EV Cooling Circuit With Charger Bypass for Pump Load and Heat Control
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Solution Overview
Problem
Conventional cooling systems for electric vehicles face challenges in balancing pump load reduction and effective cooling of the drive unit, particularly due to varying cooling needs of the charger and drive unit based on operation status.
Innovation Solution
A cooling system with a bypass route for the charger and a control device that adjusts coolant circulation based on temperature sensors, allowing coolant to bypass the charger when not in operation and utilize it as a secondary heat exchanger when needed, optimizing coolant distribution to prioritize high-temperature components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If coolant circulation is bypassed to the charger when not in operation, then pump load is reduced, but cooling of the drive unit may be insufficient when temperature rises
Solution Approach 1:
The cooling system dynamically adjusts coolant circulation paths based on real-time temperature conditions and charger operational status. The control device switches between bypass mode (when charger is inactive and drive unit temperature is low) and active cooling mode (when drive unit temperature exceeds threshold), optimizing pump load while ensuring adequate cooling when needed.
Solution Approach 2:
The charger is designed to serve dual functions: its primary function as a charging device and its secondary function as a heat exchanger. When the charger is not in operation, it can still accept coolant flow to provide passive cooling for the drive unit, eliminating the need for dedicated cooling paths and reducing overall system complexity.
2Temperature
If coolant is sent to the charger when not in operation to strengthen cooling, then drive unit cooling is improved, but pump load increases
Solution Approach 1:
The system applies partial cooling action by directing coolant to the charger only when necessary (when drive unit temperature exceeds the threshold). This partial action approach avoids continuous coolant circulation through the charger, thereby reducing pump load while still providing adequate cooling when temperature conditions require it.
3Volume of moving object
If the charger is disposed rearward of the drive unit, then space utilization is optimized, but coolant circulation path becomes longer
Solution Approach 1:
The cooling system merges the charger's structural body with the coolant circulation path by incorporating coolant channels directly into the charger housing. This integration allows the coolant to flow through the charger's existing structure rather than requiring separate external piping, thereby minimizing the additional path length despite the rearward positioning of the charger.
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 configuration reduces pump load by bypassing the charger when not in operation and enhances cooling efficiency by using the charger as a secondary heat exchanger when necessary, achieving both reduced pump load and improved drive unit cooling.
Implementation Method 1
a heat exchanger provided in the coolant circuit and configured to cool the coolant
Implementation Method 2
at least one temperature sensor provided to the drive unit and configured to detect temperature of the drive unit
Implementation Method 3
a pump provided in the coolant circuit and configured to send coolant to the coolant circuit
Data Source
AI summary
A cooling system for an electric vehicle is provided, which includes a drive unit disposed in a front part of a vehicle, a charger disposed rearward of the drive unit, a coolant circuit connected to the drive unit and the charger and having a bypass route bypassing the charger, a pump, a heat exchanger, at least one temperature sensor, and a control device which controls circulation of the coolant to the coolant circuit based on the temperature of the drive unit. The control device sends the coolant to the bypass route, when the charger is not in operation, and when the temperature of the drive unit is below a given temperature, and sends the coolant to the drive unit after sending the coolant to the charger, when the charger is not in operation, and when the temperature of the drive unit is above the given temperature.