EV Powertrain Controller for Load Bank Cooling Integration
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Solution Overview
Problem
Existing electric vehicle powertrain systems face challenges in efficiently managing heat dissipation from resistive load banks, which limits the flexibility in vehicle design due to the need for large frontal areas for air cooling, exceeding normal cooling capacity by two to five times.
Innovation Solution
Integration of a powertrain controller that regulates both electrical current to an electrically-actuated compressor and a resistive load bank, using MOSFETs or IGBTs to manage three-phase and fourth-phase electrical current, allowing the compressor to dissipate heat generated by the resistive load bank, thereby providing greater freedom in mounting locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a resistive load bank is used to dissipate excess electrical current during coasting, then electrical power can be managed, but a large frontal area is required for air cooling which exceeds normal cooling capacity
Solution Approach 1:
The patent combines the cooling function for the resistive load bank with the existing compressor system. The compressor, which normally cools the battery, is used to also cool the resistive load bank during coasting operations. This merging of cooling functions eliminates the need for separate cooling infrastructure and reduces the required frontal area while maintaining effective heat dissipation.
Solution Approach 2:
The compressor system is designed to perform multiple functions: cooling the battery during normal operation and cooling the resistive load bank during coasting operations. This multi-functionality allows the same hardware to handle different thermal management needs without requiring additional cooling capacity or frontal area.
2Ease of manufacture
If separate control systems are used for the compressor and load bank, then each component can be optimized independently, but the device complexity increases
Solution Approach 1:
The patent integrates the control of the compressor and the resistive load bank into a single unified control system. The controller receives signals from both the battery management system and the coasting detection system, and automatically manages power distribution between the compressor motor and the resistive load bank based on real-time vehicle conditions. This integration reduces control system complexity while maintaining the ability to independently optimize each component's performance.
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 solution enables efficient heat dissipation without the need for large frontal areas, allowing for more flexible vehicle design and improved space utilization by using the electrically-actuated compressor to cool the resistive load bank, enhancing the overall efficiency of the electric vehicle's powertrain system.
Implementation Method 1
The flow of electrical current into the resistive load can generate a significant amount of heat
Implementation Method 2
The flow of electrical current into the resistive load can generate a significant amount of heat that can be dissipated in a variety of ways, such as using a fan moving ambient air over the resistive bank
Data Source
AI summary
A powertrain controller for an electric vehicle (EV) includes a compressor controller configured to regulate three-phases of electrical current supplied by a vehicle battery of the EV or an electric motor of the EV to an electrically-actuated compressor; and a load bank controller configured to regulate a fourth-phase of electrical current provided by the vehicle battery or the electric motor of the EV to a resistive load bank, such that the compressor controller and the load bank controller are integrated into a common control system.