On-Board Charger Power Distribution for EV Battery and Engine Heating
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Solution Overview
Problem
Drivers of electric and hybrid vehicles in extreme temperatures face challenges in preparing their vehicles for departure due to the need for multiple external devices, such as engine heaters and battery heaters, which can be cumbersome and inefficient, especially when limited power sources are available.
Innovation Solution
A system that uses an on-board charger and electronic control unit to distribute power from a single external power source to both vehicle batteries and engine heaters, ensuring that battery and engine temperatures remain above thresholds, thereby preparing the vehicle for departure while minimizing energy waste and clutter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple external devices (EVSE, battery heater, engine heater) are used to prepare the vehicle for driving in extreme temperatures, then the vehicle components can be properly charged and warmed, but the driver faces limited power source availability and undesirable clutter in the garage
Solution Approach 1:
The patent combines multiple external devices (EVSE, battery heater, engine heater) into a single integrated external device that can provide charging and heating functions simultaneously through a single power source connection. This merging eliminates the need for multiple separate devices and reduces garage clutter while maintaining the reliability of vehicle component preparation.
Solution Approach 2:
The external device is designed with multi-functionality, capable of performing charging, battery heating, and engine heating operations through a single unit. This universal device can adapt to different vehicle components and operational requirements, replacing the need for specialized separate devices for each function.
2Reliability
If multiple external devices are used for charging and heating, then vehicle components can be properly prepared, but energy costs increase due to simultaneous operation of multiple devices
Solution Approach 1:
The system dynamically controls the operation of heating and charging functions based on real-time temperature sensors and component status. The external device adjusts power distribution dynamically, activating heating only when components are below threshold temperatures and adjusting charging rates based on battery and engine conditions, thereby reducing unnecessary energy consumption.
Solution Approach 2:
The system incorporates temperature sensors and control units that continuously monitor component temperatures and provide feedback to the external device. This feedback mechanism allows the system to adjust heating and charging operations in real-time, ensuring energy is consumed only when and where needed, thus reducing overall energy costs.
3Device complexity
If a single connection is used to power multiple components, then device complexity and clutter are reduced, but power distribution control becomes more challenging
Solution Approach 1:
The patent introduces control units and temperature sensors as intermediary components between the single power source and multiple vehicle components. These intermediaries manage power distribution by monitoring component temperatures and controlling heating/charging operations, simplifying the complexity of power management while maintaining effective control through automated feedback loops.
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 system allows for efficient charging and heating of vehicle components using a single connection, ensuring optimal performance in extreme temperatures, reducing energy costs, and eliminating the need for multiple external devices, thus enhancing convenience and energy efficiency.
Implementation Method 1
The battery heater converts electrical energy into thermal energy (heat) for increasing the battery temperature
Implementation Method 2
The engine heater converts electrical energy into heat for increasing the engine temperature
Data Source
AI summary
A system includes an on-board charger that receives energy from an external power source and a battery having a state of charge (SOC) and a battery temperature. The system also includes a battery heater that converts electrical energy into thermal energy (heat) for increasing the battery temperature. The system also includes a battery management system (BMS) that determines or detects a current SOC of the battery and a current battery temperature. The system also includes an electronic control unit (ECU) coupled to the on-board charger and to the BMS. The ECU controls the on-board charger to distribute energy to the battery and to the battery heater to cause the SOC to remain above a SOC threshold and to cause the battery temperature to remain above a battery temperature threshold based on the current SOC and the current battery temperature.