Dual Cooling Fan Control for Vehicle Thermal Management
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Solution Overview
Problem
In electric vehicles, the cooling fan in the cooling module faces challenges in efficiently controlling the cooling temperature of various components due to limited space and differing cooling requirements, leading to increased power consumption and reduced travel distance.
Innovation Solution
A method for independently controlling the operation speed of dual cooling fans in the cooling module based on the vehicle's running state and air conditioner operation, by comparing the required speeds of each component and adjusting the fans' speeds to minimize power consumption and prevent unnecessary cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the capacity of the cooling fan is increased to ensure cooling performance, then the cooling performance is improved, but the mounting space becomes insufficient and power consumption increases
Solution Approach 1:
The single cooling fan is divided into two separate cooling fans: a first cooling fan for cooling the stack and electrical equipment, and a second cooling fan for cooling the condenser. This segmentation allows each fan to be optimized for specific cooling tasks, reducing the total capacity required while maintaining overall cooling performance.
Solution Approach 2:
The control system dynamically adjusts the rotation speeds of the first and second cooling fans based on real-time temperature conditions of different components. The controller determines required speeds for each fan based on stack temperature, electrical equipment temperature, and air conditioner pressure, enabling flexible adaptation to varying cooling demands without requiring oversized fixed-capacity fans.
2Temperature
If the cooling fan operates at maximum speed to cool all constituent elements, then the cooling temperature requirement is met, but unnecessary power consumption increases and travel distance decreases
Solution Approach 1:
Different cooling strategies are applied to different components based on their specific cooling requirements. The first cooling fan's speed is controlled based on stack and electrical equipment temperatures, while the second cooling fan's speed is controlled based on air conditioner pressure. This localized quality control ensures each component receives appropriate cooling without excessive energy consumption.
Solution Approach 2:
The control system changes the operational parameters (rotation speeds) of the cooling fans based on real-time temperature and pressure conditions. By continuously adjusting fan speeds to match actual cooling demands rather than operating at fixed maximum speed, the system minimizes power consumption while maintaining required cooling temperatures.
3Device complexity
If a single cooling fan is used for all components, then the device complexity is reduced, but the ability to meet different cooling temperature requirements of each constituent element deteriorates
Solution Approach 1:
The cooling system is segmented into two independent fan control zones: one for the stack and electrical equipment, and another for the condenser. This segmentation enables independent control of each fan based on specific component requirements, significantly improving adaptability while maintaining manageable system complexity through modular control logic.
Solution Approach 2:
The dual-fan system provides universal cooling capability for multiple different components with different cooling requirements. The first cooling fan serves dual purposes (stack and electrical equipment), while the second cooling fan handles the condenser, creating a versatile system that can adapt to various operating conditions and component needs.
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 minimizes power consumption, increases travel distance, and improves noise, vibration, and harshness (NVH) performance by ensuring efficient cooling without increasing fan capacity, enhancing the cooling module's performance and operability in limited space.
Implementation Method 1
a cooling module including the cooling fan are disposed in front of the vehicle. This cooling module efficiently cools the fuel cell or the battery, and the electrical equipment depending on a running state of the vehicle and the operation of an air conditioner system
Data Source
AI summary
A cooling fan control method for a vehicle is provided. The method includes turning on a starting of the vehicle and sensing a stack temperature. A first required speed of first and second cooling fans required by the stack radiator is set and a temperature of an electrical equipment is sensed to set a second required speed of the first cooling fan. When an air conditioner is operated; an air conditioner pressure is sensed and a second required speed of the second cooling fan required by the condenser is set. The method then compares the required speeds as well as a resonance frequency RPM to determine different setting conditions of the fans. The operation of the fans is complete when the coolant temperature and an air conditioner pressure of the stack and the electrical equipment are within a predetermined setting value.