Description:TECHNICAL FIELD
[001] The present disclosure generally relates to HVAC (heating, ventilating and air conditioning) systems for vehicles and more particularly, the present disclosure relates to a heat pump cabin heating system for an electric vehicle and a hybrid vehicle that utilizes heat radiated from a powertrain and a battery of the vehicle and is integrated with a battery cooling system of the vehicle for increasing efficiency of the HVAC system and range of the electric vehicle.
BACKGROUND
[002] The heating, ventilation, and air conditioning (HVAC) system of a vehicle is responsible for maintaining a regulated cabin temperature inside the vehicle to provide comfort to the passengers of the vehicle. The HVAC of the vehicle includes an air conditioning system that is configured to heat or cool the inside of the vehicle through heat exchange, wherein a refrigerant is circulated in the system to cool the air, and the hot coolant is used to heat the air and cooled to obtain conditioned air at the desired temperature. The air conditioning system, during a cooling operation, condenses a gaseous refrigerant of high temperature and high pressure which has been compressed from a compressor and evaporated in an evaporator, to reduce temperature and humidity inside the vehicle.
[003] In vehicles having an internal combustion engine, the HVAC system includes a heating system in addition to the air conditioning system which utilizes the heat dissipated from the engine/ power train of the vehicle for heating the coolant during a heating operation. By utilizing the heat generated from the engine/ powertrain, the heat/power required by the HVAC system is free, therefore no impact on the system.
[004] However, in electric vehicles and hybrid vehicles, the heat dissipated from the powertrain is low and therefore not sufficient to heat the coolant directly. Thus, conventionally in electric vehicles, the HVAC system includes additional components to carry out the heating operation.
[005] Some electric vehicles include an air-positive temperature coefficient (PTC) heater for carrying out the heating operation. The air PTC heater includes a specialized heating material comprising a ceramic material that converts electrical energy into heat energy. The air passing to the cabin through the A/C vents is directly heated using the PTC heater. Although the air PTC heater effectively heats the air, the power consumed by the air PTC is high and since the power is directly drawn from the battery of the electric vehicle, the battery is drained faster, affecting the range of the vehicle.
[006] Further, in some electric and hybrid vehicles, a coolant PTC heater comprising the PTC heater material is connected to the coolant flow path of the HVAC system for heating the coolant. The heated coolant is passed through a secondary circuit of an aluminum heat exchanger for heating the air being circulated inside the cabin of the vehicle. This type of system involves two heat exchanges viz, one for heating the coolant by the PTC heater and the other for exchanging heat from the coolant to the air inside the HVAC. This increases the cost and the complexity of packaging the system in the vehicle. Further, the efficiency of this type of heating system is lower as the heat is generated by the conversion of electrical energy into heat energy.
[007] To overcome the drawbacks of the air PTC heater system and the PTC coolant heater system, some electric vehicles include a heat pump system. Generally, in the heat pump system employed in electric vehicles, a high-temperature and high-pressure refrigerant coming out of the compressor is passed inside the heat exchanger, where it heats up the cabin air. Further, the exiting refrigerant is passed through an expansion device to another heat exchanger to gain heat from the ambience and then the refrigerant is sent back to the compressor. In this type of heat pump system, the air PTC heater is also integrated for heating in cold ambient conditions. However, a major drawback of this type of heat pump system is that at a very low ambient temperature, the outer heat exchanger is prone to freeze, affecting the heating of the cabin as the system needs to be switched off for the safety of the components. An additional heating element such as the air PTC heater is required along with the heat pump system to support the cabin heating when extreme heating is required for maintaining cabin comfort. Further, the cost of such systems is high as the system requires high-cost components in addition to the existing system. Also, the effectiveness and efficiency of the system are dependent on external factors such as the climatic conditions, affecting the performance of the heating system.
[008] Therefore, there is a requirement for a heating system for electric and hybrid vehicles which overcomes the aforementioned drawbacks of the existing systems.
OBJECTS
[009] The principal object of an embodiment of this invention is to provide a heat pump system for heating a cabin of an electric/ hybrid vehicle which includes a battery cooling system of the vehicle integrated with an electric drive cooling system and an air conditioning system of the vehicle, configured to heat a coolant of the battery coolant system for pre-heating a refrigerant of the air conditioning system through heat exchange.
