Range Extender Thermal Management for Battery Temperature Control
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Solution Overview
Problem
Large wheeled vehicles, such as trucks, face inefficiencies in power generation and management due to the need for large internal combustion engines to support both propulsion and accessory power, leading to increased cost, complexity, and reduced engine efficiency, especially when operating in varying conditions.
Innovation Solution
A wheeled vehicle configuration that integrates multiple engine types with a generator to produce electric power, allowing the engine to operate within a preferred range, decoupling it from direct mechanical accessory power and using a battery management system to optimize power distribution and thermal management across different operating modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large internal combustion engine is used to provide both propulsion and accessory power, then the vehicle can operate in varying conditions, but the engine size and weight increase, and efficiency decreases
Solution Approach 1:
The power system is segmented into separate functional components: a smaller internal combustion engine dedicated to propulsion, an electric generator for accessory power, and a battery system for energy storage. This segmentation allows each component to be optimized for its specific function rather than requiring one oversized engine to handle all power needs.
Solution Approach 2:
The battery system serves multiple functions: storing electrical energy from the generator, providing power during high-demand periods, and enabling the vehicle to operate in electric-only mode for accessories. This multi-functionality replaces the need for a larger engine while maintaining adaptability to varying operating conditions.
2Adaptability or versatility
If a large internal combustion engine is used to support both propulsion and accessory power, then the vehicle can operate in varying conditions, but the system complexity increases
Solution Approach 1:
By separating propulsion and accessory power functions into distinct systems (ICE for propulsion, generator+battery for accessories), the overall system architecture becomes more modular and manageable. Each subsystem can be independently controlled and maintained, reducing the complexity burden despite adding components.
Solution Approach 2:
The mechanical connection between the engine and accessories (direct belt-driven operation) is replaced with an electrical system (generator producing electricity stored in batteries that power accessories). This substitution simplifies the mechanical linkage while providing flexible electrical control for accessory management.
3Power
If a large internal combustion engine is used to provide sufficient power for all functions, then the vehicle can handle varying loads, but fuel consumption increases
Solution Approach 1:
The power delivery is segmented between the ICE (for propulsion when needed) and the battery system (for accessories and auxiliary power). This allows the smaller ICE to operate at optimal efficiency points while the battery handles peak power demands, reducing overall fuel consumption compared to a single large engine operating across all conditions.
Solution Approach 2:
The system dynamically changes operational parameters by switching between different power sources (ICE only, battery only, or combined) based on instantaneous power demands. This parameter optimization allows the vehicle to maintain sufficient power output while minimizing fuel consumption by keeping the ICE operating in its most efficient range.
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 enhances engine efficiency and service life by allowing it to operate within optimal ranges, reduces the overall size and weight of the engine, and enables flexible power modes, including auxiliary and emergency operations, while maintaining battery performance across varying environmental conditions.
Implementation Method 1
a battery management system including a battery temperature control system configured to maintain an operating temperature of the batteries within a range of operating temperatures
Implementation Method 2
a control system including a processor configured to monitor the operating temperature of the batteries
Implementation Method 3
a generator for coupling to an engine
Data Source
AI summary
An electric drivetrain for installation in a vehicle chassis. A generator coupled to an engine generates electric power for charging an array of batteries. The vehicle, including components and subsystems, may be powered electrically from the batteries, allowing the engine and generator to be easily replaced or customized for an industry, geographic region, fuel type, or a set of emission requirements. A thermal management system may determine a battery temperature for the set of batteries and cause one or more of a coolant system, a refrigerant system, an exhaust gas system or an ambient air heat exchanger to add heat to the set of batteries or transfer heat away from the set of batteries.