Dual Cooling Loops for EV Battery and Power Electronics
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Solution Overview
Problem
Current cooling systems for electrified powertrains, mild hybrid powertrains, and strong hybrid powertrains face challenges in efficiently managing temperature conditions for electronic components, particularly as batteries require temperature conditioning below ambient temperatures for half of the operating time, while motor/generators can tolerate warmer temperatures.
Innovation Solution
The implementation of separate cooling loops for electronic components, where the batteries have a distinct coolant loop from the motor/generator and power electronics, with the use of three-way valves and pumps to isolate and control coolant flow based on ambient temperature conditions, and integration with cabin A/C refrigerant and Waste Heat Recovery (WHR) systems to optimize cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cooling loop is used for all electronic components, then system complexity is reduced, but temperature management efficiency deteriorates because batteries require cooling below ambient temperatures while motor/generators can tolerate warmer temperatures
Solution Approach 1:
The cooling system is divided into separate cooling loops: a first cooling loop for the battery and a second cooling loop for the motor/generator and power electronics. This segmentation allows each component to be cooled independently at its optimal temperature, resolving the contradiction between system simplicity and temperature management efficiency.
Solution Approach 2:
The system uses dynamically controllable components (variable speed pumps, three-way valves) that can adjust coolant flow distribution between different cooling loops based on real-time operating conditions. This dynamic adjustment enables the system to maintain optimal temperature management while adapting to varying operational requirements.
2Reliability
If separate cooling loops are implemented for batteries and motor/generators, then temperature management efficiency improves, but system complexity and chiller energy consumption increase
Solution Approach 1:
The system merges the cooling loops at the chiller level, allowing the single chiller to serve both the battery cooling loop and the motor/generator cooling loop. By using a common heat source and dynamically routing coolant flow, the system achieves efficient temperature management for both components while minimizing chiller energy consumption through coordinated operation.
Solution Approach 2:
The system changes operational parameters (coolant flow rates, temperatures, and routing) dynamically based on operating conditions. By adjusting these parameters optimally, the system maintains effective temperature management while reducing overall energy consumption of the cooling system.
3Device complexity
If ambient temperature conditioning is used for all components, then system simplicity is maintained, but battery performance deteriorates during conditions requiring sub-ambient cooling
Solution Approach 1:
The battery is assigned to a dedicated first cooling loop that can be independently controlled, separating it from the ambient temperature conditioning system used for other components. This segmentation ensures the battery receives appropriate temperature management while maintaining relative system simplicity through modular architecture.
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 reduces chiller energy consumption, improves system efficiency, and ensures effective temperature management for both batteries and other electronic components across varying ambient conditions, enhancing overall cooling system performance.
Implementation Method 1
a first cooling loop that circulates coolant for cooling the battery
Implementation Method 2
The first cooling loop includes a heat exchanger fluidically isolated from but in thermal communication with the refrigerant from the refrigerant loop
Implementation Method 3
a pump for circulating the coolant in the first cooling loop
Data Source
AI summary
A cooling system for an electrified vehicle includes a first cooling loop for circulating coolant for cooling at least one of power electronics and a motor/generator of the vehicle. The first coolant loop includes a heat exchanger for exchanging heat with the coolant in the first cooling loop. A second cooling loop is provided for circulating coolant for cooling a battery of the vehicle. The second cooling loop includes a coolant chiller connected to a refrigeration system of the vehicle for exchanging heat in the coolant received from the battery with the refrigeration system of the vehicle.