Multi-Way Valve Control for Smooth EV Cooling Circuit Transitions
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Solution Overview
Problem
Current thermal management systems in vehicles face challenges in smoothly transitioning between series and parallel connection modes of cooling circuits, leading to sudden temperature and pressure changes, and frequent switching during transient journeys, which affects the efficient temperature control of both electric motor and battery cooling circuits.
Innovation Solution
A thermal management system that utilizes a multi-way valve to connect the battery and electric motor cooling circuits in series, parallel, or a needs-based mixing mode, allowing for intermediate valve positions to smoothly mix coolant flows and prevent sudden transitions, with additional valves for radiator bypassing to optimize temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the multi-way valve switches between series connection mode and parallel connection mode, then the temperature control of the battery cooling circuit and electric motor cooling circuit is improved, but sudden changes in temperature and pressure occur during switching
Solution Approach 1:
The multi-way valve is designed with the ability to assume not only discrete end positions (series connection mode, parallel connection mode) but also continuous intermediate positions. This dynamic positioning capability allows the valve to transition smoothly between connection modes by gradually adjusting the mixing ratio of coolant flows from the battery cooling circuit and electric motor cooling circuit, thereby eliminating sudden temperature and pressure changes while maintaining precise temperature control.
2Adaptability or versatility
If the multi-way valve frequently switches between series and parallel connection modes during transient journeys, then the temperature control responds to changing conditions, but frequent switching causes system instability and wear
Solution Approach 1:
The continuous intermediate positioning capability of the multi-way valve enables smooth adaptation to transient journey conditions without requiring frequent discrete switching. By gradually adjusting the valve position to match changing thermal demands, the system maintains adaptability while avoiding the instability and mechanical wear associated with frequent on-off switching between fixed modes.
Solution Approach 2:
The valve maintains continuous adjustment capability throughout the transition process, allowing the coolant flow mixing ratio to be continuously optimized according to real-time thermal demands. This continuous action eliminates the need for repeated switching cycles, thereby improving system reliability and reducing mechanical wear during transient operations.
3Device complexity
If the multi-way valve uses discrete end positions for series and parallel modes, then the system structure is simplified, but smooth transition between modes cannot be achieved
Solution Approach 1:
The multi-way valve incorporates a dynamic positioning mechanism that extends the basic discrete end-position structure to include continuous intermediate positions. This is achieved through a control system that can actuate the valve to any position within its range, transforming a simple on-off valve into a continuously adjustable mixing valve while maintaining relatively simple hardware architecture.
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 enhances temperature control precision for both circuits, reduces sudden changes in temperature and pressure, and minimizes frequent switching, thereby improving the overall thermal management efficiency during transient journeys.
Implementation Method 1
the coolant flows of the two cooling circuits are mixed with each other as needed (needs-based mixing mode). Waste heat or heat loss from the electric motor cooling circuit can advantageously be dissipated to the battery cooling circuit
Data Source
AI summary
A thermal management system for use in a vehicle in which the coolant flows of the two cooling circuits can be mixed with each other as needed by a multi-way valve at an interface between a first cooling circuit for a battery and a second cooling circuit for an electric motor for driving the vehicle. A vehicle with such a thermal management system is also proposed, as well as a method for operating two cooling circuits of such a thermal management system.