EV Thermal Management Circuit for Battery and Power Electronics
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Solution Overview
Problem
Existing thermal management control circuits for electric vehicles have complex architectures requiring many actuators, making them less economical and efficient in maintaining battery and power electronics components within their optimal temperature ranges, as well as passenger cabin comfort.
Innovation Solution
A simplified thermal management control circuit using a heat pump loop with a condenser and evaporator, a single liquid fluid cooling-heating circuit, and auxiliary communication circuits to maintain power electronics and battery temperatures, minimizing energy losses and allowing for precise temperature control of both components and the passenger cabin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal management control circuit uses multiple separate loops with multiple valves to control power electronics component temperature, battery temperature, and passenger cabin temperature, then each component can be maintained within its desired temperature range, but the architecture becomes complex requiring many actuators
Solution Approach 1:
The patent merges multiple separate thermal management loops into a single integrated circuit. The power electronics component loop, battery loop, and passenger cabin loop are combined into one unified thermal management control circuit that uses a single pump and shared heat exchangers (condenser and evaporator) to control all three components, thereby reducing the number of actuators while maintaining temperature control capability.
Solution Approach 2:
The single pump and heat exchangers in the integrated circuit serve multiple functions simultaneously. The condenser and evaporator are used across different loops to provide heating or cooling as needed, and the single pump circulates liquid fluid through all three thermal management zones (power electronics, battery, and passenger cabin), making the system more economical and less complex.
2Measurement precision
If a thermal management control circuit uses many actuators to control multiple loops, then temperature control precision can be maintained, but the system becomes less economical
Solution Approach 1:
By merging multiple actuators (pumps and valves) into a single integrated circuit with one pump and shared heat exchangers, the patent reduces component count and manufacturing complexity while maintaining temperature control precision through intelligent control of the unified system.
Solution Approach 2:
The universal heat exchangers (condenser and evaporator) and single pump serve multiple thermal management functions simultaneously, reducing the number of components needed while maintaining the ability to precisely control temperatures across different zones through coordinated operation.
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 provides an economical and efficient thermal management system that maintains power electronics and battery temperatures within target ranges while also controlling passenger cabin temperature, reducing energy losses and improving comfort, with a simpler architecture requiring fewer actuators.
Implementation Method 1
the condenser configured to heat the liquid fluid
Implementation Method 2
the evaporator configured to cool the liquid fluid
Implementation Method 3
a first pump configured to circulate the liquid fluid in the cooling-heating circuit
Implementation Method 4
a second pump configured to circulate the liquid fluid in the cooling-heating circuit
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A thermal management control circuit for an electric vehicle having a power electronics component (5) to supply the drive motor and a battery (2), comprising: - a heat pump loop (8) comprising a condenser (12) and an evaporator (22), - a cooling-heating circuit configured to carry a fluid and comprising - a first circuit portion (10) comprising the condenser and the power electronics component, and configured to maintain the power electronics component within a power electronics component target temperature range (TR1), - a second circuit portion (20) comprising the evaporator, - a first auxiliary communication circuit portion (31) configured to carry some fluid heated by the condenser from the first circuit portion to the second circuit portion, and cooperating with the second circuit portion to maintain the battery within a battery target temperature range (TR2) which is different from the power electronics component target temperature range.