Integrated Heat Pump Thermal Management for EV Battery and Motor Cooling
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Solution Overview
Problem
The existing heat pump systems for electric and hybrid vehicles are complex, leading to increased size and weight due to separate cooling systems for batteries and motors, resulting in noise and vibration issues and reduced ride comfort due to frequent valve operations.
Innovation Solution
A heat pump system that uses a single chiller for heat exchange between a coolant and refrigerant to adjust battery module temperatures, incorporating a radiator, water pumps, valves, and a reservoir tank to circulate coolant, and a chiller connected to the air conditioner's refrigerant line to enhance heating efficiency by utilizing waste heat from electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling systems are used for batteries and motors, then cooling performance is improved, but system complexity and weight increase
Solution Approach 1:
The patent combines the battery cooling system and motor cooling system into a single integrated cooling circuit. The coolant flows through both the battery cooler and motor cooler sequentially, allowing both components to be cooled by the same refrigerant circulation system. This merging approach maintains adequate cooling performance for both batteries and motors while significantly reducing system complexity and eliminating the need for separate cooling loops.
Solution Approach 2:
The cooling system is designed with multi-functionality where the same coolant circuit serves multiple purposes: cooling the battery module, cooling the motor, and providing heating to the vehicle interior through the heater. The system can operate in different modes (cooling mode, heating mode, idle mode) to serve different functions, making the cooling system universal rather than dedicated to a single component.
2Adaptability or versatility
If multiple valves are used for connection with respective connection pipes, then system adaptability is improved, but noise and vibration increase
Solution Approach 1:
The patent reduces the number of valves by merging control functions. Instead of having separate valves for battery cooling and motor cooling circuits, the system uses a single multi-position valve that can direct refrigerant flow to different components (battery cooler, motor cooler, heater, or idle position). This consolidation maintains system adaptability while reducing the number of moving parts that generate noise and vibration.
3Measurement precision
If frequent valve operations are performed, then temperature control precision is improved, but ride comfort deteriorates
Solution Approach 1:
The system employs dynamic control where the single multi-position valve adjusts refrigerant flow distribution based on real-time temperature conditions of the battery and motor. The control unit monitors temperatures and dynamically switches the valve position to optimize cooling or heating distribution, maintaining precise temperature control while minimizing valve operation frequency compared to multiple independently controlled valves.
4Reliability
If separate battery cooling system is provided, then battery performance optimization is improved, but system weight increases
Solution Approach 1:
The patent integrates battery cooling into the overall thermal management system shared with motor cooling and interior heating. The battery cooler is part of the same refrigerant circulation system that cools the motor and heats the interior, eliminating the need for separate battery cooling infrastructure. This integration maintains effective battery temperature control while significantly reducing system weight compared to dedicated separate cooling systems.
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 simplifies the overall system, improves heating efficiency, optimizes battery performance, and reduces noise and vibration by efficiently managing battery module temperatures and utilizing waste heat for internal heating, thereby enhancing vehicle travel distance and reducing costs and weight.
Implementation Method 1
a chiller provided in the battery coolant line between the first valve and the battery module, and connected to a refrigerant line of an air conditioner through a refrigerant connection line, to adjust a temperature of the coolant by performing heat exchange between the coolant which is circulated in the battery coolant line and a refrigerant
Implementation Method 2
a condenser included in the air conditioner is connected to the heating line to pass the coolant circulating through the heating apparatus
Implementation Method 3
a condenser included in the air conditioner is connected to the heating line to pass the coolant circulating through the heating apparatus
Implementation Method 4
the interior of the vehicle is warmed or cooled through heat exchange by a condenser and an evaporator during a process in which a refrigerant discharged by driving of a compressor circulates back to the compressor after passing through a condenser, a receiver dryer, an expansion valve, and an evaporator
Implementation Method 5
a refrigerant discharged by driving of a compressor circulates back to the compressor after passing through a condenser
Data Source
AI summary
A heat pump system may include a cooling apparatus of circulating a coolant in a coolant line to cool at least one electrical component provided in the coolant line; a battery cooling apparatus of circulating the coolant to the battery module; a chiller for heat exchanging the coolant with a refrigerant to control a temperature of the coolant; a heating apparatus that heats an interior of the vehicle using the coolant; a branch line; a chiller connection line connecting the chiller and the first valve; and wherein the reservoir tank is provided in the coolant line between the radiator and the first valve, and is connected to the coolant line connecting the first valve and the first water pump through the supply line, and wherein a condenser included in the air conditioner is connected to the heating line to pass the coolant circulating through the heating apparatus.