EV Thermal Management Layout for Battery and Power Electronics Cooling
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Solution Overview
Problem
Current thermal management systems for electric vehicles require separate cooling systems for batteries and power electronics, leading to inefficiencies such as excessive energy consumption and reduced vehicle range due to the need for refrigerant compressor operation even in moderate temperatures.
Innovation Solution
A cooling system with a battery section, electronics section, radiator section, and storage section, connected via valves to alternate between using the radiator for cooling the battery or power electronics, and a heat store for thermal energy management, allowing for efficient cooling and heating based on operational demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a refrigerant circuit with compressor is used to cool the battery, then the battery can be cooled effectively even in high ambient temperatures, but the electrical energy consumption increases due to continuous compressor operation
Solution Approach 1:
The system dynamically switches between two cooling modes: radiator-based cooling for moderate temperatures and refrigerant circuit cooling for high temperatures. The control unit monitors ambient temperature and battery temperature to determine when to activate the compressor, enabling adaptive thermal management that reduces energy consumption while maintaining effective cooling.
Solution Approach 2:
The thermal management system is segmented into two independent cooling paths: a radiator-based cooling path for moderate temperature conditions and a refrigerant circuit-based cooling path for high temperature conditions. This segmentation allows the system to select the appropriate cooling method based on environmental conditions, avoiding unnecessary compressor operation.
2Reliability
If separate cooling systems are used for battery and power electronics, then each component can be cooled according to its specific requirements, but the system complexity and structural space increase
Solution Approach 1:
The radiator is designed as a universal heat dissipation device that can cool both the battery and power electronics. The coolant circuit includes branches that can be selectively connected to different components, allowing the single radiator to serve multiple cooling functions and reducing the need for separate cooling systems.
Solution Approach 2:
The system merges the battery cooling function and power electronics cooling function into a single integrated thermal management system. Both components share common elements including the radiator, coolant pump, and control unit, while maintaining separate coolant circulation paths that can be independently controlled.
3Temperature
If the refrigerant circuit is used for battery cooling in moderate temperatures, then adequate cooling is provided, but the electrical energy that could be saved by not running the compressor is instead used to heat the battery via PTC heater
Solution Approach 1:
The system converts the waste heat generated by power electronics into a useful resource for heating the battery during cold starts. The heat exchanger transfers thermal energy from the power electronics coolant to the battery coolant, eliminating the need for PTC heater operation and the associated energy consumption that would reduce vehicle range.
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 reduces energy consumption by minimizing refrigerant compressor usage and extends vehicle range by optimizing thermal management, enabling efficient cooling of both battery and power electronics while utilizing stored heat for heating during cold starts.
Implementation Method 1
a radiator section (20) comprising a radiator (21)
Implementation Method 2
a radiator section (20) comprising a radiator (21)
Implementation Method 3
a storage section (25) comprising a heat store (26)
Implementation Method 4
a battery heat exchanger (4) in thermal contact with a refrigerant circuit
Implementation Method 5
a battery heat exchanger (4) in thermal contact with a refrigerant circuit
Data Source
AI summary
Methods and systems are provided for a cooling system. In one example, the cooling system includes a battery section including a battery, an electronics section including a set of power electronics, a radiator section including a radiator, a storage section including a heat store, and a plurality of valves configured to control a fluid connection between each of the battery section, the electronics section, the radiator section, and the storage section.