EV Cooling System Thermal Coupling via Heat Exchanger
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electric vehicles with internal combustion engine/generator units face challenges in achieving a compact and efficient cooling system to manage the heat generated during operation, which affects the range and efficiency of the vehicle.
Innovation Solution
A dual cooling system with separate circuits for the electric drive and internal combustion engine, thermally coupled via a heat exchanger, allowing for independent temperature control and utilizing waste heat from the electric drive to cool the engine, eliminating the need for additional radiators and simplifying maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate cooling circuit is used for the internal combustion engine, then the temperature control of the engine is improved, but the device complexity and component count increase
Solution Approach 1:
The patent merges the cooling functions of the electric drive and internal combustion engine into a single integrated cooling system. The heat exchanger enables thermal coupling between the two previously separate cooling circuits, allowing heat transfer from the engine to the electric drive cooling fluid. This combination reduces component count while maintaining independent temperature control capabilities through the thermostat mechanism.
Solution Approach 2:
The integrated cooling system performs multiple functions: it cools the electric drive components, controls the internal combustion engine temperature, and enables waste heat recovery. The single cooling circuit with heat exchanger serves both cooling and heat transfer purposes, eliminating the need for separate radiators and cooling circuits for each system.
2Productivity
If a heat exchanger is added to couple the cooling circuits, then the thermal management efficiency is improved, but the device complexity increases
Solution Approach 1:
The heat exchanger converts the harmful waste heat from the internal combustion engine into a beneficial resource by transferring it to the electric drive cooling fluid. This waste heat recovery improves overall thermal management efficiency, particularly during regenerative braking when the electric drive generates heat that can be transferred to the engine cooling side.
3Device complexity
If the cooling system is simplified by removing additional radiators, then the device complexity is reduced, but the ability to release heat to the environment is worsened
Solution Approach 1:
The patent combines the heat release functions into a single radiator that serves both the electric drive and internal combustion engine cooling circuits. The integrated cooling system with heat exchanger allows one radiator to efficiently dissipate heat from both sources by circulating cooling fluid through the heat exchanger and then through the shared radiator.
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 solution enables efficient temperature regulation, reduces component count, and extends the life and efficiency of the internal combustion engine, while maintaining a compact and low-cost cooling system, allowing for seamless operation with or without the range extender.
Implementation Method 1
a heat exchanger (3), which is designed to couple the first cooling circuit (1) and the second cooling circuit (2) thermally to one another
Data Source
AI summary
A cooling system for thermal management of an electric vehicle having a range extender. The temperature of the components of the electric drive system of the electric vehicle and at least that of the internal combustion engine of an internal combustion engine/generator unit of the range extender are controlled by separate cooling circuits. The cooling circuit of the electric drive and the cooling circuit of the internal combustion engine are coupled to one another thermally by a heat exchanger.