EV Charging Station Cooling System Augments Battery Thermal Management
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Solution Overview
Problem
Conventional vehicle charging stations lack an effective cooling mechanism to manage the high heat generated during DC fast charging events, which can overwhelm the thermal management system of electrified vehicles, potentially leading to reduced charging efficiency and battery pack longevity.
Innovation Solution
A vehicle charging station equipped with a cooling system that includes a fan and a chiller assembly, capable of communicating cooling airflow to the electrified vehicle's thermal management system, augmenting its cooling capacity during DC fast charging events through a heat exchanger and venting mechanism, and controlled by a controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If DC fast charging is performed at high power, then charging speed is improved, but heat generation increases and overwhelms the vehicle's thermal management system
Solution Approach 1:
The charging station introduces an intermediary cooling system that acts as a mediator between the battery pack and the environment. The cooling system includes a chiller assembly that circulates coolant through heat exchangers positioned near the battery pack, providing an additional thermal management pathway that doesn't rely solely on the vehicle's native thermal management system.
Solution Approach 2:
The patent merges the charging station's cooling system with the vehicle's thermal management system by positioning heat exchangers in thermal communication with the battery pack. This combination allows the stationary cooling infrastructure to supplement the mobile thermal management system during high-power charging operations.
2Temperature
If the vehicle's thermal management system is upgraded to handle DC fast charging heat, then cooling capacity is improved, but vehicle cost and complexity increase
Solution Approach 1:
The charging station provides self-service cooling by housing a complete cooling system including compressor, condenser, expansion device, and evaporator within the charging infrastructure itself. This transfers the cooling burden from the vehicle to the charging station, allowing vehicles to receive DC fast charging without requiring upgraded thermal management systems.
Solution Approach 2:
The charging station's cooling system serves as an intermediary that handles the thermal management burden, allowing the vehicle's native thermal management system to remain simple while still supporting high-power DC fast charging operations.
3Temperature
If cooling system operates continuously, then battery temperature control is improved, but energy consumption increases
Solution Approach 1:
The cooling system operates periodically based on thermal demand rather than continuously. The controller monitors battery temperature and activates the compressor and fan only when cooling is required, such as during DC fast charging events or when battery temperature exceeds predetermined thresholds, thereby reducing unnecessary energy consumption.
Solution Approach 2:
The system incorporates feedback control where the controller monitors battery temperature and adjusts cooling system operation accordingly. When battery temperature rises during fast charging, the controller activates the cooling system; when temperature is within acceptable ranges, the cooling system remains inactive, optimizing energy usage based on actual thermal conditions.
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
The cooling system effectively augments the thermal management of the battery pack, reducing heat buildup and enhancing charging efficiency and battery health by providing additional cooling airflow during and after DC fast charging events.
Implementation Method 1
The chiller assembly includes a heat exchanger, and the fan is configured to communicate airflow across the heat exchanger to generate the cooling airflow
Implementation Method 2
the fan is configured to communicate airflow across the heat exchanger to generate the cooling airflow
Data Source
AI summary
A vehicle charging station according to an exemplary aspect of the present disclosure includes, among other things, a cooling system configured to communicate a cooling airflow to a portion of a thermal management system located onboard an electrified vehicle, the cooling system including a fan and a chiller assembly.