EV Thermal Management With Sensor-Fused Waste Heat Estimation
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Solution Overview
Problem
Existing thermal management systems in electrified vehicles struggle to accurately quantify the amount of heat absorbed by coolant from electric drive modules, leading to inefficient heat distribution and potential overheating of components like the battery system and vehicle cabin.
Innovation Solution
A thermal management system utilizing sensor fusion and probability distributions, such as Gaussian mixture models, to estimate the heat absorbed by the coolant, optimizing coolant distribution between electric drive modules and heat sinks through a controller that adjusts valve operation based on temperature sensors and mathematical models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional thermal management systems are used in electrified vehicles, then the system structure is simple and easy to implement, but the accuracy of heat absorption estimation by coolant is insufficient
Solution Approach 1:
The patent merges multiple temperature sensors and mathematical estimation methods (including neural networks and probability distributions) into a unified thermal management system. This integration allows the system to combine data from multiple sources to improve heat absorption estimation accuracy while managing the overall system complexity through a centralized control approach.
Solution Approach 2:
The patent replaces traditional mechanical measurement methods with mathematical modeling and computational estimation techniques. Instead of relying solely on physical sensors to directly measure heat absorption, the system uses temperature data combined with mathematical models (including Gaussian distributions and neural networks) to estimate heat absorption, thereby improving measurement precision without requiring complex physical measurement devices.
2Productivity
If coolant distribution is not optimized, then the system operation is simple, but heat transfer efficiency is poor and components may overheat
Solution Approach 1:
The patent implements dynamic coolant distribution control by continuously adjusting valve positions based on real-time temperature sensor data and heat absorption estimates. The system dynamically optimizes coolant flow distribution to multiple heat sources (electric motors, batteries, HVAC) according to their instantaneous thermal requirements, thereby improving heat transfer efficiency while automating the control process.
Solution Approach 2:
The patent employs feedback control mechanisms where temperature sensors continuously monitor thermal conditions, the system estimates heat absorption using mathematical models, and the controller adjusts coolant distribution accordingly. This closed-loop feedback system automatically optimizes heat transfer efficiency without requiring manual intervention, resolving the contradiction between improved productivity and ease of operation.
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
Enhances the accuracy of heat absorption estimation, enabling efficient heat transfer and management, thereby optimizing the thermal performance and reducing the risk of component overheating.
Implementation Method 1
a first and second temperature sensor at opposite ends of the EDM and a controller that receives the temperature signals
Implementation Method 2
determining an optimal estimate of heat absorbed by the coolant
Implementation Method 3
the heat produced by the heat sources (such as electric drive modules) can be transferred to other heat sinks within the electrified vehicle
Implementation Method 4
Coolant distribution is optimized based on thermal demands and heat absorption estimates
Data Source
AI summary
A thermal management system for an electrified vehicle includes an electrified powertrain having at least one electric drive module (EDM), a battery system that powers the EDM, a heating ventilation and air conditioning (HVAC) system, a first, second and third coolant loop associated with the respective EDM, battery system and HVAC system, at least one valve that opens and closes to modify an amount of coolant being delivered between the first, second and third coolant loops, a first and second temperature sensor at opposite ends of the EDM, and a controller that receives the temperature signals; approximates an estimator probability distribution; determines an optimal estimate of heat absorbed by the coolant that maximizes the probability distribution; and communicates a signal to the at least one valve to modify an amount of coolant sent between the first coolant loop and at least one of the second and third coolant loops.