Electric Machine Heating for EV Cold-Start Powertrains

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Solution Overview

Problem

Electric vehicles face challenges with cold starts due to reduced battery efficiency and increased power losses, leading to shorter operational ranges and component wear, especially since most batteries are temperature-sensitive and require separate heating systems that add complexity and cost.

Innovation Solution

A method involving passing an electric current through the electric machine while the vehicle is stationary to heat the powertrain, utilizing existing components and reducing the need for separate heating systems, thereby enhancing efficiency and extending the operational range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate heating system is added to heat the powertrain, then the battery efficiency is improved, but the device complexity increases

Engineering Contradiction:

Improvebattery efficiencyVSAvoidheating system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electric machine is made to serve dual functions: propulsion and heating. By passing electric current through the electric machine during cold starts, the system generates heat as a byproduct of the electrical operation, eliminating the need for a separate heating system while maintaining battery efficiency

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The electric machine heats itself and the powertrain components through its own electrical operation. The current passing through the machine's windings generates resistive heating that warms the powertrain, allowing the system to service its own heating needs without external heating components

Inventive Principle:

Principle #25Self-service

2Loss of energy

If the powertrain is heated before operation, then the power losses are reduced, but the energy consumption increases

Engineering Contradiction:

Improvepower lossesVSAvoidenergy consumption

Core Design Contradiction:

Loss of energyVSUse of energy by moving object

Solution Approach 1:

The resistive heating effect, which is normally considered an unwanted energy loss in electric machines, is converted into a beneficial heating function. By intentionally utilizing this effect during cold starts, the system transforms energy that would have been wasted into useful heat for warming the powertrain and battery

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The electric machine performs heating action before the vehicle enters into normal operation. By warming the powertrain components during the initial current passing phase, the system prepares the components for efficient operation, reducing subsequent power losses during actual driving

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the electric current is passed through the electric machine to heat the powertrain, then the component wear is reduced, but the manufacturing cost increases

Engineering Contradiction:

Improvecomponent lifetimeVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The electric machine is designed to perform multiple functions including propulsion, heating, and component protection. This multi-functionality eliminates the need for separate heating components, reducing overall system complexity and manufacturing costs while extending component lifetime through reduced wear during cold starts

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 method effectively heats the powertrain, reduces power losses, and minimizes component wear, thereby increasing the available operational range of electric vehicles in a cost-efficient and simple manner.

Implementation Method 1

the electric machine operate through the interaction between the magnetic field of the magnets and electric current in the wire windings to generate power in the form of torque and rotation of a rotor

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

passing an electric current through the electric machine to rotate a rotor (6) of the electric machine

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20230415613A1Method of heating powertrain, computer program, computer-readable medium, control arrangement, powertrain, and vehicle

Publication Date: 2023.12.28 SCANIA CV AB

AI summary

A method of heating a powertrain of a vehicle is disclosed, wherein the powertrain comprises an electric machine configured to provide motive power to the vehicle. The method comprises the step of passing an electric current through the electric machine to rotate a rotor of the electric machine while ensuring stand still of the vehicle. The present disclosure further relates to a computer program, a computer-readable medium, a control arrangement, a powertrain for a vehicle, and a vehicle comprising a powertrain.