Vehicle Thermal Loop Switching for Battery and Cabin Heating
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Solution Overview
Problem
Existing thermal management systems in battery electric and hybrid electric vehicles face limitations in utilizing available heat sources and maintaining battery systems within optimal operating temperatures, requiring inefficient energy use for heating.
Innovation Solution
A thermal management system with a refrigerant and coolant system, including multiple valve units and a control unit, allows flexible heat source utilization by varying coolant flow directions among control loops to maximize heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat pump is used to heat the vehicle cabin, then heating capability is improved, but energy consumption increases due to limited waste heat availability
Solution Approach 1:
The patent combines multiple heat sources (waste heat from powertrain, battery thermal energy, and ambient air) into a unified thermal management system. The coolant system integrates these diverse heat sources through a common circulation network with multiple control loops, allowing the system to aggregate available thermal energy and reduce reliance on the heat pump alone, thereby lowering energy consumption for cabin heating.
Solution Approach 2:
The system dynamically switches between different heat sources and operational modes based on real-time conditions. The control unit adjusts the operation of multiple valves and pumps to optimize heat transfer paths, enabling the system to adaptively select the most efficient heat source (battery, powertrain, or ambient air) depending on vehicle operating conditions, thus minimizing energy consumption while maintaining heating capability.
2Reliability
If the battery system operates at optimal temperature, then battery performance is improved, but flexibility in using battery thermal energy for other purposes is reduced
Solution Approach 1:
The thermal management system is segmented into multiple independent control loops, each capable of serving different functions. The first control loop is dedicated to battery thermal management, while the second control loop can utilize battery thermal energy for cabin heating when available. This segmentation allows the battery loop to maintain optimal temperature for reliability while enabling flexible utilization of excess thermal energy for other purposes, resolving the contradiction between reliability and adaptability.
Solution Approach 2:
The battery thermal management system is designed with multi-functionality, serving both as a dedicated cooling/heating system for battery reliability and as a potential heat source for cabin heating. The universal coolant circulation system can redirect thermal energy from the battery to the cabin heater when the battery operates within acceptable temperature ranges, thus maintaining reliability while enhancing versatility in heat source utilization.
3Adaptability or versatility
If multiple heat sources are integrated into the thermal management system, then heat source flexibility is improved, but system complexity increases
Solution Approach 1:
The system divides the thermal management network into modular control loops (first control loop for battery, second control loop for powertrain, third control loop for ambient air) with dedicated valves and heat exchangers for each. This segmentation allows each module to be independently controlled and optimized, managing the complexity of multiple heat sources through a structured, organized architecture rather than a monolithic system.
Solution Approach 2:
The control unit acts as an intermediary that manages the complexity of coordinating multiple heat sources. It receives inputs from various sensors, processes thermal management requirements, and automatically adjusts valve positions and pump operations to optimize heat transfer among different sources. This centralized control mediation simplifies the overall system operation despite the presence of multiple heat sources and control elements.
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 energy efficiency by flexibly using various heat sources, including waste heat and ambient air, to minimize energy requirements for vehicle cabin and battery heating.
Implementation Method 1
a first heat exchanger configured to transfer heat to the refrigerant system
Implementation Method 2
The first control loop, the second control loop and the third control loop are configured to transfer heat to the first heat exchanger
Data Source
AI summary
The present disclosure relates to a thermal management system for a vehicle including a refrigerant system, a coolant system and a control unit. The coolant system includes a first control loop thermally coupled to an energy storage system, a second control loop thermally coupled to a drive train system, a third control loop thermally coupled to a radiator system, a first multiple valve unit and a second multiple valve unit, and a first heat exchanger 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.