Integrated EV Thermal Management System with Valve Group
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Solution Overview
Problem
Current thermal management systems in electric vehicles lack comprehensive integration and efficiency, particularly in managing thermal conditions for both the cabin and vehicle components, leading to suboptimal energy use and potential icing issues during cold ambient conditions.
Innovation Solution
An integrated thermal management system that combines a coolant circuit with component, battery, cabin heating, and cabin cooling circuits, utilizing multiple valves and pumps to selectively interconnect or isolate these circuits, along with a control module to operate in various modes, including cooling, heating, dehumidification, and preconditioning, to enhance thermal control and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a heat pump refrigerant system is used for cabin heating in cold ambient conditions, then energy efficiency is improved, but icing may occur on the evaporator
Solution Approach 1:
The system performs preliminary heating of the evaporator using waste heat from the battery thermal conditioning circuit or component thermal conditioning circuit before activating the heat pump. This pre-heating action prevents the evaporator temperature from dropping to icing conditions, allowing the heat pump to operate efficiently in cold ambient conditions without forming ice on the evaporator surfaces.
Solution Approach 2:
The system converts the waste heat that would otherwise be discarded from the battery and component thermal conditioning circuits into a useful function by using it to prevent evaporator icing. This transforms a potentially harmful cold environment into an opportunity to utilize waste heat for protecting the heat pump system, improving overall energy efficiency while preventing icing.
2Adaptability or versatility
If multiple separate thermal management systems are used for different components, then each component can be controlled independently, but system complexity and energy consumption increase
Solution Approach 1:
The system merges multiple separate thermal management circuits into a single integrated coolant circulation system. The battery thermal conditioning circuit, component thermal conditioning circuit, and cabin climate control system share common coolant pumps, radiators, and valve groups. This consolidation maintains the ability to independently control each component's thermal conditions while significantly reducing overall system complexity and eliminating redundant components.
Solution Approach 2:
The coolant circulation system is designed with multi-functionality, where the same coolant loops and thermal exchange components serve multiple purposes. For example, the first radiator serves both the battery thermal conditioning and component thermal conditioning circuits, and the valve group enables a single coolant pump to distribute coolant to multiple destinations based on thermal management needs, reducing the number of dedicated components required.
3Device complexity
If traditional HVAC systems are used for cabin heating, then simplicity is maintained, but noise, vibration, and harshness increase
Solution Approach 1:
The system replaces traditional mechanical HVAC heating components (such as combustion heaters or high-power resistive heaters with associated fans and blowers) with a coolant-based thermal exchange system. The first cabin heat exchanger group uses coolant circulation to provide cabin heating, eliminating the need for noisy mechanical heating devices and reducing noise, vibration, and harshness while maintaining system functionality.
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 provides improved energy efficiency, enhanced thermal control synergy, and delays icing by effectively managing thermal conditions across vehicle components and the cabin, while reducing noise, vibration, and harshness, and improving comfort and safety.
Implementation Method 1
a first cabin heat exchanger group (58) and a second cabin heat exchanger group (64)
Implementation Method 2
coolant circuit (12) having a component thermal conditioning circuit (16), a battery thermal conditioning circuit (18), a cabin heating circuit (20) and a cabin cooling circuit (22)
Implementation Method 3
a first coolant pump (38), a second coolant pump (54), a third coolant pump (60) and a fourth coolant pump (66)
Data Source
AI summary
An integrated thermal management system includes a cooling circuit having a component thermal conditioning circuit, a battery thermal conditioning circuit, a cabin heating circuit, a cabin cooling circuit and a valve group configured for selectively interconnecting or isolating the component thermal conditioning circuit, the battery thermal conditioning circuit, the cabin heating circuit and the cabin cooling circuit.