Dual EV Cooling Circuits With Switchable Heat Exchange Paths
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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 critical components like batteries and drive motors.
Innovation Solution
A dual cooling circuit system with integrated switching points and valves allows for flexible distribution of heat or cold between circuits, using a common coolant medium, and includes components like indirect condensers, chillers, and heat exchangers to manage temperature dynamically based on ambient and operational conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a dual cooling circuit system with multiple heat exchangers and switching points is implemented, then temperature control flexibility and energy efficiency are improved, but device complexity increases
Solution Approach 1:
The cooling system is divided into two separate cooling circuits (first cooling circuit for battery, second cooling circuit for power electronics) that can be independently controlled. Each circuit has its own heat exchangers and switching points, allowing independent temperature management for different components with different thermal requirements.
Solution Approach 2:
Heat exchangers are designed to serve multiple functions: they can cool components during high-load operation, recover heat during low-load operation, and transfer thermal energy between circuits. The same heat exchanger can switch between cooling and heat recovery modes based on operational requirements.
Solution Approach 3:
The system incorporates switching points with controllable valves that dynamically redirect coolant flow based on real-time thermal conditions. The switching points enable the system to adapt its configuration continuously, transitioning between different operational modes (cooling, heat recovery, mixed operation) to optimize performance.
2Loss of energy
If heat exchangers are used for both cooling and heat recovery, then energy efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
Heat exchangers are designed as multi-functional components that can operate in different modes: cooling mode during high-power operation and heat recovery mode during low-power operation. This eliminates the need for separate cooling and heating systems, reducing overall system complexity while improving energy efficiency.
Solution Approach 2:
The operational parameters of the heat exchangers are dynamically adjusted based on system requirements. By changing flow rates, temperature differentials, and operational modes, the same hardware can achieve both cooling and heat recovery functions without requiring additional components.
3Measurement precision
If cooling medium flow is divided between parallel sections, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The cooling circuit is segmented into parallel flow paths with independent control. Each section can receive a controlled portion of the total coolant flow, allowing precise temperature management for different components. The segmentation enables independent optimization of cooling for battery, power electronics, and other components.
Solution Approach 2:
Temperature sensors and flow control mechanisms work together in a feedback loop to monitor and adjust coolant distribution. Based on real-time temperature measurements, the system dynamically adjusts flow rates to each section to maintain optimal temperature ranges, improving control precision.
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 enhances energy efficiency by optimizing temperature control of vehicle components, reducing energy consumption, and ensuring optimal operating conditions for batteries and drive motors while providing flexible heating and cooling capabilities.
Implementation Method 1
a heat exchanger designed as an indirect condenser (5) for transferring heat between the first cooling circuit (K1) and the coolant circuit (K3)
Implementation Method 2
a heat exchanger designed as a chiller (6) for transferring heat between the second cooling circuit (K2) and the coolant circuit (K3)
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
A cooling system for a motor vehicle, in particular for an electrically powered motor vehicle, havinga 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-controlleda heat exchanger designed as an indirect condenser for transferring heat between the first cooling circuit and the coolant circuit,wherein the second cooling circuit has:at least one second component to be temperature-controlleda heat exchanger designed as a chiller for transferring heat between the second cooling circuit and the coolant circuit,wherein the first and second cooling circuit can be connected by means of a first connecting section and a second connecting section, and, at least on the first connecting section, a second switching point is arrangedwherein the second switching point connects the first connecting section to the first cooling circuit in such a way that a cooling medium flows completely or at least partially through the first connecting section.