[010] Another object of an embodiment of this invention is to provide the heat pump system which is configured to selectively utilize ambient heat and heat dissipated by a powertrain and the battery of the vehicle for heating a coolant, thereby reducing power consumption, and resulting in increasing the range of the electric vehicle.
[011] Yet another object of an embodiment of this invention is to provide the heat pump system which eliminates the requirement for an additional heating element for heating the refrigerant circulating in the heat pump system by utilizing the components of the battery cooling system and e-drive cooling system, thereby reducing the cost of the heat pump system.
[012] Another object of an embodiment of this invention is to provide the heat pump system which is configured to utilize the ambient heat for heating the coolant in a first mode of operation.
[013] Yet another object of an embodiment of this invention is to provide the heat pump system which is configured to utilize heat dissipated from the powertrain of the vehicle for heating the coolant in a second mode of operation.
[014] Still another object of an embodiment of this invention is to provide the heat pump system which is configured to utilize heat dissipated from the power train and battery of the vehicle for heating the coolant in a third mode of operation.
[015] Another object of an embodiment of this invention is to provide the heat pump system which is configured to heat the coolant with a heater of a battery cooling system in a fourth mode of operation.
[016] Yet another object of an embodiment of this invention is to provide the heat pump system which is configured to utilize heat dissipated from the battery of the vehicle for heating the coolant in a fifth mode of operation.
[017] Still another object of an embodiment of this invention is to provide the heat pump system which is configured to utilize the heat dissipated from the battery and the heater of the battery cooling system for heating the coolant in a sixth mode of operation.
[018] Another object of an embodiment of this invention is to provide the heat pump system in which the heating operation is independent of ambient conditions, which is efficient as it eliminates the requirement of an additional heating element and is cost-effective because of the lesser number of components required than the conventional heating systems in electric vehicles.
[019] Yet another object of an embodiment of this invention is to provide methods for heating a coolant in a heat pump system for pre-heating a refrigerant of an air conditioning system by utilizing heat from ambient, and heat dissipated from powertrain and battery of the vehicle.
[020] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[021] The embodiments herein are illustrated in the accompanying drawings, throughout which reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[022] Fig.1 is a block diagram of a heat pump system comprising a battery cooling system integrated with an e-drive cooling system and an air conditioning system of an electric/hybrid vehicle, according to an embodiment of the invention as disclosed herein;
[023] Fig.2 is an operating state diagram of the heat pump system illustrating an operation of the heat pump system in a first mode, according to an embodiment of the invention as disclosed herein;
[024] Fig.3 is an operating state diagram of the heat pump system illustrating an operation of the heat pump system in a second mode, according to an embodiment of the invention as disclosed herein;
[025] Fig.4 is an operating state diagram of the heat pump system illustrating an operation of the heat pump system in a third mode, according to an embodiment of the invention as disclosed herein;
[026] Fig.5 is an operating state diagram of the heat pump system illustrating an operation of the heat pump system in a fourth mode, according to an embodiment of the invention as disclosed herein;
[027] Fig.6 is an operating state diagram of the heat pump system illustrating an operation of the heat pump system in a fifth mode, according to an embodiment of the invention as disclosed herein; and
[028] Fig.7 is an operating state diagram of the heat pump system illustrating an operation of the heat pump system in a sixth mode, according to an embodiment of the invention as disclosed herein.
DETAILED DESCRIPTION
[029] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[030] The embodiments herein achieve a heat pump system for heating a cabin of an electric/ hybrid vehicle which includes a battery cooling system of the vehicle integrated with an electric drive cooling system and an air conditioning system of the vehicle, configured to heat a coolant of the battery coolant system for pre-heating a refrigerant of the air conditioning system through heat exchange. Further, the embodiments herein achieve the heat pump system which utilizes ambient heat and heat dissipated by a powertrain and the battery of the vehicle for heating a coolant, thereby reducing power consumption, and resulting in increasing the range of the electric vehicle. Furthermore, the embodiments herein achieve the heat pump system which eliminates the requirement for an additional heating element for heating the coolant circulated in the heat pump system, thereby reducing the cost of the heat pump system. Additionally, the embodiments herein achieve the heat pump system in which the heating operation is not dependent on the ambient condition, which is efficient as it does not require an additional heating element and is cost-effective because of the lesser number of components required than the conventional heating systems in electric vehicles.
