Split Thermal Circuit Layout for EV Cabin Heat and Battery Protection
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Solution Overview
Problem
Thermal management systems in electrified vehicles face challenges in maintaining passenger cabin temperature in cold ambient conditions due to reduced waste heat generation from high-efficiency electrical components, leading to reduced vehicle range.
Innovation Solution
A thermal circuit with a main and partial circuit, each equipped with a pump and heat exchanger, connected by a valve for controlled fluid flow, allowing for gradual temperature distribution and storage, thereby optimizing heat allocation and reducing temperature shocks in components like high voltage batteries and electric drive machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electric heaters or heat pumps are used to generate thermal energy for passenger cabin heating, then the temperature control requirement is met, but the vehicle range is reduced
Solution Approach 1:
The thermal circuit is divided into a main circuit and a partial circuit that can be independently controlled. The main circuit handles overall thermal management while the partial circuit specifically serves temperature-controlled components, allowing for optimized heat distribution and reduced energy consumption for cabin heating.
Solution Approach 2:
A connecting valve is introduced as an intermediary element between the main circuit and partial circuit to control fluid flow distribution. This valve enables dynamic adjustment of thermal energy allocation, allowing waste heat to be effectively redirected to the passenger cabin without requiring additional electrical heating power.
2Use of energy by moving object
If waste heat is used for temperature control, then energy consumption is reduced, but insufficient thermal energy is available in cold ambient temperatures
Solution Approach 1:
The thermal circuit system is designed to serve multiple functions: it manages temperature for powertrain components, provides cabin heating, and recovers waste heat for reuse. The connecting valve enables the system to dynamically allocate thermal energy to different destinations based on demand, ensuring sufficient thermal energy availability across various operating conditions.
3Speed
If thermal energy is rapidly transferred to components, then temperature control response is faster, but temperature shocks occur in components
Solution Approach 1:
The partial circuit acts as a buffer or cushioning element between the main circuit and temperature-controlled components. By introducing this intermediate thermal pathway with controlled fluid flow, rapid temperature changes from the main circuit are dampened, preventing thermal shocks to sensitive components while still enabling responsive temperature control.
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 solution enhances temperature control homogeneity and efficiency, reducing the need for electrical heating, thus conserving energy and extending vehicle range by effectively managing thermal energy within the vehicle's thermal management system.
Implementation Method 1
a heat exchanger provided behind the first pump
Implementation Method 2
a first pump and a heat exchanger provided behind the first pump
Data Source
AI summary
A thermal circuit having a main conveying direction for a thermal management system of an electrified vehicle, the thermal circuit including a main circuit with a main circuit first conduit portion having a first pump and a heat exchanger provided behind the first pump and a main circuit second conduit portion. The thermal circuit includes a partial circuit with a partial circuit first conduit portion having a second pump and a component arranged to be temperature-controlled behind the second pump and a partial circuit second conduit portion. The thermal circuit further includes a connecting valve connected to the main circuit first conduit portion or the partial circuit first conduit portion and the main circuit second conduit portion or the partial circuit second conduit portion for controlling a volume flow. The thermal circuit includes a first fluid connection connected to the connecting valve, and a second fluid connection.