Dual Refrigerant Loop Cooling System for Vehicle Cabin and Battery
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Solution Overview
Problem
Existing vehicle cooling systems face challenges in efficiently managing the cooling needs of both the cabin and the battery, often requiring complex configurations and energy optimizations to balance cooling demands and minimize noise, vibration, and harshness (NVH) while maintaining performance.
Innovation Solution
A dual refrigerant loop cooling system with a coolant loop that selectively directs coolant flow between a first and second chiller, and a controller that adjusts compressor speeds and valve operations to satisfy cabin and battery cooling needs, operating in various modes such as AC only, dual refrigerant loop, and chiller only modes to optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cooling system is used for both cabin and battery, then system complexity is reduced, but cooling performance and efficiency deteriorate due to conflicting cooling demands
Solution Approach 1:
The cooling system is divided into two independent refrigerant loops: a first refrigerant loop dedicated to cabin cooling and a second refrigerant loop dedicated to battery cooling. Each loop has its own compressor, evaporator, and chiller, allowing independent optimization of cooling performance for each application without compromise.
Solution Approach 2:
The first chiller and second chiller can both exchange heat with the coolant loop, enabling the system to flexibly allocate cooling capacity between cabin and battery based on real-time demands. The coolant loop serves as a universal heat exchange medium that can interface with either or both refrigerant loops as needed.
2Productivity
If compressor speeds are increased to meet high cooling demands, then cooling capacity is improved, but noise, vibration, and harshness increase
Solution Approach 1:
The system dynamically adjusts the speeds of the first and second compressors based on real-time cooling demands, NVH limits, and operational conditions. The controller continuously monitors and modifies compressor speeds to maintain optimal performance while staying within acceptable NVH thresholds, allowing the system to adapt its output to match actual needs rather than operating at fixed high speeds.
Solution Approach 2:
The controller receives feedback on cooling demands, compressor performance, and NVH levels, then adjusts compressor speeds accordingly. This closed-loop control enables the system to optimize the balance between cooling capacity and NVH by reducing compressor speeds when full capacity is not needed or when NVH limits are approached.
3Adaptability or versatility
If dual refrigerant loops are implemented, then cooling efficiency and adaptability are improved, but system complexity and cost increase
Solution Approach 1:
The cooling system is divided into two independent refrigerant loops: a first refrigerant loop having a first compressor and a second refrigerant loop having a second compressor. Each loop can operate independently or in coordination, providing flexibility to meet varying cooling demands while maintaining manageable system architecture.
Solution Approach 2:
The coolant loop acts as an intermediary between the two refrigerant loops and the battery, enabling heat exchange without direct coupling of the refrigerant systems. This mediator approach allows the dual-loop system to coordinate their operations through the shared coolant loop while maintaining their independence.
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 balances cabin and battery cooling, optimizing energy use and reducing NVH by dynamically adjusting compressor speeds and coolant distribution, enhancing overall cooling system efficiency and performance.
Implementation Method 1
an evaporator configured to exchange heat with a cabin of the vehicle
Implementation Method 2
a first chiller configured to exchange heat with the coolant loop
Implementation Method 3
a second chiller configured to exchange heat with the coolant loop
Implementation Method 4
a first refrigerant loop having a first compressor, an evaporator configured to exchange heat with a cabin of the vehicle
Data Source
AI summary
A method of operating a cooling system for a vehicle including providing a cooling system including a coolant loop having a coolant valve, a first refrigerant loop having a first compressor and a first chiller configured to exchange heat with the coolant loop, a second refrigerant loop having a second compressor and a second chiller configured to exchange heat with the coolant loop, and a cooling system controller operably coupled to the first compressor, the second compressor, and the coolant valve. The coolant valve is configured to selectively direct or prevent the flow of coolant between the battery and each of the first chiller and the second chiller. The method further includes operating the cooling system in one of a second chiller only mode, a first chiller only mode, an air conditioning (AC) only mode, a first refrigerant loop only mode, and a dual refrigerant loop mode.