EV Thermal Management Layout With Four-Way Valve and Shared Cooling Loops
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Solution Overview
Problem
Existing electric vehicle thermal management systems face issues such as high energy consumption, complex piping, high costs, and limited functionality, particularly in low-cost models and extreme weather conditions, with heat pumps being inefficient below -15°C and natural air cooling failing to heat batteries in winter.
Innovation Solution
A simplified thermal management system integrating a water tank, liquid-gas separator, four-way valve, and pumps to form multiple circuits for heating and cooling, eliminating the heat pump and reducing parts, while maintaining heat recovery functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a heat pump system is used for heating the passenger compartment, then energy consumption is reduced, but the working temperature is limited to above -15°C and the system cost increases
Solution Approach 1:
The thermal management system is designed to perform multiple functions using a single integrated system. The system can switch between heat pump heating mode, PTC heating mode, and battery cooling mode through the four-way valve, making it universally applicable across different temperature conditions and functional requirements without needing separate systems
Solution Approach 2:
The system dynamically adapts its configuration based on operating conditions. The four-way valve enables dynamic switching between different circuit configurations - connecting the radiator to either the evaporator or PTC heater, and routing coolant flow through different paths depending on whether heating or cooling is required, thus adapting to varying temperature requirements
2Adaptability or versatility
If PTC heating is used for the passenger compartment, then heating function is provided, but energy consumption increases significantly
Solution Approach 1:
The system uses an intermediary approach by introducing a four-way valve that enables selective connection of the radiator to either the evaporator or PTC heater. This intermediary mechanism allows the system to preferentially use the more energy-efficient heat pump pathway when conditions permit, while still providing PTC heating capability when necessary, thus mediating between efficiency and functionality
3Ease of manufacture
If natural air cooling is used for the battery, then cost is reduced, but the battery cannot be heated in low temperature conditions and fast charging function is limited
Solution Approach 1:
The system merges the battery thermal management circuit with the existing coolant circulation system. The battery water jacket is integrated into the coolant loop controlled by the four-way valve, allowing the battery to share the thermal management infrastructure with other vehicle components. This merging enables both cooling and heating capabilities through the same liquid cooling infrastructure
Solution Approach 2:
The liquid cooling system serves multiple functions: it can cool the battery during high-temperature operation and fast charging, and it can heat the battery during low-temperature conditions through the PTC heater pathway. The same cooling liquid circulation infrastructure performs both heating and cooling roles depending on system configuration
4Ease of manufacture
If a simplified thermal management system without heat pump is used, then cost is reduced, but heating efficiency in low temperature conditions deteriorates
Solution Approach 1:
The system enables self-service heating by using the PTC heater that is already integrated into the thermal management circuit. When heating is required, the four-way valve routes coolant through the PTC heater, allowing the system to generate its own heat without requiring external heating sources or additional complex equipment, thus achieving cost reduction while maintaining heating capability
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 system reduces costs, flow resistance, and heat loss, providing efficient heating and cooling across various conditions, extending vehicle range and reducing energy consumption.
Implementation Method 1
the four-way valve comprises a first valve port, a second valve port, a third valve port and a fourth valve port; an outlet of the radiator and the water tank are both in communication with the first valve port
Implementation Method 2
the first water pump is used for pumping a cooling liquid of the liquid-gas separator into the battery water jacket
Implementation Method 3
the second water pump is used for pumping a cooling liquid flowing out of the fourth valve port into the electric appliance water jacket
Implementation Method 4
the second valve port, the heat exchanger main body, the liquid-gas separator, the first water pump, the battery water jacket and the third valve port are sequentially in communication with each other
Implementation Method 5
an outlet of the radiator and the water tank are both in communication with the first valve port
Data Source
Figure 1
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AI summary
An electric vehicle thermal management system, comprising a water tank (1), a liquid-gas separator (2), a four-way valve (3), a first water pump (4), a second water pump (5), a battery water jacket (6), an electric appliance water jacket (7) which is simultaneously used for a voltage converter (71) and a vehicle-mounted charger (72), a radiator (8), a heat exchanger main body (91) of a battery cooler (9), an electric motor controller water jacket (10) and/or an electric motor water jacket (11). The four-way valve (3) comprises a first valve port, a second valve port, a third valve port and a fourth valve port. An outlet of the radiator (8) and the water tank (1) are both in communication with the first valve port. The second valve port, the heat exchanger main body (91), the liquid-gas separator (2), the first water pump (4), the battery water jacket (6) and the third valve port are sequentially in communication with each other, and the first water pump (4) is used for pumping a cooling liquid of the liquid-gas separator (2) into the battery water jacket (6). The fourth valve port, the second water pump (5), the electric appliance water jacket (7), the electric motor water jacket (11) and/or the electric motor controller water jacket (10), and an inlet of the radiator (8) are sequentially in communication with each other; and the second water pump (5) is used for pumping a cooling liquid flowing out of the fourth valve port into the electric appliance water jacket (7). Further provided is a vehicle. The electric vehicle thermal management system and the vehicle can reduce the number of system parts, thereby simplifying the system and reducing the cost.