EV Thermoregulation Circuit Using Drive Heat for Battery Warming
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Solution Overview
Problem
Full electric drive vehicles face challenges in maintaining optimal battery and electric motor temperatures due to limited heat generation, leading to reduced range and efficiency, as they rely on electric heaters or heat pumps that consume battery power, and existing thermoregulation systems are not energy-efficient or cost-effective.
Innovation Solution
A thermoregulation system that utilizes a solenoid valve and heat exchangers to optimize heat distribution between electric drive systems, air conditioning, and battery heating, allowing for efficient heat generation and use, with a control unit managing solenoid valves to minimize energy consumption and maximize range by selectively using electric heaters and drive system heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electric heaters or heat pumps are used to generate heat for the battery and passenger compartment, then the heating function is achieved, but the battery power consumption increases and the vehicle range is reduced
Solution Approach 1:
The system converts waste heat from the electric motor and electronic power converter into useful thermal energy for heating the battery and passenger compartment. Instead of dissipating this heat as waste, the thermoregulation system captures and redirects it through heat exchangers and solenoid valves, transforming a harmful thermal byproduct into a beneficial resource that reduces battery power consumption for heating operations.
Solution Approach 2:
The thermoregulation system enables the electric drive system to serve its own thermal needs. The electric motor and electronic power converter, which generate excess heat during operation, now contribute to heating the battery and passenger compartment without requiring additional battery power. The system self-regulates through solenoid valves that redirect thermal fluid between cooling and heating circuits based on real-time temperature requirements.
2Reliability
If the battery and electric motor are cooled to maintain optimal operating temperature, then their efficiency and reliability are improved, but the system complexity increases
Solution Approach 1:
The thermoregulation system employs a multi-functional design where the same thermal fluid circulation system serves both cooling and heating functions. The heat exchangers, solenoid valves, and circulation pumps form a universal system that can redirect thermal energy between the battery, electric motor, and passenger compartment as needed. This eliminates the need for separate cooling and heating systems, reducing overall complexity while maintaining reliable temperature control for all components.
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
The system achieves higher energy efficiency in heat generation for the vehicle, reducing battery power consumption and extending the vehicle's range while being compact and economical to manufacture.
Implementation Method 1
a heat exchanger configured to heat the battery when it is too cold by using heat from the drive system
Implementation Method 2
A thermoregulation system that utilizes a solenoid valve and heat exchangers to optimize heat distribution
Data Source
Figure 1
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Figure 3
AI summary
A vehicle (1) having: at least one electric drive system (3); a battery (6); a passenger compartment (10); an air conditioning system (11) to air-condition the passenger compartment (10) and provided with at least one heat exchanger (13); a first thermoregulation circuit (15) configured to have the fluid flow through the drive system (3); a second thermoregulation circuit (16) configured to have the fluid flow through the battery (6); a third thermoregulation circuit (17) configured to have the fluid flow through the heat exchanger (13); an electric heater (18), which is arranged along the third thermoregulation circuit (17) and can be operated in order to heat the fluid flowing in the third thermoregulation circuit (17); and at least one solenoid valve (19) movable between an isolation position, in which the fluid flowing through the first thermoregulation circuit (15) does not flow through the third thermoregulation circuit (17), and a connection position, in which the fluid flowing through the first thermoregulation circuit (15) also flows through the third thermoregulation circuit (17).