EV Thermal Management Layout for Low-Resistance Coolant Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional thermal management systems in electric vehicles face challenges in increasing the flow rate of coolant through coolant lines and radiators, leading to reduced cooling performance, especially in high-performance vehicles, due to high flow resistance and inadequate heat radiation handling.
Innovation Solution
The implementation of a thermal management system with a parallel coolant line structure and flow control valves, such as five-way valves, to distribute coolant flow effectively between radiators and heat exchangers, reducing line resistance and optimizing coolant flow rates across power electronic components and the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional cooling system with series-connected power electronic parts along a single coolant line is used, then the system structure is simple, but the flow resistance of the coolant is high and cooling performance is insufficient
Solution Approach 1:
The patent divides the single coolant line into multiple parallel coolant lines (first coolant line for power electronic parts, second coolant line for battery). This segmentation reduces flow resistance in each line while maintaining manageable system structure through modular parallel architecture.
2Reliability
If the coolant flow rate is increased to improve cooling performance, then cooling performance improves, but the flow resistance and power consumption increase
Solution Approach 1:
By segmenting the coolant flow into parallel lines, each pump only needs to overcome the resistance of its dedicated line rather than a long series path, reducing the power required to achieve adequate flow rates.
Solution Approach 2:
Flow control valves act as intermediaries to optimize coolant distribution. They regulate flow rates in each parallel line to match actual cooling demands, preventing excessive flow and associated power consumption while ensuring adequate cooling performance.
3Reliability
If a parallel coolant line structure with flow control valves is implemented, then coolant flow rates and cooling performance are improved, but the device complexity increases
Solution Approach 1:
The parallel line structure segments the cooling system into functionally distinct modules (power electronic cooling line, battery cooling line), making the complexity manageable through clear functional separation rather than a monolithic system.
Solution Approach 2:
Flow control valves provide dynamic adjustment capability, allowing the system to adapt coolant distribution to varying thermal loads. This dynamic control optimizes performance while the valves themselves are relatively simple components that don't significantly increase overall system complexity.
4Reliability
If high flow rates are used to handle heat radiation in high-performance vehicles, then cooling capacity is sufficient, but line resistance becomes prohibitive
Solution Approach 1:
Segmenting the coolant path into parallel lines dramatically reduces the length and complexity of each individual path. This allows high flow rates to be achieved in each line without the prohibitive line resistance that would occur in a single long series line required to cool all components.
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 approach significantly increases coolant flow rates and enhances cooling performance under various conditions, improving energy efficiency and reducing power consumption by minimizing line resistance and optimizing temperature control for power electronic components and batteries.
Implementation Method 1
a first electric water pump and a second electric water pump configured to pump the coolant so as to circulate the coolant
Implementation Method 2
a first radiator and a second radiator configured to dissipate heat from the coolant
Implementation Method 3
flow control devices installed at upstream ends and downstream ends of the first radiator and the second radiator so as to control a coolant flow direction
Data Source
AI summary
A thermal management system includes: a first radiator, a first electric water pump, and a first coolant line configured to allow a coolant to be circulated by the first electric water pump; a second radiator, a second electric water pump, and a second coolant line configured to allow a coolant to be circulated by the second electric water pump; and a first flow control device and a second flow control device installed at front ends and rear ends of the first radiator and the second radiator so as to control a coolant flow direction between the first coolant line, the second coolant line, and a third coolant line. The third coolant line is installed so as to connect the first flow control device and the second flow control device to each other.