EV Cabin Pre-Cooling for Battery Thermal Load Management

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Solution Overview

Problem

Electrified vehicles face challenges in managing battery and cabin cooling loads, where high battery cooling demands can compromise cabin comfort and battery state of charge, especially when the thermal management system is overwhelmed.

Innovation Solution

Implementing a cabin pre-cooling strategy managed by a controller that pre-cools the cabin when the expected battery cooling load exceeds a threshold, using a thermal management system with shared components for both battery and cabin conditioning, and selectively activating blower and air conditioner based on vehicle state and user input.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the thermal management system prioritizes battery cooling when battery cooling load is high, then battery temperature is controlled within acceptable range, but cabin comfort deteriorates due to insufficient cooling capacity

Engineering Contradiction:

Improvebattery temperatureVSAvoidcabin comfort

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The system performs preliminary cooling of the cabin before the vehicle departure time is reached. When the controller predicts that the battery cooling load will exceed the threshold upon vehicle startup, it activates the cabin cooling system in advance during the parked state, reducing the cabin temperature beforehand so that both battery and cabin cooling requirements can be met after vehicle startup.

Inventive Principle:

Principle #10Preliminary action

2Temperature

If the thermal management system cools both battery and cabin simultaneously at full capacity, then both temperature requirements are met, but energy consumption exceeds available battery capacity

Engineering Contradiction:

Improvecabin temperatureVSAvoidbattery energy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The controller periodically monitors the vehicle state, battery temperature, cabin temperature, and predicted battery cooling load. It dynamically adjusts the cooling strategy by switching between different operating modes (prioritizing battery cooling, simultaneous cooling, or cabin pre-cooling) based on real-time conditions, creating a periodic control cycle that optimizes energy usage.

Inventive Principle:

Principle #19Periodic action

3Device complexity

If the thermal management system uses shared components for both battery and cabin conditioning, then device complexity is reduced, but the system becomes overwhelmed when both cooling loads are high simultaneously

Engineering Contradiction:

Improvethermal management system structureVSAvoidcooling performance reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The system dynamically adjusts the operating parameters of the shared thermal management components based on real-time vehicle state. The controller modifies compressor capacity, coolant flow distribution, and heat exchanger operation to prioritize battery cooling when necessary while still providing adequate cabin cooling, allowing the single system to adapt to varying dual cooling demands without requiring separate independent systems.

Inventive Principle:

Principle #15Dynamics

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 strategy effectively balances battery and cabin cooling loads, improving passenger comfort while preserving battery state of charge by prioritizing cooling when needed and optimizing energy use.

Implementation Method 1

a thermal management system configured to thermally condition both the battery and the cabin

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The circuits, or loops, that thermally condition the passenger cabin and the battery pack may share a number of common components, such as a common compressor and condenser unit

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

cabin pre-cooling strategy to pre-cool the cabin when an expected cooling load of the battery exceeds an upper battery cooling load threshold

Methodology Applied

Scientific EffectEvaporative cooling: Evaporation

Data Source

PatentUS11916208B2Electrified vehicle with cabin pre-cooling strategy for managing battery and cabin cooling loads

Publication Date: 2024.02.27 FORD GLOBAL TECH LLC

AI summary

This disclosure relates to an electrified vehicle having a cabin pre-cooling strategy for managing battery and cabin cooling loads. A corresponding method is also disclosed. An example electrified vehicle includes a battery for propulsion, a cabin, a thermal management system configured to thermally condition both the battery and the cabin, and a controller configured to follow a cabin pre-cooling strategy to pre-cool the cabin when an expected cooling load of the battery, if the electrified vehicle were to be driven in present conditions, exceeds an upper battery cooling load threshold.