Integrated Thermal Management for Shared Radiator EV Cooling
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Solution Overview
Problem
Existing thermal management systems for electric vehicles inefficiently utilize radiator space by dividing it for separate cooling of power electronics (PE) parts and batteries, leading to reduced heat exchange performance and energy inefficiency.
Innovation Solution
An integrated thermal management system that combines refrigerant and cooling water circuits with an integrated heat exchanger, allowing selective sharing of heat between PE parts and batteries, and uses a controller to manage valve operations for optimal temperature regulation and heat pumping processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the heat exchange area of a radiator is divided into separate areas for cooling PE parts and battery, then each component can be cooled separately, but the overall heat exchange performance deteriorates and a portion of the radiator area is not efficiently utilized
Solution Approach 1:
The cooling system is segmented into multiple independent cooling circuits (first cooling water line for PE parts, second cooling water line for battery) that can operate independently or in combination. Each circuit has its own pump and control valves, allowing selective cooling of different components without requiring separate physical radiator sections.
Solution Approach 2:
The single radiator serves multiple functions by receiving cooling water from both the PE part cooling circuit and battery cooling circuit. The radiator acts as a universal heat exchange component that can cool different components simultaneously or separately through integrated flow distribution, maximizing its heat exchange area utilization.
2Reliability
If separate radiators are used for cooling PE parts and battery, then each component has dedicated cooling capacity, but the overall system size and complexity increase
Solution Approach 1:
The patent merges the PE part cooling system and battery cooling system into a single integrated thermal management system. Both components share a common radiator, coolant reservoir, and control architecture, reducing the number of separate components while maintaining independent cooling capabilities through electronic flow control valves and pumps.
Solution Approach 2:
The controller acts as an intermediary that manages the complex interactions between multiple pumps, valves, and cooling circuits. It coordinates the operation of the first pump, second pump, first valve, and second valve to ensure proper coolant distribution, thereby simplifying the control complexity despite the integrated system architecture.
3Adaptability or versatility
If a partition is applied in the radiator to divide heat exchange areas, then separate cooling zones are created, but the overall cooling performance is reduced due to decreased effective heat exchange area
Solution Approach 1:
The system uses hydraulic flow control through pumps and valves to dynamically direct coolant flow to different radiator sections. The first pump and second pump can independently control coolant circulation in the first cooling water line and second cooling water line, allowing selective activation of cooling zones without physical partitions that would reduce heat exchange area.
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
Ensures efficient use of radiator area, improves cooling performance, enhances energy efficiency by sharing heat between PE parts and batteries, and maintains optimal temperatures while minimizing energy consumption.
Implementation Method 1
an integrated heat exchanger connected to the refrigerant circuit, the first cooling water line, and the second cooling water line such that the refrigerant and cooling water exchange heat with each other
Implementation Method 2
a third cooling water line connected to the first cooling water line and the second cooling water line and including a radiator
Data Source
AI summary
Proposed is an integrated thermal management system of which the cooling performance is secured because the entire area of a radiator is used when cooling a PE part and a battery. In particular, heat of the PE part and heat of the battery are selectively shared and thus the entire circuit of the system becomes compact and the energy efficiency is improved.