Hybrid Vehicle Thermal Management via Dynamic Charge Level Control
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Solution Overview
Problem
Hybrid vehicles face overheating issues due to increased heat rejection loads exceeding the cooling system's capacity during extreme conditions like extreme heat, heavy traffic, or steep road grades, especially when the power supply is in a low state of charge, leading to potential combustion engine or component overheating.
Innovation Solution
The hybrid vehicle determines expected operating conditions and adjusts its mode to maintain a high charge level in the power supply proactively, switching to a mode that decreases the charge level when the heat rejection load surpasses the cooling system's capacity, thereby reducing the risk of overheating by managing the operation of the combustion engine and electric motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the cooling system is designed for reduced capacity to lower complexity and cost, then the cooling system becomes less complex and costly, but the system cannot handle increased heat rejection loads during extreme operating conditions
Solution Approach 1:
The cooling system operates in dynamic modes that adapt to operating conditions. The system switches between a first mode (with reduced cooling capacity) and a second mode (with increased cooling capacity) based on real-time temperature sensors and operating parameters, allowing the cooling capacity to be dynamically adjusted rather than fixed at maximum capacity
Solution Approach 2:
The system changes operational parameters of the combustion engine and power supply based on thermal conditions. When temperature sensors detect elevated temperatures, the controller modifies engine operation parameters and power supply charging/discharging rates to reduce heat generation and manage thermal loads within the reduced cooling capacity
2Quantity of substance
If the combustion engine operates continuously to charge the power supply, then the power supply charge level increases, but the heat rejection load increases and may exceed cooling system capacity
Solution Approach 1:
The system uses temperature sensors to continuously monitor thermal conditions and feeds this information back to the controller. Based on the feedback, the controller adjusts the combustion engine operation and power supply charging/discharging rates in real-time to balance charge level maintenance with heat rejection management
Solution Approach 2:
The system periodically alternates between charging and discharging the power supply based on thermal conditions. When heat rejection load becomes excessive, the system switches to using the power supply to power the drivetrain, allowing the combustion engine to operate at reduced load and generate less heat, then alternates back to charging when thermal conditions improve
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 helps prevent overheating by ensuring the power supply remains at a safe level during adverse conditions, reducing the strain on the combustion engine and cooling system, thus maintaining optimal vehicle performance and component safety.
Implementation Method 1
a cooling system (e.g., a cooling system having several separated cooling loops)
Implementation Method 2
a cooling system (e.g., a cooling system having several separated cooling loops)
Implementation Method 3
a power supply configured to power the electric motor(s)... the power supply can also be charged by connecting the power supply to an external power source
Implementation Method 4
an electric motor (e.g., one or more electric motors) configured to power the drivetrain
Implementation Method 5
a combustion engine configured to charge the power supply and to power the drivetrain
Data Source
AI summary
An example method includes making a first determination that a load of a cooling system of a vehicle is expected to increase and become greater than a capacity of the cooling system; operating, in response to making the first determination, the vehicle in a first mode where a combustion engine and an electric motor operate such that a charge level of a power supply of the vehicle increases or is maintained above a threshold charge level; making, after operating the vehicle in the first mode, a second determination that the load of the cooling system has become greater than the capacity of the cooling system; and operating, in response to making the second determination, the vehicle in a second mode where the combustion engine and the electric motor operate such that the charge level of the power supply decreases or is maintained below the threshold charge level.