Systems and methods for managing the heating of thermal fluids
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Solution Overview
Problem
Hybrid electric engines face issues with thermal fluid viscosity increasing at low temperatures, leading to inefficient circulation and potential component wear, particularly in battery systems, due to the use of dielectric thermal fluids.
Innovation Solution
A thermal management system with a dual-pump configuration, utilizing a common driver for both pumps, and a magnetic clutch to selectively engage the second pump during low temperatures, combined with an electric heater to heat a secondary thermal fluid for efficient circulation and heating of battery thermal fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a dielectric thermal fluid is used to warm batteries, then the batteries can be heated effectively, but the fluid viscosity increases at low temperatures causing poor circulation and potential pump wear
Solution Approach 1:
The system divides the thermal management function into two separate pumps: a first pump for circulating thermal fluid through the battery, and a second pump for circulating thermal fluid through the operator cab. This segmentation allows each pump to be optimized for its specific function and operating conditions, reducing wear and improving reliability.
Solution Approach 2:
The system uses a clutch mechanism to dynamically engage or disengage the second pump based on temperature conditions. When the operator cab temperature is below the threshold, the clutch engages the second pump; when above, it disengages. This dynamic operation reduces unnecessary pump wear while maintaining effective thermal management.
2Device complexity
If a single driver operates both pumps, then device complexity is reduced, but the second pump cannot be selectively engaged during low temperatures
Solution Approach 1:
A clutch mechanism is introduced as an intermediary between the single driver and the second pump. The clutch selectively transmits or blocks rotational force from the driver to the second pump based on temperature conditions, enabling adaptive control while maintaining a simple single-driver configuration.
Solution Approach 2:
The single driver is designed to universally drive both the first pump and the second pump through the clutch mechanism. This multi-functional driver configuration reduces overall system complexity while maintaining the ability to selectively operate pumps based on temperature requirements.
3Temperature
If the thermal fluid circulates through the fluid circuit, then heat can be transferred to batteries, but energy consumption increases due to high viscosity at low temperatures
Solution Approach 1:
The system applies partial action by using the clutch to engage the second pump only when necessary (when operator cab temperature is below threshold). This prevents excessive energy consumption that would occur if the pump operated continuously, while still providing sufficient heating when needed.
Solution Approach 2:
The thermal management system uses the vehicle's existing thermal fluid and heat exchanger infrastructure to provide heating services to both the battery and operator cab. This self-service approach reduces additional energy consumption by utilizing already-present system components rather than adding separate heating systems.
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
Enhances thermal fluid circulation efficiency, reduces energy consumption, and prolongs pump durability by optimizing pump operation based on temperature conditions, ensuring effective heating of batteries and operator cabs in varying ambient temperatures.
Implementation Method 1
The magnetic coupling transfer a force between the first and second portions of the magnetic coupling to rotatably displace the second portion of the magnetic coupling, and thereby rotate the second portion of the first drive shaft
Implementation Method 2
an electric heater to heat a secondary thermal fluid for efficient circulation and heating of battery thermal fluids
Implementation Method 3
a second fluid pump positioned for at least partial submersion in a second thermal fluid in a first pressurized reservoir of a second thermal circuit... circulating... a second thermal fluid at least through a heat exchanger
Data Source
AI summary
A system for operating at least a pair of pumps using a driver. The driver can be coupled to a first portion of a first drive shaft that is not positioned in within an interior area of a thermal fluid tank of a first thermal circuit. A magnetic coupling can couple the first portion to a second portion of the first drive shaft that is within the thermal fluid tank. Rotational displacement of the first portion of the first drive shaft can be translated, via the magnetic coupling, to the second portion of the first drive shaft to drive a first fluid pump. The first portion of the first drive shaft can also be coupled to a second drive shaft by a clutch, the second drive shaft being used to operate a second fluid pump that provides a force for circulating a second thermal fluid of a second thermal circuit.