Dual-Mode Cooling Control for Battery and Fuel Cell Heat Loads
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Solution Overview
Problem
Traditional cooling systems for electric power sources in mobile equipment are inefficient and costly due to the lack of a sufficient temperature differential for heat transfer, necessitating the use of refrigeration systems that are less energy-efficient and more complex, especially in high ambient temperatures.
Innovation Solution
A dynamically-controlled cooling system with multiple cooling units operating in different modes, managed by a machine controller that adjusts operation based on sensor data to optimize energy efficiency and capacity, using a combination of refrigeration and radiator circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional forced-convection water radiator system is used to cool the electric power source, then the system structure is simple and cost is low, but the cooling temperature cannot reach the required set point in high ambient temperatures due to insufficient temperature differential
Solution Approach 1:
The system dynamically switches between radiator mode and refrigeration mode based on ambient temperature conditions and cooling demand. The controller adjusts the operating mode in real-time, allowing the system to adapt to varying environmental conditions and maintain optimal cooling performance without being locked into a fixed configuration.
Solution Approach 2:
The cooling system is designed to perform multiple functions: it can operate as a simple radiator system under favorable conditions, and switch to refrigeration mode when higher cooling temperatures are required. This multi-functionality allows the same system to handle both low and high ambient temperature scenarios effectively.
2Temperature
If a refrigeration system is used to achieve the required cooling temperature, then the cooling temperature can reach the set point, but energy efficiency decreases and cost, weight, volume and complexity increase
Solution Approach 1:
The system dynamically selects between radiator and refrigeration modes based on real-time conditions. The controller evaluates ambient temperature and cooling demand to determine the most energy-efficient operating mode, switching between passive radiator cooling and active refrigeration cooling as needed.
Solution Approach 2:
The system changes its operational parameters by switching between two distinct cooling modes. The radiator mode is used when ambient temperature allows sufficient heat transfer, while refrigeration mode is activated when higher cooling temperatures are needed, optimizing energy consumption based on environmental parameters.
3Temperature
If a refrigeration system is used to achieve the required cooling temperature, then the cooling temperature can reach the set point, but cost and system complexity increase
Solution Approach 1:
The system dynamically adjusts its configuration based on operating conditions. The controller monitors ambient temperature and cooling demand, activating the refrigeration system only when necessary to reach the required set point temperature, rather than operating continuously or in a fixed configuration.
Solution Approach 2:
The cooling system is designed with multi-functionality, incorporating both radiator and refrigeration capabilities in a single integrated system. This allows the system to handle a wide range of cooling requirements without needing separate dedicated systems for different temperature ranges.
4Temperature
If cooling units operate continuously in high ambient temperature environments, then the cooling temperature can be maintained, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts its operation based on real-time conditions. The controller monitors ambient temperature, cooling demand, and system state to determine the optimal operating mode, switching between radiator and refrigeration modes to minimize energy consumption while maintaining the required cooling temperature.
Solution Approach 2:
The system changes its operational parameters by selecting between different cooling modes based on environmental conditions. When ambient temperature is favorable, the radiator mode is used with lower energy consumption. When higher cooling temperatures are required, the refrigeration mode is activated, optimizing the balance between cooling performance and energy use.
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 maintains electric power source temperatures within acceptable ranges, optimizing energy efficiency and reducing costs by dynamically adjusting cooling unit operation based on environmental conditions.
Implementation Method 1
a refrigeration circuit including a compressor, a condenser, an expansion device, and an evaporator
Implementation Method 2
the evaporator being configured to cool the coolant circulating through the evaporator
Implementation Method 3
a condenser configured to receive the refrigerant from the compressor and output the refrigerant to the expansion device
Implementation Method 4
a radiator circuit including a radiator and a fan configured to blow air across the radiator
Implementation Method 5
an expansion device configured to receive the refrigerant from the condenser and output the refrigerant to the evaporator
Data Source
AI summary
Typically, electric power sources, such as batteries and fuel cells, require cooling to temperatures near or below ambient temperature for safe and efficient operation. Traditional cooling systems are not be able or practical to cool the components to the required temperatures, due to the lack of temperature differential between the required cooling temperature and the ambient temperature, which drives the heat transfer. Disclosed embodiments optimize the efficiency of a cooling system based on ambient conditions. In particular, embodiments determine input parameters from one or more sensed parameters, such as ambient temperature and ambient pressure, and utilize these input parameters in a process that maximizes the operation of cooling units in the most efficient mode.