Reversible thermal management system and method for a work machine
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heavy work machines require efficient thermal management to balance power usage and size, with existing systems being inefficient and bulky due to large batteries and lack of power refinement, necessitating optimization of energy resources including thermal management.
Innovation Solution
A reversible thermal management system for work machines comprising a prime mover, battery, first circuit with glycol for thermal energy exchange, and second circuit with refrigerant for air exchange, utilizing gear pumps and a controller to direct fluid flow for cooling and heating modes, eliminating the need for a compressor and enabling thermal storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional thermal management system with compressor is used, then cooling function is provided, but system weight and size increase
Solution Approach 1:
The patent removes the compressor from the thermal management system, extracting the harmful heavy component while maintaining cooling functionality through an electric motor-driven pump system that circulates refrigerant through the heat exchanger
Solution Approach 2:
The mechanical compressor is replaced with an electric motor-driven pump system that uses electrical power to circulate refrigerant, substituting a mechanical compression-based cooling system with an electrically-driven fluid circulation system that achieves cooling through heat exchanger efficiency
2Temperature
If a conventional thermal management system with compressor is used, then cooling function is provided, but system complexity increases
Solution Approach 1:
The compressor, which is a complex mechanical component with moving parts, is extracted from the system and replaced with a simpler electric motor-driven pump system that uses electrical control to achieve the same cooling function
Solution Approach 2:
The heat exchanger is designed to serve multiple functions - it acts as both a condenser and evaporator depending on the direction of refrigerant flow controlled by the electric motor-driven pumps, eliminating the need for separate components for different thermal management modes
3Power
If battery size is increased to provide more power, then power availability improves, but vehicle size and weight increase
Solution Approach 1:
The thermal management system recovers waste heat from the electric motor and other system components, using it to pre-heat coolant or provide cabin heating, thereby reducing the energy demand on the battery and allowing for smaller battery capacity while maintaining power availability
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
The system optimizes space and weight by eliminating the compressor, reduces power consumption, and allows reversible operation for both cooling and heating, enhancing power efficiency and reducing the size of batteries, thus addressing the inefficiencies in existing thermal management systems.
Implementation Method 1
The heat exchanger operates as an evaporator to release thermal energy to the refrigerant within the second circuit
Implementation Method 2
The second circuit absorbs thermal energy from the air through an evaporator
Implementation Method 3
The second circuit releases thermal energy to air through a condenser
Implementation Method 4
The first circuit comprises of a first gear pump that circulates the glycol in the first circuit. The second circuit comprises a second gear pump that circulates the refrigerant in the second circuit
Data Source
AI summary
A reversible thermal management system and method for a work machine is disclosed. The system comprises a prime mover, a battery, a first circuit, and a second circuit. The battery supplies at least a portion of power of the prime mover. The first circuit circulates a glycol adapted to exchange thermal energy with one or more of an electronic component, a transmission circuit, a hydraulic circuit and the battery. The second circuit circulates a refrigerant. The second circuit, which is thermally coupled to the first circuit by at least one heat exchanger, is adapted to exchange thermal energy with air.