Electric Vehicle Cooling Device Post-Stop Thermal Management
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Solution Overview
Problem
Conventional cooling devices for electric vehicles cannot continue to cool the engine and battery charger assemblies after the vehicle has stopped, leading to potential overheating and battery discharge issues.
Innovation Solution
A cooling device with a control system that maintains power and circulates coolant to both the engine and charger assemblies, using two pumps and valves to manage coolant flow, and a hydraulic restriction to ensure continuous cooling while preventing unnecessary energy consumption, with closed-loop regulation to optimize flow rates and conserve energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the cooling device is placed on standby after the vehicle has stopped, then energy consumption from the battery is reduced, but the engine assembly cannot be cooled leading to potential overheating
Solution Approach 1:
The cooling device transitions from a static standby state to a dynamic controlled operation state. The control system dynamically adjusts pump operation and valve positions based on real-time temperature readings from temperature sensors, enabling the system to respond adaptively to cooling needs after vehicle stoppage while managing energy consumption.
Solution Approach 2:
The control system implements a feedback mechanism using temperature sensors to monitor coolant temperature in the engine assembly. When the temperature exceeds a predetermined threshold after vehicle stoppage, the control system activates the cooling device. The system continues operation until the temperature drops below the threshold, creating a closed-loop feedback control that balances cooling effectiveness with energy conservation.
2Reliability
If the cooling device remains powered up after vehicle stoppage, then the engine assembly continues to be cooled, but unnecessary energy is consumed from the battery
Solution Approach 1:
The cooling device operates in periodic cycles rather than continuously. The control system activates cooling when temperature thresholds are exceeded and deactivates it when thresholds are satisfied, creating periodic on-off operation. This approach provides necessary cooling while avoiding continuous energy consumption, directly resolving the contradiction between maintaining cooling capability and conserving battery energy.
Solution Approach 2:
The cooling system serves itself through automatic control based on temperature feedback. The control system monitors temperature conditions and autonomously decides when to activate or deactivate cooling without requiring external intervention. This self-service capability ensures cooling is provided only when genuinely needed, preventing unnecessary energy consumption while maintaining reliability.
3Reliability
If coolant flow is increased to improve cooling effectiveness, then cooling performance improves, but energy consumption and pump wear increase
Solution Approach 1:
The control system dynamically changes the flow rate parameter of the coolant based on temperature conditions. Rather than maintaining constant high flow rate, the system adjusts the flow parameter to match the actual cooling demand, using higher flow rates only when temperature thresholds indicate urgent cooling needs and lower rates when cooling demand is reduced, thereby optimizing energy consumption.
Solution Approach 2:
The cooling system applies partial action by providing cooling at reduced capacity when temperature thresholds are marginally exceeded, rather than always operating at full capacity. The control system modulates pump operation to provide just sufficient cooling to maintain temperatures below critical thresholds, avoiding excessive cooling action that would waste energy and increase pump wear.
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
Prevents engine overheating and battery discharge by maintaining cooling after the vehicle has stopped, optimizing energy use and extending battery life by controlling coolant flow based on temperature and battery voltage.
Implementation Method 1
a cooling circuit capable of cooling an engine assembly including an electronic driver system and a battery charger assembly using a coolant
Implementation Method 2
a radiator, which is a heat exchanger used to cool the liquid
Data Source
AI summary
A cooling device for an automotive vehicle of electric type, the cooling device being able to be powered up or powered down and including a cooling circuit capable of cooling an engine assembly including an electronic driver system using a coolant, the cooling circuit being controlled by a control system capable of keeping the device powered up when the vehicle is at end of mission and the temperature of the coolant is above a threshold temperature. The electric vehicle includes a battery charger assembly, and the cooling circuit is capable of cooling the charger assembly and the engine assembly.