Hybrid Vehicle Cooling Circuit Thermal Coupling
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Solution Overview
Problem
Hybrid vehicle power electronics cooling requires a separate cooling circuit due to differing temperature requirements from the engine circuit, resulting in an oversized, heavy, and expensive cooling system, especially at low vehicle speeds where high power loss occurs with limited cooling air flow.
Innovation Solution
Thermally coupling the charge air cooling circuit and electronics cooling circuit with a single cooling medium cooler, using separate pumps for each circuit to maintain constant temperature and meet varying cooling demands, allowing for independent control and reduced system weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate cooling circuit is provided for power electronics, then the power electronics can be cooled effectively, but the cooling system becomes oversized, heavy, and expensive
Solution Approach 1:
The patent merges the power electronics cooling circuit with the charge air cooling circuit into a single integrated cooling system. Both circuits share common components including the cooler, pump, and coolant, thereby eliminating the need for a separate dedicated cooling system for power electronics. This reduces the overall weight, size, and cost of the cooling system while maintaining effective cooling of the power electronics.
2Reliability
If a separate cooling circuit is provided for power electronics, then the power electronics can be cooled effectively, but the cooling system becomes oversized and expensive
Solution Approach 1:
The patent combines multiple cooling functions into a single integrated circuit that serves both the charge air cooling and power electronics cooling needs. This consolidation reduces the number of separate components, control systems, and maintenance requirements, thereby simplifying the overall system architecture and reducing complexity.
3Reliability
If the cooling medium cooler is designed to cover all critical operating points, then the power electronics can be cooled at low vehicle speeds, but the cooler becomes relatively large
Solution Approach 1:
The cooling system is designed as a universal multi-functional system that serves both charge air cooling and power electronics cooling purposes. The single cooler is sized and designed to handle the cooling demands of both functions across various operating conditions, including low vehicle speeds where power electronics cooling is most critical. This multi-functionality eliminates the need for oversized dedicated coolers while ensuring adequate cooling performance.
4Weight of stationary object
If a common cooling circuit is used for charge air and power electronics, then weight and cost are reduced, but it is difficult to keep the electronics at a constant temperature level
Solution Approach 1:
The patent employs dynamic control mechanisms including variable speed pumps and controllable throttles that can adjust coolant flow rates in real-time based on the thermal demands of different components. This dynamic adjustment capability allows the system to maintain stable temperatures for power electronics while sharing the cooling system with charge air cooling, overcoming the temperature stability issues that would otherwise arise from using a common cooling circuit.
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 configuration ensures efficient and cost-effective cooling of power electronics with minimal temperature fluctuations, reducing overall system weight, space, and cost while maintaining consistent cooling performance across different operating conditions.
Implementation Method 1
a coolant cooler (16) for cooling a first cooling medium (18) used for the intercooler (14)
Implementation Method 2
the charge air cooling circuit (22) and the electronics cooling circuit (30) being thermally coupled
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a drive (10) for a hybrid vehicle, comprising an internal combustion engine (12), an intercooler (14) for cooling combustion air fed to the internal combustion engine (12), a cooling-medium cooler (16) for cooling a first cooling medium (18) used for the intercooler (14), a first pump (20) for circulating the first cooling medium (18) in an intercooling circuit (22) comprising the intercooler (14) and the cooling-medium cooler (16), an electric drive unit (24), and a second pump (26) for circulating a second cooling medium (28) in an electronics-cooling circuit (30) comprising the electric drive unit (24), wherein the intercooling circuit (22) and the electronics-cooling circuit (30) are thermally coupled.