Water-to-Water Heat Pump Integration for EV Thermal Loops
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Solution Overview
Problem
Electric and hybrid vehicles face reduced autonomy due to high energy consumption by air conditioning systems, which also increase the vehicle's bulk with existing thermal management solutions.
Innovation Solution
A compact glycolated water heat pump system that facilitates efficient thermal energy management by using intermediate fluids for heat exchange between the electric machine, air conditioning unit, and battery, optimizing space and energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a water heat pump with intermediate fluids is used, then the vehicle autonomy is increased and energy consumption is reduced, but the device complexity increases due to multiple fluid circuits and heat exchangers
Solution Approach 1:
The thermal management system is divided into multiple independent fluid circuits (first intermediate fluid circuit for electric machine, second intermediate fluid circuit for air conditioning, third intermediate fluid circuit for battery), each with its own heat exchanger. This segmentation allows independent control and optimization of each thermal zone, reducing overall energy consumption while managing complexity through modular design
Solution Approach 2:
The heat pump system serves multiple functions simultaneously: it cools the electric machine, cools the battery, and provides air conditioning for the passenger compartment. The same heat pump unit and control system manage all these thermal requirements, reducing the need for separate dedicated systems and thereby limiting the increase in device complexity
2Volume of stationary object
If a water heat pump with intermediate fluids is used, then the vehicle bulk is reduced by freeing up front space, but the device complexity increases due to relocated and integrated heat exchangers
Solution Approach 1:
The heat exchangers are relocated from traditional front-mounted positions to integrated locations within the thermal management system architecture. The first heat exchanger is integrated with the electric machine housing, the second with the air conditioning unit, and the third with the battery assembly. This spatial reorganization frees up front vehicle space while distributing thermal management components across available volumes, managing complexity through strategic spatial distribution
Solution Approach 2:
Multiple heat exchanger functions are merged into a coordinated system where the first, second, and third heat exchangers work together with the single heat pump unit. The heat pump's fluid circuit integrates all three heat exchangers into one unified thermal management loop, reducing the need for separate cooling systems and thereby limiting the increase in device complexity while achieving compact integration
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 enhances vehicle autonomy by reducing energy consumption and bulk, while ensuring efficient heat transfer and thermal management, maintaining optimal operating temperatures for both the electric machine and battery.
Implementation Method 1
a first heat exchanger configured to ensure the heat exchange between the heat transfer fluid of the heat pump and at least the first intermediate fluid of the first fluid circuit of the temperature control module of the electric machine, a second heat exchanger configured to ensure the heat exchange between the heat transfer fluid of the heat pump and at least a second intermediate fluid of the heat exchanger of the air conditioning unit
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a thermal energy management device for a vehicle comprising an electric motor, including: an electric battery (2) configured to store the vehicle's electrical energy, an electric machine (1) for converting the electrical energy stored in the battery (2) into mechanical rotational energy for the vehicle, a temperature control module for the electric machine (3) comprising a first fluid circuit (31) suitable for receiving a first intermediate fluid and a first low-temperature heat exchanger (32), a heat exchanger for an air conditioning unit (4), characterized in that the device includes a water/water heat pump (5) comprising - a fluid circuit (53) suitable for receiving a heat transfer fluid,- a first heat exchanger (51) configured to ensure heat exchange between the heat transfer fluid of the heat pump (5) and at least the first intermediate fluid of the first fluid circuit (31) of the temperature control module of the electric machine (3); - a second heat exchanger (52) configured to ensure heat exchange between the heat transfer fluid of the heat pump (5) and at least a second intermediate fluid of the heat exchanger of the air conditioning unit (4); - a compressor (54); - the fluid circuit (53) being configured to connect the first heat exchanger (51) with the compressor (54), the compressor (51) with the second heat exchanger (52), and the second heat exchanger (52) with the first heat exchanger (51). Its application lies in the field of so-called electric or hybrid vehicles.