Dual-Fluid Vehicle Thermal Circuits With Dynamic Flow Routing
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Solution Overview
Problem
Current thermal management systems for vehicles, including energy storage systems, electric power units, and passenger compartments, are complex and energy-intensive, leading to increased energy consumption and manufacturing and maintenance costs.
Innovation Solution
A thermal management system with dual working fluid circuits and a controller to dynamically regulate temperature, utilizing a first coolant circuit and a second refrigerant circuit with parallel connections and heat exchangers to simplify and reduce the number of thermal loops and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous complex thermal loops and components are used to regulate temperature of energy storage systems, electric power units, and passenger compartments, then temperature regulation capability is improved, but energy consumption increases and manufacturing and maintenance costs increase
Solution Approach 1:
The patent implements a multi-functional thermal management system where a single integrated controller manages multiple temperature regulation circuits (engine coolant circuit, radiator circuit, condenser circuit, evaporator circuit, battery coolant circuit). The system uses working fluids that serve multiple purposes: the first working fluid handles both engine cooling and battery cooling, while the second working fluid manages both HVAC and condenser functions. This universal approach allows one system to perform what previously required multiple separate systems, thereby reducing energy consumption while maintaining comprehensive temperature regulation capability.
2Reliability
If numerous complex thermal loops and components are used to regulate temperature of energy storage systems, electric power units, and passenger compartments, then temperature regulation capability is improved, but manufacturing and maintenance costs increase
Solution Approach 1:
The patent implements a multi-functional thermal management system where a single integrated controller manages multiple temperature regulation circuits (engine coolant circuit, radiator circuit, condenser circuit, evaporator circuit, battery coolant circuit). The system uses working fluids that serve multiple purposes: the first working fluid handles both engine cooling and battery cooling, while the second working fluid manages both HVAC and condenser functions. This universal approach allows one system to perform what previously required multiple separate systems, thereby reducing energy consumption while maintaining comprehensive temperature regulation capability.
3Reliability
If multiple separate temperature regulation circuits are used for different vehicle components, then each component's temperature needs are met, but system complexity increases
Solution Approach 1:
The patent merges multiple separate temperature regulation circuits into a single integrated thermal management system. The controller consolidates management of the engine coolant circuit, radiator circuit, condenser circuit, evaporator circuit, and battery coolant circuit into one unified control architecture. The first and second working fluid circuits are integrated rather than operating as separate systems, reducing the overall number of thermal loops and components while maintaining the ability to independently regulate temperatures of the engine, battery, HVAC system, and condenser.
4Ease of manufacture
If a simplified thermal management system with fewer thermal loops and components is used, then manufacturing and energy costs are reduced, but temperature regulation capability may be compromised
Solution Approach 1:
The patent employs dynamic control strategies where the controller continuously adjusts the operation of pumps, valves, and heat exchangers based on real-time temperature sensors and system conditions. The system can dynamically switch between different operating modes (e.g., cooling mode, heating mode, battery thermal management mode) and adjust flow rates and heat transfer coefficients as needed. This dynamic adaptability ensures that the simplified system maintains full temperature regulation capability across all components under varying operating conditions, matching or exceeding the performance of more complex static systems.
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
The system effectively regulates the temperature of energy storage systems, electric power units, and passenger compartments with reduced complexity and energy consumption, optimizing performance and safety while minimizing the number of thermal loops and components.
Implementation Method 1
a first heat exchanger configured to transfer heat between the first working fluid and the second working fluid
Implementation Method 2
a second heat exchanger configured to transfer heat between the first working fluid and the second working fluid
Implementation Method 3
a third heat exchanger configured to transfer heat between the first working fluid and an internal environment of the vehicle
Implementation Method 4
a fourth heat exchanger configured to transfer heat between the first working fluid and an external environment of the vehicle
Data Source
AI summary
A thermal management system configured for use on a vehicle, the thermal management system including a first temperature regulation circuit, a second temperature regulation circuit, and a controller configured to operate the first temperature regulation circuit and the second regulation circuit, wherein the first temperature regulation circuit is configured to circulate a fluid through a plurality of heat exchangers, an energy storage system, and an electric power unit, the second temperature regulation circuit is configured to circulate a fluid through a plurality of heat exchangers and a compressor, and the controller is configured to convert one or more of the first temperature regulation circuit to a first temperature regulation sub-circuit and the second temperature regulation circuit to a second temperature regulation sub-circuit to direct the flow of one or more of the fluids through one or more of the first temperature regulation circuit and the second temperature regulation circuit.