cost-effective cooling system design.
3Measurement precision
If separate cooling circuits are used for the battery and electric drive unit, then the temperature control precision is improved, but the device complexity increases
Solution Approach 1:
The patent creates a unified cooling system that can perform multiple cooling functions through a single integrated circuit with switchable paths. The path control device enables the system to selectively activate different coolant flow paths based on which component requires cooling, thereby maintaining precise temperature control for both the battery and electric drive unit while avoiding the complexity of completely separate cooling circuits.
Solution Approach 2:
The cooling circuit is segmented into distinct pathways (first coolant passage for battery, second coolant passage for electric drive unit) that can be independently controlled. The path control device selectively opens or closes specific segments based on thermal requirements, allowing precise temperature control for each component while sharing common cooling infrastructure.
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
Enables downsizing of the cooling system by efficiently managing coolant flow and temperature to enhance the maximum current capacity without enlarging the cooling circuit components.
Implementation Method 1
the first heat exchanger and the second heat exchanger are each a device that releases heat from the coolant
Implementation Method 2
a connection path configured to connect the first coolant passage and the second coolant passage is provided between the first coolant passage and the second coolant passage
Data Source
AI summary
A first cooling circuit is provided with a first coolant passage, and a second cooling circuit is provided with a second coolant passage. A connection path is provided between them. A cooling control device includes a current amount calculation part that calculates a required amount of current of an electric drive unit; a coolant temperature determination part that determines a necessary coolant temperature, which is a temperature of the coolant to flow in the second coolant passage, according to the required amount of current; and a system control part that acquires a temperature of the coolant before being supplied to the electric drive unit cooling part as a second coolant temperature, and, when the second coolant temperature is higher than the necessary coolant temperature, controls the path control device so that the coolant flows from the first coolant passage to the second coolant passage via the connection path.