EV Thermal Management System Minimizing Power Consumption

Solution Overview

Problem

Current thermal management systems for electric vehicles are inefficient in minimizing power consumption while maintaining battery operating temperatures, affecting overall vehicle efficiency and driving range.

Innovation Solution

A method that characterizes the thermal management system by determining power dissipation and consumption data sets, periodically assessing cooling demands, and deriving optimal blower fan and coolant pump settings to minimize power usage while meeting thermal demands, using a controller to apply these settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If thermal management system operates with high power consumption to maintain battery temperature, then battery operating temperature is maintained, but overall vehicle efficiency decreases

Engineering Contradiction:

Improvebattery operating temperatureVSAvoidpower consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The system dynamically adjusts coolant pump speed and blower fan speed based on real-time thermal conditions and vehicle operating state. The controller continuously monitors battery temperature, ambient temperature, and vehicle speed to optimize pump and fan operations, reducing power consumption while maintaining thermal management effectiveness.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters including coolant flow rate, air flow rate through radiator, pump speed, and fan speed based on varying thermal demands and vehicle conditions. By adjusting these parameters dynamically rather than operating at fixed settings, the system minimizes power consumption while maintaining battery temperature within acceptable ranges.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If thermal management system uses high coolant flow rate and high fan speed, then cooling effectiveness is improved, but power consumption increases

Engineering Contradiction:

Improvecooling effectivenessVSAvoidpower consumption

Core Design Contradiction:

TemperatureVSUse of energy by stationary object

Solution Approach 1:

The system dynamically adjusts coolant pump speed and blower fan speed based on real-time thermal conditions and vehicle operating state. The controller continuously monitors battery temperature, ambient temperature, and vehicle speed to optimize pump and fan operations, reducing power consumption while maintaining thermal management effectiveness.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses feedback from temperature sensors and vehicle state sensors to continuously adjust pump and fan operations. The controller receives information about battery temperature, ambient conditions, and vehicle speed, then adjusts coolant flow and air flow rates to achieve optimal cooling with minimum power consumption.

Inventive Principle:

Principle #23Feedback

3Reliability

If thermal management system operates continuously at high capacity, then battery temperature control is ensured, but vehicle range is reduced

Engineering Contradiction:

Improvebattery temperature controlVSAvoiddriving range

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The system operates pumps and fans at variable speeds and only when necessary based on thermal conditions. Instead of continuous high-capacity operation, the system uses periodic adjustments and variable speed operations to maintain battery temperature, thereby conserving energy and extending driving range.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system dynamically adjusts coolant pump speed and blower fan speed based on real-time thermal conditions and vehicle operating state. The controller continuously monitors battery temperature, ambient temperature, and vehicle speed to optimize pump and fan operations, reducing power consumption while maintaining thermal management effectiveness.

Inventive Principle:

Principle #15Dynamics

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 approach effectively reduces power consumption in the thermal management system, enhancing overall vehicle efficiency and extending driving range by optimizing cooling operations.

Implementation Method 1

a heat exchanger (e.g., a radiator) and a heat source (e.g., battery pack, drive train, power electronics, etc.)

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

The step of determining the first plurality of power dissipation datum relative to a plurality of air speeds through the heat exchanger

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS10150383B2EV adaptive thermal management system optimized to minimize power consumption

Publication Date: 2018.12.11 ATIEVA INC(US)

AI summary

A method of operating the thermal management system in a vehicle is provided, where the thermal management system includes a heat exchanger (e.g., a radiator) and a heat source (e.g., battery pack, drive train, power electronics, etc.). After characterizing the thermal management system, whenever the system controller issues a cooling demand an appropriate set of operating settings is determined that minimizes the amount of power consumed by the system's actuators (e.g., blower fan, coolant pump) while still meeting the cooling demand. As a result, the heat source is cooled to the degree required with a minimum expenditure of power, thereby minimizing the impact on driving range and vehicle performance.