On-Board Charger Cooling Efficiency for Plug-In Hybrid Vehicles
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Solution Overview
Problem
The on-board charging system of plug-in hybrid vehicles consumes excessive power due to inefficient cooling of the on-board charger, which affects battery lifespan and performance, as the cooling system circulates excessive coolant to manage heat generated during charging.
Innovation Solution
A system and method that adjust the frequency and intensity of cooler operation based on the voltage of the high-voltage battery, using a controller to decrease cooling when the voltage is within a reference range and increase it when outside this range, optimizing the operation of the water pump and radiator fan to minimize power consumption and improve charging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling system circulates coolant to cool the OBC when temperature rises, then the OBC temperature is controlled within range, but excessive power is consumed by the cooling system
Solution Approach 1:
The patent implements dynamic control of the cooling system by adjusting the water pump operation frequency and coolant flow rate based on real-time OBC temperature monitoring. The system transitions from static full-speed cooling to dynamic adaptive cooling, where the cooling intensity matches the actual thermal conditions, thereby reducing unnecessary power consumption while maintaining temperature control.
Solution Approach 2:
The system changes the operating parameters of the cooling system (water pump frequency, coolant flow rate) based on the OBC temperature and charging status. By adjusting these parameters dynamically rather than maintaining constant high-intensity cooling, the system achieves effective temperature control with reduced energy consumption.
2Temperature
If the cooling system operates with high intensity to ensure OBC cooling, then temperature control is effective, but charging efficiency is reduced due to power consumption
Solution Approach 1:
The cooling system operates dynamically adjusted intensity based on real-time temperature monitoring rather than constant high-intensity operation. The water pump frequency and coolant flow are adapted to match actual cooling needs, reducing parasitic power consumption that would otherwise reduce charging efficiency while maintaining adequate temperature control.
3Temperature
If excessive coolant is circulated to cool the OBC, then temperature control is maintained, but the cooling system consumes more power
Solution Approach 1:
The system applies partial cooling action rather than excessive continuous cooling. The water pump operates at adjusted frequencies and coolant flow rates are optimized based on actual thermal conditions, providing just enough cooling to maintain temperature within range without the energy waste of excessive cooling capacity.
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 reduces unnecessary power consumption by the cooling system, enhancing the on-board charging efficiency and effectively managing the temperature of the on-board charger, thereby improving the overall performance and lifespan of the battery and charging system.
Implementation Method 1
a cooler configured to cool an OBC by circulating coolant therethrough
Implementation Method 2
The cooler may include a water pump configured to cause a cooling medium to circulate when the OBC is required to be cooled
Implementation Method 3
The cooler may include a radiator fan configured to adjust a temperature of a cooling medium that circulates to cool the OBC
Data Source
AI summary
A system and method for charging a plug-in hybrid vehicle can improve the on-board charging efficiency of the plug-in hybrid vehicle by adjusting a frequency of operation of a cooler when cooling an on-board charger (OBC) by circulating coolant when the temperature of the OBC rises while a high-voltage battery is being charged. The operations of a water pump and a radiator fan are controlled by determining whether the voltage of the high-voltage battery is within or out of a reference voltage range in which the on-board charging of the high-voltage battery is performed. This consequently prevents power from being unnecessarily consumed by operation of the cooler, such that the efficiency of charging is improved and the OBC is properly cooled.