Dynamic EV Coolant Loop Switching for Battery and Drivetrain Thermal Control
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Solution Overview
Problem
Existing thermal systems in electric vehicles, particularly mass-transit vehicles, are inadequate for managing battery performance due to sensitivity to environmental conditions, leading to frequent recharging and suboptimal passenger comfort.
Innovation Solution
A dynamically adjustable thermal system with flow paths that alter based on vehicle drive profile and environmental conditions, utilizing flow control components and a vehicle control system to manage coolant flow rates and paths for targeted thermal management of battery packs and other vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional powertrain cooling and heating system is used in electric vehicles, then the system structure is simple, but the battery performance cannot be optimally managed due to sensitivity to environmental conditions
Solution Approach 1:
The thermal system is divided into separate thermal zones for the battery pack and powertrain components, with independent cooling circuits and control mechanisms. This segmentation allows optimized thermal management for each component's specific requirements, ensuring reliable battery performance while maintaining manageable system complexity through modular design.
Solution Approach 2:
The thermal system incorporates dynamically adjustable flow paths and variable speed pumps that can adapt coolant distribution in real-time based on environmental conditions and component thermal demands. This dynamic capability enables optimal battery performance management across varying operating conditions without requiring an overly complex fixed-architecture system.
2Duration of action of moving object
If thermal management is optimized for battery packs, then driving distance increases and recharging frequency decreases, but the system complexity increases due to dynamically adjustable flow paths
Solution Approach 1:
The thermal system employs multi-functional control valves and flow distribution manifolds that can direct coolant to different thermal zones (battery pack, powertrain, cabin) through a single integrated circuit. This universal approach extends driving distance by optimizing battery thermal management while avoiding the complexity of completely separate cooling systems for each function.
Solution Approach 2:
The system incorporates thermal sensors and control logic that automatically monitor battery temperature and adjust coolant flow accordingly, enabling self-regulating thermal management. This extends driving distance through optimized battery performance without requiring complex manual intervention or overly sophisticated control systems.
3Reliability
If a complete redesign of thermal system architecture is implemented, then battery performance is optimized, but the ease of manufacture decreases
Solution Approach 1:
The redesigned thermal system is organized into modular segments (battery cooling circuit, powertrain cooling circuit, cabin HVAC integration) that can be manufactured and tested independently before final assembly. This segmentation optimizes battery performance through customized thermal paths while improving ease of manufacture through standardized modular components.
Solution Approach 2:
The design merges the battery thermal management system with the existing powertrain cooling architecture through integrated coolant circuits and shared components where possible. This combination optimizes battery performance within a unified thermal system, simplifying manufacturing processes compared to completely separate systems while maintaining the necessary thermal management capabilities.
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
Enhances battery performance and passenger comfort by optimizing thermal management, increasing driving distance and reducing recharging frequency.
Implementation Method 1
The coolant supports heat transfer from or to vehicle components based on conduction (e.g., heat transfer from or to the coolant based on physical contact with the vehicle components and/or one or more components in thermal connection to the vehicle components)
Implementation Method 2
The coolant supports heat transfer from or to vehicle components based on conduction (e.g., heat transfer from or to the coolant based on physical contact with the vehicle components and/or one or more components in thermal connection to the vehicle components) and/or convection (e.g., provide heat transfer based on the propagation of the coolant through the conduits)
Data Source
AI summary
Embodiments of the invention are directed to a thermal system for an electric vehicle. The thermal system features a vehicle control system and a first control valve. The first control valve, upon placement into a first operational state by the vehicle control system, separates a flow of coolant used to thermally adjust one or more components within the electric vehicle into parallel thermal loops from a serial thermal loop. The parallel thermal loops include a first thermal loop responsible for thermal adjustment of a plurality of battery packs and a second thermal loop responsible for thermal adjustment of a drivetrain including at least an electric motor. The thermal system may further include a second control valve that, upon placement into a first operational state by the vehicle control system, routes the flow of coolant to bypass a radiator of the electric vehicle prior to routing to the first control valve.