Integrated EV Heat Cycle Layout for In-Wheel Motor Cooling
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Solution Overview
Problem
In electric vehicles (EVs), the cooling of electric drive systems using heat pumps increases vehicle cost and weight due to the need for additional heat exchangers, pumps, and piping, while existing solutions fail to effectively reduce power consumption and simplify the layout without increasing costs or weight.
Innovation Solution
A heat cycle system with a single circulation path for refrigerant, incorporating a compressor, accumulator, electric drive unit, indoor, and outdoor heat exchangers, and a four-way valve to switch refrigerant flow between them, allowing for efficient cooling and heating of both the vehicle's interior and electric drive unit without increasing the number of parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a heat pump is used for cooling the electric drive system, then power consumption is reduced, but the number of parts and vehicle weight increase
Solution Approach 1:
The patent merges the air conditioning system and electric drive system cooling functions into a single integrated heat cycle system. The refrigerant circulation system serves dual purposes: providing cabin air conditioning through the indoor heat exchanger and cooling the electric drive system through the outdoor heat exchanger. This eliminates the need for separate cooling systems, reducing overall vehicle weight while maintaining the power consumption benefits of heat pump technology.
Solution Approach 2:
The outdoor heat exchanger performs multiple functions: it acts as the condenser for air conditioning during normal operation and as the evaporator for cooling the electric drive system when needed. The four-way valve enables the system to switch between different operational modes, allowing the same hardware components to serve multiple cooling purposes, thereby reducing the total number of parts required.
2Use of energy by moving object
If a heat pump is used for cooling the electric drive system, then power consumption is reduced, but the number of parts increases
Solution Approach 1:
The patent combines the air conditioning system and electric drive system cooling into one integrated heat cycle system. The same compressor, expansion valve, and refrigerant circulation infrastructure serve both the cabin air conditioning and the electric drive system cooling, eliminating the need for separate pumps, heat exchangers, and control valves that would be required in a dual-system configuration.
Solution Approach 2:
The outdoor heat exchanger is designed to perform dual functions: serving as the condenser during air conditioning operation and as the evaporator during electric drive system cooling. The four-way valve enables seamless switching between these modes, allowing the system to use the same hardware components for multiple purposes, thereby reducing the total number of parts while maintaining full functionality.
3Reliability
If separate cooling systems are used for air conditioning and electric drive system, then system independence is maintained, but vehicle cost and weight increase
Solution Approach 1:
The patent merges the air conditioning and electric drive system cooling into a single heat cycle system with shared components. The refrigerant circulation system provides cooling to both the cabin and the electric drive system simultaneously or independently, reducing vehicle weight while maintaining functional separation through control valves that can direct refrigerant flow to different destinations as needed.
4Reliability
If separate cooling systems are used for air conditioning and electric drive system, then system independence is maintained, but vehicle cost increases
Solution Approach 1:
The patent combines the air conditioning and electric drive system cooling into one integrated heat cycle system. By sharing the compressor, expansion valve, and refrigerant circulation infrastructure, the system reduces the total number of parts required, thereby lowering manufacturing costs while maintaining the ability to independently control cooling for each system through the four-way valve and associated control mechanisms.
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 configuration reduces power consumption, decreases vehicle weight, and simplifies the layout by eliminating the need for additional pumps and valves, providing a low-cost, efficient cooling system for EVs.
Implementation Method 1
a refrigerant compressed by the compressor
Implementation Method 2
an indoor heat exchanger and an outdoor heat exchanger that perform heat exchange of the refrigerant
Data Source
AI summary
The purpose of the present invention is to provide a low-cost heat cycle system that can reduce power consumption; an in-wheel motor that is driven by using this heat cycle system; and a vehicle in which this heat cycle system is installed. This heat cycle system is provided with: a compressor; an accumulator; an electric drive unit comprising an electric motor; a refrigerant compressed by the compressor; and an indoor heat exchanger and an outdoor heat exchanger responsible for heat exchange of the refrigerant. The heat cycle system comprises a four-way valve that comprises a single circulation path for circulating the refrigerant and that can switch the connection destination of a refrigerant discharge section of the compressor to the indoor heat exchanger or the outdoor heat exchanger. A cooling unit of the electric drive unit is arranged upstream of the accumulator in the flow of the refrigerant.