Electric Heater Control for Cabin Warm-Up in Electrified Vehicles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrified vehicles face unique thermal management challenges in achieving passenger cabin comfort while balancing fuel economy and electric range, as reduced heat generation from internal combustion engines degrades warm-up capabilities and efficiency.
Innovation Solution
An electrically powered heating device, such as a positive temperature coefficient (PTC) heater or resistive heating device, is controlled based on target and actual discharge air temperatures, as well as available power, to condition airflow and offset the load of the heater core, using a controller that powers the device with either a battery pack or DC/DC converter to achieve optimal cabin heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an internal combustion engine is used to heat airflow in conventional vehicles, then heating capability is sufficient, but fuel consumption increases and emissions are generated
Solution Approach 1:
The patent replaces the mechanical/internal combustion engine-based heating system with an electric heating system. The electrically powered heating device uses electrical energy from the battery pack or DC/DC converter to generate heat through resistive heating elements, eliminating the need to run the internal combustion engine solely for heating purposes, thereby reducing fuel consumption and emissions while maintaining adequate heating capability
Solution Approach 2:
The electrically powered heating device serves multiple functions: it provides cabin heating, offsets the load of the heater core, and can operate independently of engine operation. This multi-functionality allows the system to maintain heating capability without being tied to engine runtime, thus improving fuel economy while ensuring passenger comfort
2Loss of energy
If the internal combustion engine is reduced or eliminated in electrified vehicles, then fuel economy and electric range improve, but warm-up capabilities and heat generation are degraded
Solution Approach 1:
The electrically powered heating device acts as an intermediary heating source that compensates for the reduced heat generation from the internal combustion engine. It provides the necessary thermal energy to maintain cabin warmth and support heater core operation without requiring the engine to run continuously, thus preserving warm-up capabilities while improving fuel economy
Solution Approach 2:
The system changes the heating parameter source from mechanical engine heat to electrical energy conversion. By controlling the electrically powered heating device based on target and actual discharge air temperatures along with available power, the system dynamically adjusts heating output to maintain optimal warm-up capabilities while adapting to varying power availability and thermal demands
3Productivity
If an electrically powered heating device is added to the HVAC system, then cabin heating performance improves and fuel economy increases, but device complexity increases
Solution Approach 1:
The heating function is segmented into two independent sources: the traditional heater core and the new electrically powered heating device. This segmentation allows each component to operate independently with its own control strategy, enabling the electric heating device to offset the heater core load without requiring complete system redesign, thus improving heating performance while managing complexity through modular addition
Solution Approach 2:
The controller continuously monitors target discharge air temperature, actual discharge air temperature, and available power to dynamically control the electrically powered heating device. This feedback mechanism ensures optimal heating performance by adjusting electric heater operation based on real-time thermal conditions and power availability, while preventing excessive complexity through rule-based control logic
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 solution enhances passenger cabin heating performance, reduces warm-up times, and improves fuel economy by increasing engine efficiency and heat generation, while maintaining optimal comfort levels.
Implementation Method 1
An electrically powered heating device configured to heat airflow for conditioning a passenger cabin of an electrified vehicle
Implementation Method 2
the electrically powered heating device includes a positive temperature coefficient (PTC) heater
Data Source
AI summary
An electrified vehicle includes a passenger cabin, an electrically powered heating device configured to heat airflow for conditioning the passenger cabin, and a controller configured to selectively command actuation of the electrically powered heating device based on a target discharge air temperature, an actual discharge air temperature, and an amount of power available.