EV Heat Pump Heat Exchanger De-Icing With Ultrasonic Vibration
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Solution Overview
Problem
Existing thermal control systems for electric vehicles face inefficiencies in heating at low temperatures due to ice formation on heat exchangers, leading to reduced effectiveness and increased energy consumption.
Innovation Solution
Incorporating a vibration device, such as an ultrasonic transducer, on the heat exchangers to remove ice through mechanical energy transfer, allowing for effective operation of heat pumps in colder climates with reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a heat pump is used to heat the battery and cabin at low temperatures, then energy efficiency is improved, but ice formation on heat exchangers occurs reducing effectiveness
Solution Approach 1:
An ultrasonic transducer is mounted on the heat exchanger to generate mechanical vibrations at frequencies between 20 kHz and 5 MHz. These vibrations create cavitation bubbles at the ice interface and induce turbulence in the heat exchange medium, effectively removing ice buildup and maintaining heating effectiveness without sacrificing energy efficiency
Solution Approach 2:
The system changes the physical state of the heat exchange medium by inducing cavitation and turbulence through ultrasonic vibrations. This transforms laminar flow into turbulent flow, enhancing heat transfer coefficients and preventing ice adhesion on the heat exchanger surfaces
2Temperature
If heating power is provided by the high voltage battery pack at low temperatures, then the battery and cabin can be heated, but the driving range is reduced
Solution Approach 1:
The patent replaces the direct electrical heating system (Joule heating from battery) with a thermodynamic heat pump system. The heat pump uses mechanical work from the compressor to move heat from the ambient environment to the battery and cabin, achieving heating with much lower energy consumption from the high voltage battery pack and thus preserving driving range
3Reliability
If the ultrasonic transducer operates continuously at low temperatures, then ice removal is effective, but power consumption increases
Solution Approach 1:
The control unit operates the ultrasonic transducer in periodic cycles rather than continuously. The transducer is activated for specific durations when ice formation is detected or anticipated, then deactivated. This periodic operation maintains effective ice removal while significantly reducing the average power consumption of the transducer system
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 solution results in up to 20% energy savings and extended driving range by efficiently managing ice formation and enhancing heat transfer, particularly at low temperatures.
Implementation Method 1
The ultrasonic transducer is placed on the first heat exchanger and that is adapted to generate sonic waves along an outer surface of the heat exchanger, which outer surface forms an interface with an ice layer, for melting ice, such as by causing cavitation bubbles, at the interface layer
Implementation Method 2
the vibration device comprises an ultrasonic transducer that is placed on the first heat exchanger and that is adapted to generate sonic waves along an outer surface of the heat exchanger
Implementation Method 3
The use of a heat pump for transporting heat from the ambient air to the cabin and battery provides an energy-effective way of heating
Implementation Method 4
a second heat exchanger in thermal contact with the battery
Implementation Method 5
the vibration device comprises an ultrasonic transducer that is placed on the first heat exchanger and that is adapted to generate sonic waves along an outer surface of the heat exchanger
Implementation Method 6
the ultrasonic waves cause increased turbulence in the heating medium and result in an increase in heat transfer
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a thermal control system (1) for an electric vehicle comprising: - a high voltage battery (2), - a first heat exchanger (6) adapted to be in contact with the ambient (4) for circulating a heat exchange medium in thermal contact with the ambient, - a second heat exchanger (3) in thermal contact with the battery (2), - a heat transport system (5) for transporting the heat exchange medium from the first heat exchanger (6) to an evaporator/condenser assembly (15,18) that is in thermal contact with the second heat exchanger (3) for transfer of heat to the battery (2) and for transporting the heat exchange medium back to the first heat exchanger (6). At least one of the first and second heat exchangers (3,6) is provided with a vibration device (20,23, 27), such as an ultrasonic transducer, for releasing of ice formed on the at least one heat exchanger (3,6).