EV Charging Controller with Thermal Circuit for Battery Conditioning
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Solution Overview
Problem
Electric vehicle batteries experience suboptimal charging and discharging at low temperatures, such as below freezing, which affects their performance and efficiency.
Innovation Solution
A system and method that includes a thermal circuit and a controller with multiple power settings, allowing for concurrent battery charging and thermal conditioning of the vehicle's cabin, using a mobile application to manage power distribution and select between external power, charging, discharging, and mixed charging and conditioning modes based on predefined criteria and user profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the battery is charged at low temperatures (below freezing), then the charging process can proceed, but the charging and discharging performance becomes suboptimal
Solution Approach 1:
The system performs preliminary thermal conditioning of the battery before charging begins. The controller activates heating elements when the battery temperature is below a threshold value, warming the battery to an optimal temperature range prior to initiating the charging process, thereby ensuring optimal charging performance from the start
Solution Approach 2:
The system maintains continuous thermal management during the charging process. The controller monitors battery temperature throughout charging and dynamically adjusts heating power to maintain the battery within the optimal temperature range, ensuring continuous optimal charging conditions rather than intermittent heating
2Reliability
If power is used for thermal conditioning of the battery, then the battery temperature is optimized for charging, but the available power for charging is reduced
Solution Approach 1:
The system dynamically adjusts the power distribution between thermal conditioning and charging based on real-time battery temperature. When the battery temperature is below the threshold, the controller prioritizes heating with reduced charging power; when the temperature reaches the optimal range, the controller increases charging power or activates full charging, creating a dynamic balance between thermal management and energy storage
Solution Approach 2:
The system changes the operating parameters of the charging process based on temperature conditions. The controller modifies charging current and voltage parameters in response to temperature feedback, allowing optimal charging parameters to be applied only when the battery is at the optimal temperature, thereby maximizing charging efficiency at each moment
3Productivity
If the battery is warmed up before charging, then the charging efficiency is improved, but the total time required (warm-up time + charging time) increases
Solution Approach 1:
The system eliminates idle time by continuously performing useful work throughout the process. Instead of completing warm-up then starting charging as separate sequential steps, the system simultaneously performs thermal conditioning and charging, with the controller dynamically adjusting power distribution to maintain optimal temperature throughout the entire charging duration, ensuring every moment contributes to both warming and charging
Solution Approach 2:
The system initiates thermal conditioning in advance of full charging power being applied. The controller begins low-power heating before the charging process starts and maintains this preliminary warming throughout charging, ensuring the battery is continuously in the optimal temperature range for maximum charging efficiency without requiring a separate pre-warm-up phase
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
Enables intelligent pre-conditioning and fast charging of electric vehicle batteries and cabins under various weather conditions, improving the vehicle's performance and functionality by optimizing power distribution and thermal management.
Implementation Method 1
A thermal circuit is configured to selectively receive power from the charging source... allowing sufficient time for warming up the battery prior to the departure time
Data Source
AI summary
System and method of controlling power distribution from a charging source to an electric vehicle having a battery. The system includes a plurality of switches selectively connectable between the charging source, the battery and a thermal circuit. A controller is configured to control operation of the plurality of switches to provide multiple settings for the electric vehicle. The controller is configured to select from the multiple settings based on part on a trigger signal from a mobile application. The multiple settings include an external power mode, a charging mode, a discharging mode and a mixed charging and conditioning mode. The mixed charging and conditioning mode allows charging of the battery concurrently with thermal conditioning of at least one of the battery and a cabin of the vehicle. The mixed charging and conditioning mode enables a power split between a thermal conditioning power (PT) and a charging power (PC).