EV Multi-Mode Thermal Management with Parallel Series Loops
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Solution Overview
Problem
Existing thermal management systems for electric vehicles face challenges in efficiently controlling the temperature of battery packs and drive train components while optimizing overall vehicle operating efficiency, as they often require complex configurations and compromise on performance, range, reliability, and cost.
Innovation Solution
A thermally efficient thermal management system utilizing three separate control circuits: a battery thermal control loop, a drive train control loop, and a refrigerant-based thermal control loop, with a valve assembly that allows for parallel or serial operation of these loops, and a refrigerant-air heat exchanger coupled to the HVAC system, enabling independent or combined operation to optimize temperature control across vehicle subsystems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single thermal management system is used to control both battery pack and drive train components, then system complexity is reduced, but temperature control precision for each component deteriorates
Solution Approach 1:
The thermal management system is divided into separate control loops for the battery pack and drive train components. Each loop has its own temperature sensors and control valves that independently regulate the coolant flow to maintain optimal temperatures for each component, thereby achieving precise temperature control without excessive system complexity.
2Measurement precision
If multiple separate thermal control loops are used for battery and drive train, then temperature control precision improves, but device complexity increases
Solution Approach 1:
The system merges the battery thermal control loop and drive train thermal control loop into a unified thermal management system that shares common components such as the coolant pump, radiator, and control unit. This integration reduces overall system complexity while maintaining separate temperature control capabilities for each component through dedicated control valves and sensors.
3Reliability
If thermal management system prioritizes battery temperature control, then battery reliability improves, but drive train component temperature control deteriorates
Solution Approach 1:
The control system dynamically adjusts the coolant flow distribution between the battery pack and drive train components based on real-time temperature measurements and operational conditions. The control unit monitors both battery and drive train temperatures, and automatically modulates the control valves to prioritize cooling to the component that requires it most at any given moment, ensuring both maintain acceptable temperature ranges.
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 effectively regulates the temperature of battery packs, drive train components, and passenger cabins, enhancing overall vehicle efficiency by allowing flexible configuration of thermal loops to manage heat transfer efficiently, thereby maintaining performance, range, and cost-effectiveness.
Implementation Method 1
a refrigerant-air heat exchanger coupled to the HVAC system
Implementation Method 2
a first circulation pump that circulates a heat transfer fluid within the battery thermal control loop
Implementation Method 3
the battery thermal control loop is thermally coupled to a vehicle battery pack
Data Source
AI summary
A multi-mode vehicle thermal management system is provided that allows efficient thermal communication between a refrigerant-based thermal control loop and two non-refrigerant-based thermal control loops, where one of the non-refrigerant-based loops is thermally coupled to the vehicle's battery system and the other of the non-refrigerant-based control circuits is thermally coupled to the vehicle's drive train. The refrigerant-based control loop may be operated either in a heating mode or a cooling mode and is coupled to the vehicle's HVAC system using a refrigerant-air heat exchanger, and to the battery thermal control loop using refrigerant-fluid heat exchangers. A valve assembly is used to couple and/or decouple the battery and drive train thermal control loops, thereby allowing these two thermal control loops to operate either in parallel or in series.