Three-Loop Thermal Management System for EV Cabin Heating
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Solution Overview
Problem
Electric and hybrid-electric vehicles face challenges in effectively utilizing system waste heat for cabin comfort, as previous thermal management systems have failed to efficiently harvest and reuse waste heat for thermal management.
Innovation Solution
A three-loop, two-pump thermal management system that allows one or more loops to be placed offline to reduce energy usage, with a direct heat pump system for cabin heating and a water loop heater coil, and an electric heater to heat the coolant, which can also harvest excess heat from the battery and electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a thermal management system is designed to harvest waste heat for cabin comfort, then energy efficiency is improved, but system complexity increases
Solution Approach 1:
The thermal management system is designed with multi-functional components that can operate in different modes. The first and second cooling loops can serve both component cooling and cabin heating functions by redirecting waste heat from batteries or motors to the cabin through heat exchangers, allowing one system to perform multiple thermal management tasks simultaneously
Solution Approach 2:
The system divides thermal management into separate functional loops - a first cooling loop for battery cooling, a second cooling loop for motor cooling, and a cabin heating loop. This segmentation allows independent optimization of each loop while enabling flexible reconfiguration to harvest waste heat from any source for cabin comfort
2Reliability
If multiple loops are used to enable failure mode operation, then reliability is improved, but device complexity increases
Solution Approach 1:
Each cooling loop is designed with independent thermal management capabilities and can operate autonomously. The first cooling loop can cool batteries while the second cools motors, or either loop can be redirected for cabin heating. This local independence ensures that failure in one loop does not compromise the entire system, as other loops can continue functioning or provide backup capacity
Solution Approach 2:
The system incorporates dynamic reconfiguration capabilities through controllable valves and pumps that can redirect coolant flow between different loops based on operational requirements. This dynamic flexibility allows the system to adapt to various failure modes by rerouting thermal pathways, maintaining operational reliability despite component failures
3Object-affected harmful factors
If pumps are positioned far from the cabin to reduce noise and vibration, then cabin comfort is improved, but system complexity increases
Solution Approach 1:
The pump components are extracted from the cabin area and positioned in external locations such as the vehicle undercarriage or engine bay. This physical separation removes the noise and vibration sources from the passenger compartment, improving cabin acoustic comfort while the pump functions remain integrated into the thermal management system through extended coolant pathways
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 system enhances energy efficiency, reduces noise and vibration in the cabin, and allows the vehicle to travel longer distances before repair by operating in multiple failure modes, effectively managing thermal energy for both component cooling and cabin comfort.
Implementation Method 1
a direct heat pump system for cabin heating
Implementation Method 2
a water loop heater coil
Implementation Method 3
an electric heater to heat the coolant
Data Source
AI summary
A thermal management system comprises two pumps and three coolant loops. The loops are interconnectable such that most if not all of the functions of the thermal management system can be accomplished with one of the two pumps deactivated or inoperable. The thermal management system is selectively configurable to utilize waste heat from a battery, an electrical drivetrain system, and/or a wireless charger to heat cabin air. The thermal management system is further selectively configurable to heat or cool a battery, to cool an electrical drivetrain system, and to cool a wireless charger.