Multi-Port EV Thermal Management for Coupled Heat Transfer
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Solution Overview
Problem
Conventional architectures in electric vehicles (EVs) handle cabin climate control, energy storage system management, and power electronics cooling with limited integration, resulting in inefficient systems that struggle under varying operating conditions, such as extreme temperatures and off-road operations.
Innovation Solution
An integrated thermal management system (ITMS) utilizing a multi-port valve assembly to selectively interconnect cabin, energy storage system, and power electronics thermal management loops, enabling efficient energy transfer and holistic management through various operating modes, including the use of a heat pump system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional separate architectures are used for cabin climate control, ESS management, and power electronics cooling, then system simplicity is maintained, but system efficiency deteriorates under varying operating conditions
Solution Approach 1:
The patent combines three separate thermal management systems (cabin climate control, ESS management, and power electronics cooling) into a single integrated thermal management system. This merging allows heat transfer between previously isolated systems, enabling waste heat from power electronics to be utilized for cabin heating or ESS temperature maintenance, thereby reducing overall energy consumption and improving system efficiency.
Solution Approach 2:
The integrated thermal management system performs multiple functions simultaneously: it cools power electronics, conditions cabin air, and manages ESS temperature. The system can operate in various modes (heating mode, cooling mode, ESS-only mode) to handle different operating conditions, making the thermal management system universal and adaptable to diverse vehicle operating scenarios.
2Productivity
If an integrated thermal management system is implemented to enable holistic energy transfer, then system efficiency improves, but device complexity increases
Solution Approach 1:
The patent employs a multi-port valve assembly as an intermediary component to manage the complexity of integrating three thermal management loops. The valve assembly selectively connects or isolates different loops based on operating conditions, enabling controlled heat transfer between systems while maintaining a modular architecture that simplifies system control and management.
3Adaptability or versatility
If thermal management loops are selectively coupled and isolated using a multi-port valve assembly, then adaptability to various operating conditions improves, but device complexity increases
Solution Approach 1:
The multi-port valve assembly provides dynamic connectivity, allowing the thermal management system to adapt its configuration based on real-time operating conditions. The valve can selectively couple or isolate different thermal management loops (cabin, ESS, power electronics) to optimize performance for heating, cooling, or mixed-mode operations, enhancing system versatility.
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 ITMS enhances efficiency and cost competitiveness by effectively managing energy transfer among the cabin, energy storage system, and power electronics, improving performance under diverse conditions and reducing energy consumption.
Implementation Method 1
effective use of a heat pump
Implementation Method 2
manage energy transfer in a more efficient and holistic manner among the cabin, ESS, and power electronics
Data Source
AI summary
An integrated thermal management system, method, and non-transitory computer readable medium for a vehicle, including a cabin thermal management loop; an energy storage system thermal management loop; a power electronics thermal management loop; and a multi-port valve assembly coupled to the cabin thermal management loop, the energy storage system thermal management loop, and the power electronics thermal management loop, adapted to, responsive to an operating state of the vehicle, selectively isolate and couple the cabin thermal management loop, the energy storage system thermal management loop, and the power electronics thermal management loop from and to one another.