Vehicle Thermal Loop Switching for Flexible Heat Source Use
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Solution Overview
Problem
Battery electric and hybrid electric vehicles face limitations in utilizing available heat sources for efficient cabin and battery thermal management due to restricted waste heat and thermal inertia, necessitating an improved thermal management system that maximizes heat source flexibility and reduces energy consumption.
Innovation Solution
A thermal management system comprising a refrigerant system, a coolant system with multiple control loops, and a control unit that utilizes multiple valve units to selectively switch heat transfer paths between the energy storage, drive train, and radiator systems, allowing flexible use of heat sources, including ambient air, waste heat, and thermal inertia, to efficiently heat or cool the vehicle cabin and battery system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional thermal management system with limited heat sources is used, then the system structure is simple, but the heat source flexibility and energy efficiency are insufficient
Solution Approach 1:
The thermal management system is designed to perform multiple functions by enabling the coolant system to selectively connect different heat sources (energy storage system, drive train system, ambient air via radiator) to the refrigerant system. The multiple valve units allow the same thermal management system to serve different heating needs depending on operating conditions, making the system universal and adaptable to various scenarios.
Solution Approach 2:
The system employs dynamic control through the control unit that continuously monitors operating conditions and adjusts the valve units accordingly. This allows the thermal management system to dynamically switch between different heat sources and configurations based on real-time requirements, optimizing heat source flexibility while managing system complexity through intelligent control.
2Adaptability or versatility
If multiple heat sources are integrated into the thermal management system, then heat source flexibility improves, but the system complexity increases
Solution Approach 1:
The thermal management system is segmented into distinct control loops (first, second, and third control loops) that can operate independently or in combination. Each loop is responsible for managing specific heat sources, and the segmentation allows the system to activate only the necessary loops based on operating conditions, thereby reducing the effective complexity while maintaining high flexibility.
Solution Approach 2:
The control unit acts as an intermediary that manages the complexity of coordinating multiple valve units and control loops. By centralizing the control logic, the system can handle the complexity of multiple heat sources through a single intelligent mediator that makes decisions based on sensor inputs, rather than requiring complex mechanical coordination mechanisms.
3Use of energy by moving object
If waste heat from vehicle components is utilized, then energy efficiency improves, but the amount of available waste heat is limited
Solution Approach 1:
The system merges multiple heat sources including waste heat from the energy storage system, waste heat from the drive train system, and ambient air heat through the radiator. By combining these heat sources, the system overcomes the limitation of insufficient waste heat quantity while maintaining high energy efficiency, as the merged heat sources provide sufficient thermal energy for cabin heating.
Solution Approach 2:
The thermal management system is designed to universally utilize any available heat source depending on operating conditions. The system can switch between using waste heat from energy storage, waste heat from drive train, or ambient air heat, making the energy utilization flexible and efficient while overcoming the limitation of limited waste heat quantity from any single source.
4Use of energy by moving object
If thermal inertia of components is utilized for heating, then energy efficiency improves, but the thermal inertia is restricted by optimal operating temperature requirements
Solution Approach 1:
The system dynamically adjusts the thermal management strategy based on the operating temperature of the energy storage system. When the battery temperature is within an optimal range and excess heat is available, the system utilizes this thermal inertia for cabin heating. When the battery temperature approaches limits, the system dynamically switches to other heat sources, thereby efficiently utilizing thermal inertia while respecting temperature constraints.
Solution Approach 2:
The control unit continuously monitors the temperature of the energy storage system and uses this feedback to determine whether to utilize its thermal inertia for heating. This feedback mechanism ensures that the system can efficiently use thermal inertia when safe to do so, while automatically switching to alternative heat sources when temperature constraints are approached, thus resolving the contradiction between energy efficiency and temperature management.
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 enhances energy efficiency by optimizing the use of multiple heat sources, allowing for flexible and efficient thermal management of the vehicle cabin and battery system, minimizing energy consumption and ensuring optimal operating temperatures.
Implementation Method 1
a first heat exchanger configured to transfer heat to the refrigerant system
Implementation Method 2
The control unit is configured to switch the first multiple valve unit and the second multiple valve unit in a first mode to couple the first control loop with the second control loop
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The thermal management system comprises a refrigerant system (300), a coolant system (200) and a control unit. The coolant system comprises a first control loop (11) thermally coupled to an energy storage system (1), a second control loop (12) thermally coupled to a drive train system (2), a third control loop (13) thermally coupled to a radiator system (3), a first multiple valve unit (21) and a second multiple valve unit (22), and a first heat exchanger (chiller) (31) configured to transfer heat to the refrigerant system. The first control loop, the second control loop and the third control loop are configured to transfer heat to the first heat exchanger. The first heat exchanger is arranged between the first multiple valve unit and the second multiple valve unit. The control unit is configured to switch the first multiple valve unit and the second multiple valve unit in a first mode to couple the first control loop with the second control loop to collectively transfer heat to the first heat exchanger independently of the third control loop.