Integrated Motor Heater Control Circuit for EV Thermal Management
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Solution Overview
Problem
Current in-vehicle heating systems for electric vehicles are costly and inefficient, with high costs due to the use of multiple PTC devices and complex control circuits, which also occupy valuable space and increase vehicle weight, while lacking optimal thermal energy utilization.
Innovation Solution
A heating apparatus and control method utilizing a motor control unit with an inverter and controller connected to three-phase windings, allowing the motor and electric heater to share control circuits, reducing the need for separate control circuits and optimizing heat emission by controlling currents in the windings to manage heating requirements efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two PTC devices are used for heating the power battery and cabin separately, then heating requirements can be met, but manufacturing costs increase significantly
Solution Approach 1:
The patent merges the motor and electric heater into a single integrated unit, where the motor's three-phase windings serve dual purposes: driving the motor and heating the coolant. The heater coil is integrated with the motor structure, eliminating the need for separate PTC heating devices and reducing manufacturing costs while maintaining reliable heating functionality for both power battery and cabin
Solution Approach 2:
The motor is designed with multi-functionality, serving both as a propulsion device and as a heating device. The three-phase windings can operate in motor mode for vehicle propulsion or in heater mode for thermal management, allowing a single component to fulfill multiple functions and eliminate the need for separate dedicated heating devices
2Adaptability or versatility
If two separate control circuits are disposed for two PTC devices, then flexible heat control is achieved, but device complexity and costs increase
Solution Approach 1:
A single control circuit is designed to control both the motor and the integrated heater coil through the same three-phase windings. The controller can switch between motor operation and heating operation, or operate both functions simultaneously, providing flexible heat control without requiring separate dedicated control circuits for each heating zone
Solution Approach 2:
The control circuits for motor and heater are merged into a single unified control system. The controller manages both the motor drive and the heating coil through integrated control algorithms, reducing the total number of control circuits while maintaining the ability to independently control heating for power battery and cabin when needed
3Adaptability or versatility
If two PTC devices are disposed in parallel on separate control circuits, then independent heating control is achieved, but in-vehicle space occupation increases
Solution Approach 1:
The motor and heater are merged into a single integrated component, eliminating the need for separate PTC heating devices and their associated mounting spaces. The heater coil is embedded within the motor structure, significantly reducing the space occupied by heating system components while maintaining the ability to independently control heating for different zones through coolant circulation management
4Adaptability or versatility
If two PTC devices with separate control circuits are used, then heating flexibility is improved, but vehicle weight increases
Solution Approach 1:
The motor and heater are combined into a single integrated unit, eliminating duplicate components such as separate PTC heating elements, multiple control circuits, and associated mounting structures. This integration significantly reduces the overall weight of the heating system while preserving the flexibility to independently control heating for power battery and cabin through coolant flow management
5Adaptability or versatility
If PTC devices are located in different coolant loops for separate control, then independent heating is achieved, but thermal energy optimization becomes difficult
Solution Approach 1:
The motor-driven coolant circulation system integrates both heating functions into a unified coolant loop. The single coolant circulation pump and heat exchanger system can selectively direct heated coolant to either the power battery or the cabin based on real-time thermal management needs, simplifying the coolant loop structure while maintaining independent heating control capability through intelligent flow distribution
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 solution reduces manufacturing costs, weight, and space occupancy by eliminating the need for separate control circuits, improving thermal energy utilization, and enhancing control flexibility, thereby extending the endurance mileage of electric vehicles.
Implementation Method 1
the controller can control the inverter to control currents in the three-phase windings in the motor, to control the motor to rotate and emit heat
Implementation Method 2
the electric heater is connected to the connection point, and the controller can control the inverter to control currents in the three-phase windings in the motor, to control the electric heater to emit heat
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A heating apparatus includes: a motor control unit, having an inverter and a controller that are connected to each other; an electric heater; and a motor, having three-phase windings, where ends of the three-phase windings are connected to the inverter, the other ends of the three-phase windings are connected to a connection point, and the connection point is connected to the electric heater. Therefore, the other ends of the three-phase windings in the motor can be connected to the connection point to form three-phase windings of a Y connection, the electric heater is connected to the connection point, and the motor control unit can control currents in the three-phase windings in the motor to control the motor to rotate and emit heat, and can further control the currents in the three-phase windings to control a current flowing through the electric heater through the connection point, to control the electric heater to emit heat. Therefore, the electric heater can be controlled by using the motor control unit that controls the motor, without a need to independently dispose a control circuit for controlling the electric heater, so that a quantity of controllers, a weight of the heating apparatus, a required occupation space of the heating apparatus, and costs of the heating apparatus can be reduced.