Dual Cooling Circuit Control for EV Thermal Energy Routing
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Solution Overview
Problem
Existing cooling systems for electric vehicles struggle with inefficient energy management for heating and cooling, leading to high energy consumption and suboptimal temperature control of components like batteries and passenger compartments.
Innovation Solution
A dual cooling circuit system with a first and second cooling circuit, connected via a coolant circuit, allows for flexible distribution of heat or cold using chiller, condenser, and heat exchangers, controlled by switching points and valves to manage temperature effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a dual cooling circuit system with multiple switching points is used to flexibly distribute heat and cold, then adaptability and energy efficiency are improved, but device complexity increases
Solution Approach 1:
The cooling system is divided into a first cooling circuit for drive components and a second cooling circuit for the passenger compartment, with each circuit having dedicated switching points (V1-V4) that can be independently controlled. This segmentation allows flexible heat distribution to different components without requiring a completely redesigned integrated system, resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The cooling medium circulating in the first cooling circuit serves multiple functions: it can cool drive components directly, transfer heat to the second cooling circuit via the indirect condenser for passenger compartment cooling, or be routed through the radiator for direct heat dissipation. This multi-functionality improves energy efficiency without proportionally increasing system complexity.
2Measurement precision
If switching points are controlled based on multiple parameters (ambient temperature, component temperatures) then temperature control precision is improved, but control complexity increases
Solution Approach 1:
The control unit continuously monitors ambient temperature (TU) and component temperatures (T1, T2) and uses this feedback information to dynamically adjust the switching points. This feedback mechanism enables precise temperature control of the battery and drive components while automating the control process to manage complexity.
Solution Approach 2:
The switching points are designed to be dynamically adjustable based on real-time temperature conditions rather than fixed in position. The control unit can open or close different switching points depending on whether heating or cooling is required, allowing the system to adapt to varying thermal conditions and maintain optimal temperatures across different operating scenarios.
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 system optimizes energy use by efficiently heating or cooling components and the passenger compartment, maintaining optimal operating temperatures with reduced energy consumption across various ambient conditions.
Implementation Method 1
An indirect condenser refers to when cooling medium that circulates in a cooling circuit is used for heat transfer in the condenser
Implementation Method 2
A heat exchanger designed as a chiller, which is arranged in the second cooling circuit, transfers heat between the second cooling circuit and the coolant circuit
Implementation Method 3
A heat exchanger designed as a radiator is also arranged in the first cooling circuit for transferring heat between the first cooling circuit and the ambient air
Data Source
AI summary
An operating method for operating a cooling system for a motor vehicle, in particular for an electrically powered motor vehicle, wherein the cooling system has a first cooling circuit, a second cooling circuit, and at least one coolant circuit;wherein the first cooling circuit has at least one first component to be temperature-controlled and an indirect condenser, which are arranged in two sections extending parallel to one another, with a first switching point which is arranged on the first or second branching point and which controls the inflow of a cooling medium into the first component to be temperature-controlled and the indirect condenser;wherein the second cooling circuit has at least one second component to be temperature-controlled and a chiller;wherein the first and second cooling circuits can be connected by means of a first and second connecting section, and a second switching point, which controls the inflow of the cooling medium into at least the first connecting section, is arranged at least on the first connecting section;wherein a third switching point, which controls the inflow of cooling medium into the chiller, is arranged in the second cooling circuit;wherein, in the first cooling circuit, a radiator is arranged downstream of the second connecting section, and a fourth switching point, which controls the inflow of cooling medium into the radiator, is arranged upstream of the radiator, characterized in thatthe first, second, third, and fourth switching point are controlled at least as a function of an ambient temperature Tu.