Three-Circuit Battery Cooling System for High-Heat Electric Vehicles
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Solution Overview
Problem
Existing cooling systems for electric vehicle batteries, particularly in heavy vehicles like mining trucks and freight locomotives, are inadequate for maintaining battery temperature within safe limits due to high heat generation and ambient temperatures, limiting the deployment of battery technology in these applications.
Innovation Solution
A multi-loop cooling system with separate circuits for dielectric fluid, refrigerant, and brine/glycol coolant, utilizing a control system to switch between refrigeration and free-cooling modes based on temperature and ambient conditions, and incorporating existing internal combustion engine radiators as dry coolers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery pack size is increased to power heavy vehicles, then the energy storage capacity is improved, but the cooling difficulty and thermal management complexity increase
Solution Approach 1:
The cooling system is divided into three separate circuits: primary circuit for battery cooling, secondary refrigeration circuit for active cooling, and tertiary free-cooling circuit for passive cooling. This segmentation allows each circuit to be optimized for its specific function while working together to manage the thermal loads of large battery packs in heavy vehicles.
Solution Approach 2:
The system dynamically switches between refrigeration mode and free-cooling mode based on ambient temperature and battery thermal conditions. The control system adjusts the operation of compressors, pumps, and flow distribution to adapt to changing conditions, optimizing cooling efficiency for varying battery sizes and environmental conditions.
2Device complexity
If conventional single-circuit cooling systems are used, then the device simplicity is maintained, but the cooling effectiveness for large battery packs in high ambient temperatures is insufficient
Solution Approach 1:
The cooling system is divided into three separate circuits: primary circuit for battery cooling, secondary refrigeration circuit for active cooling, and tertiary free-cooling circuit for passive cooling. This segmentation allows each circuit to be optimized for its specific function while working together to manage the thermal loads of large battery packs in heavy vehicles.
Solution Approach 2:
The system changes operational parameters by switching between refrigeration mode (with compressors active) and free-cooling mode (with compressors inactive) based on ambient temperature conditions. This parameter change allows the system to maintain reliable battery temperature control while adapting to varying environmental conditions.
3Reliability
If active refrigeration cooling is continuously used, then the battery temperature control is improved, but the power consumption increases
Solution Approach 1:
The system dynamically switches between refrigeration mode and free-cooling mode based on ambient temperature and battery thermal conditions. The control system adjusts the operation of compressors, pumps, and flow distribution to adapt to changing conditions, optimizing cooling efficiency for varying battery sizes and environmental conditions.
Solution Approach 2:
The free-cooling circuit enables the system to utilize ambient conditions for passive cooling when temperatures permit, reducing the need for active refrigeration. The system automatically directs coolant flow through the appropriate circuit based on conditions, minimizing energy consumption while maintaining battery 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
The system effectively maintains battery temperature within safe limits, reduces power consumption, minimizes corrosion and thermal stratification, and optimizes coolant usage, achieving efficient thermal management with minimal component count and energy use.
Implementation Method 1
a secondary coolant circuit including an evaporator and a condenser, the evaporator being incorporated into the first heat exchanger
Implementation Method 2
a primary cooling circuit including a battery and a first heat exchanger
Implementation Method 3
a secondary coolant circuit including an evaporator and a condenser, the evaporator being incorporated into the first heat exchanger
Implementation Method 4
the condenser being incorporated into the second heat exchanger
Implementation Method 5
a pump which circulates a first liquid coolant between the battery and the first heat exchanger
Implementation Method 6
a tertiary cooling circuit including a second heating exchanger and a dry cooler
Implementation Method 7
a tertiary cooling circuit including a second heating exchanger and a dry cooler
Data Source
AI summary
A cooling system for cooling the battery of an electric vehicle is described including: a primary cooling circuit including a battery and a first heat exchanger, and a pump which circulates a first liquid coolant between the battery and the first heat exchanger; a secondary coolant circuit including an evaporator and a condenser, the evaporator being incorporated into the first heat exchanger, and at least one compressor which circulates a refrigerant fluid between the evaporator and the condenser; and a tertiary cooling circuit including a second heating exchanger and a dry cooler, the condenser being incorporated into the second heat exchanger, and a second pump which circulates a second liquid coolant between the second heat exchanger and the dry cooler.