EV Thermal Management With Switchable Battery-Power Electronics Coupling
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Solution Overview
Problem
Electric vehicles face challenges in maintaining optimal temperatures for their battery systems, passenger cabins, and power electronics, which affects their efficiency and operational range, as existing temperature management systems lack efficient thermal isolation and interaction configurations.
Innovation Solution
A temperature control system for electric vehicles that includes separate and interactive configurations for battery, cabin, and power electronics temperature control, utilizing fluid conduits and heat exchangers to manage temperatures, with a controller for thermal decoupling or coupling of these systems to optimize cooling and heating based on operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the battery temperature control system and power electronics temperature control system are thermally isolated, then temperature control precision is improved, but system complexity increases
Solution Approach 1:
The temperature control system is divided into separate controllable modules: battery temperature control system and power electronics temperature control system. Each module can be independently configured as thermally isolated or thermally interacting, allowing precise temperature control for each component while managing system complexity through modular design.
Solution Approach 2:
The thermal configuration of the system is made dynamic and adjustable. The system can switch between thermally isolated configuration (for precise independent temperature control) and thermally interacting configuration (for simplified heat management), allowing adaptation to different operating conditions and requirements.
2Device complexity
If the battery temperature control system and power electronics temperature control system thermally interact, then system complexity is reduced, but temperature control precision deteriorates
Solution Approach 1:
The system maintains separate control pathways for battery and power electronics, allowing thermal interaction when beneficial for simplicity while preserving the capability for thermal isolation when precision is required. The segmented architecture enables flexible configuration based on operational needs.
Solution Approach 2:
The shared coolant system serves multiple functions: it can provide thermal isolation for precise control when needed, or enable thermal interaction for simplified operation and heat recovery. This multi-functional design reduces overall system complexity while maintaining temperature control precision when required.
3Measurement precision
If separate temperature control systems are used for battery and power electronics, then temperature control precision is improved, but energy consumption increases
Solution Approach 1:
The coolant system is designed to serve multiple thermal management functions through a single integrated infrastructure. The same coolant circulation system can provide thermal isolation for precise control or enable thermal interaction for energy efficiency, reducing overall energy consumption while maintaining precision when needed.
Solution Approach 2:
The system can convert excess heat from power electronics into a beneficial resource by allowing thermal interaction with the battery system when the battery requires heating. This heat recovery approach reduces energy consumption for thermal management while maintaining precise temperature control through selective configuration.
4Measurement precision
If thermal isolation is implemented between systems, then temperature control precision is improved, but manufacturing complexity increases
Solution Approach 1:
The thermal management system is designed with modular, segmented components that can be manufactured and assembled independently. The battery temperature control system and power electronics temperature control system are separate modules that can be manufactured using standard processes, reducing manufacturing complexity while enabling precise temperature control through selective thermal isolation.
Solution Approach 2:
The system uses standardized intermediaries such as heat exchangers and coolant distribution manifolds that facilitate both thermal isolation and thermal interaction. These intermediary components are designed for ease of manufacture and assembly, allowing precise temperature control without significantly increasing manufacturing complexity.
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 temperatures across various components, enhancing the efficiency and range of electric vehicles by allowing for selective thermal management, reducing energy consumption, and extending operational times.
Implementation Method 1
a cabin temperature control system configured to control flow of a refrigerant through one or more heat exchangers to control a temperature of a cabin of the electric vehicle, a battery temperature control system configured to control the flow of a coolant through one or more heat exchangers to control a temperature of a battery system of the electric vehicle, and a power electronics temperature control system configured to control the flow of coolant through one or more heat exchangers to control a temperature of one or more power electronics
Data Source
AI summary
A temperature control system for an electric vehicle includes a cabin temperature control system configured to control flow of a refrigerant through one or more heat exchangers to control a temperature of a cabin of the electric vehicle, a battery temperature control system configured to control the flow of a coolant through one or more heat exchangers to control a temperature of a battery system of the electric vehicle, and a power electronics temperature control system configured to control the flow of coolant through one or more heat exchangers to control a temperature of one or more power electronics. In a first configuration of the temperature control system, the battery temperature control system and the power electronics temperature control system may be thermally isolated, and, in a second configuration, the battery temperature control system and the power electronics temperature control system may thermally interact.