EV Cooling Circuit Switching for Battery Overheat Prevention
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Solution Overview
Problem
The parallel operation of motor and battery cooling circuits in electric vehicles often results in excessively hot coolant from the motor cooling circuit entering the battery cooling circuit, posing a risk to temperature-sensitive components and potentially triggering error messages due to temperature discrepancies.
Innovation Solution
A method involving a switching device that reroutes a first radiator from the motor cooling circuit to the battery cooling circuit, reducing the conveying capacity of the battery circuit pump to slow down coolant flow and facilitate temperature equalization, using an ambient air radiator to cool the coolant, and potentially reversing the pump direction to further cool the coolant before reintroducing it into the battery circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the first radiator is switched from the motor cooling circuit to the battery cooling circuit, then the cooling function for the battery is improved, but excessively hot coolant from the motor cooling circuit may enter the battery cooling circuit causing overheating risks
Solution Approach 1:
The control device performs preliminary cooling action by routing hot coolant from the motor cooling circuit through the first radiator (ambient air radiator) before it enters the battery cooling circuit. This preliminary cooling prevents the coolant from being excessively hot when it reaches the battery, thus resolving the contradiction between improving battery cooling function and preventing overheating risks.
2Stability of the object's composition
If the conveying capacity of the battery circuit pump is reduced to slow down coolant flow, then temperature homogenization is accelerated, but the cooling efficiency may be reduced
Solution Approach 1:
The control device implements periodic action by temporarily reducing the conveying capacity of the battery circuit pump only during the transition phase when hot coolant enters the battery cooling circuit. This temporary slowdown allows temperature homogenization to occur, after which the pump capacity can be restored to normal levels to maintain cooling efficiency, thus resolving the contradiction between temperature homogeneity and cooling efficiency.
3Object-affected harmful factors
If coolant flow is guided past the drive battery through the battery bypass line, then overheating is prevented, but the cooling function for the battery is temporarily suspended
Solution Approach 1:
The control device uses the battery bypass line as an intermediary pathway. When hot coolant from the motor cooling circuit enters the battery cooling circuit, the control device temporarily guides the coolant flow past the drive battery through the bypass line, preventing direct contact between hot coolant and the battery. This intermediary routing prevents overheating while maintaining system safety, resolving the contradiction between overheating prevention and cooling function.
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 accelerates temperature homogenization, preventing overheating issues and enabling faster resumption of the cooling function for the drive battery, thereby avoiding error messages and ensuring safe operation.
Implementation Method 1
The first radiator (8) is an ambient air radiator, which is a heat exchanger through which coolant can flow and around and/or through which ambient air can flow, wherein the coolant is cooled by the ambient air.
Implementation Method 2
a battery cooling circuit, in which flow occurs through a battery circuit pump (4) and a drive battery (3)
Data Source
AI summary
A method for controlling a cooling system includes providing a motor cooling circuit and providing a battery cooling circuit. In a first operating state, a first radiator is incorporated via a switching device into the motor cooling circuit. In in the first operating state, coolant flows through the motor cooling circuit and the battery cooling circuit fluidically separated from one another. A switch is made to a second operating state by actuating the switching device. Together with the actuation of the switching device, a conveying capacity of the battery circuit pump is reduced and the coolant is guided past the drive battery through the battery bypass line.