[031] The embodiments herein achieve the heat pump system which is configured to utilize the ambient heat for heating the coolant in a first mode of operation and which is configured to utilize heat dissipated from the powertrain of the vehicle for heating the coolant in a second mode of operation. Further, the embodiments herein achieve the heat pump system which is configured to utilize heat dissipated from the powertrain and battery of the vehicle for heating the coolant in a third mode of operation and is configured to heat the coolant with a heater of a battery cooling system in a fourth mode of operation. Furthermore, the embodiments herein achieve the heat pump system which is configured to utilize heat dissipated from the battery of the vehicle for heating the coolant in a fifth mode of operation and utilizes the heat dissipated from the battery and the heater of the battery cooling system for heating the coolant in a sixth mode of operation. The embodiments herein achieve methods for heating a coolant in a heat pump system for pre-heating a refrigerant of an air conditioning system by utilizing heat from ambient, and heat dissipated from powertrain and battery of the vehicle. Referring now to the drawings, and more particularly to FIGS. 1 through 7, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[032] Figure 1 depicts a block diagram of the heat pump system (100) of the electric/ hybrid vehicle, according to an embodiment of the invention. The heat pump system (100) includes a battery cooling system (10) integrated with an electric drive (e-drive) cooling system (20) and an air conditioning system (30), wherein the heat pump system (100) is configured to selectively heat a coolant flowing through the battery cooling system (10) and the electric drive cooling system (20) for heating a refrigerant flowing through the air conditioning system (30) by heat exchange to circulate heated air/ warm air in a cabin of the vehicle.
[033] In an embodiment, the battery cooling system (10) includes a high voltage battery (11), a chiller (12), a heater (13) provided in connection with the battery (11) for heating the coolant passing through the battery (11), and a first pump (P1) connected to the chiller (12) and the battery (11), connected in a battery coolant circuit comprising a plurality of battery coolant lines (bcl1, bcl2, bcl3), and configured to circulate the coolant for cooling the battery (11) of the vehicle.
[034] Further, according to an embodiment, the electric drive cooling system (20) comprises an onboard charger (21), a dc-dc converter (22), a powertrain of the vehicle comprising a rear e-drive (motor) (23) and a front e-drive (motor) (24), a radiator (25) connected to a coolant storage tank (26) and disposed at a front portion of the vehicle, and a second pump (P2), connected in an e-drive coolant circuit comprising a plurality of e-drive coolant lines (ecl1, ecl2, ecl3, ecl4, ecl5, ecl6), wherein the electric drive cooling system (20) is configured to circulate the coolant for cooling the electric motors (23, 24) of the powertrain of the vehicle.
[035] In an embodiment, the air conditioning system (30) includes a compressor (35), an external condenser (31), a first evaporator (37), a second evaporator (38), a first expansion valve (xv1) provided in connection with the first evaporator (37), a second expansion valve (xv2) provided in connection with the second evaporator (38), and an internal heat exchanger (34), connected in a refrigerant circuit comprising a plurality of refrigerant lines, and configured to circulate a refrigerant to heat an interior of the vehicle. The air conditioning system (30) also includes a fan (32) provided in connection with the external condenser (31), and a blower (39) provided in connection with the evaporators (37,38) and is configured to circulate the conditioned air into the cabin of the vehicle.
[036] The heat pump system (100), according to an embodiment, further includes an internal condenser (36), a plurality of direction control valves (v1, v2, v3, v4, v5), a plurality of non-return valves (nrv1, nrv2), and an external refrigerant storage tank (33). In an embodiment, the internal condenser (36) is connected in the air conditioning refrigerant circuit, provided in communication with the compressor (35) and the first evaporator (37). The internal condenser (36) is configured to receive the compressed (high temperature and high pressure) gaseous refrigerant from the compressor (35), wherein the refrigerant is condensed to a high-temperature liquid refrigerant in the internal condenser (36). This high-temperature liquid refrigerant exiting from the internal condenser (36) is then supplied to the external condenser (31) in the cooling mode and chiller (12) in heat pump mode via the refrigerant circuit. Further, in an embodiment, the heat pump system (100) includes a first direction control valve (v1) connected in the battery coolant circuit, provided in connection with the heater (13) and battery (11) of the battery cooling system (10). The first direction control valve (v1) is configured to selectively direct the flow of the coolant from the heater (13) to the battery (11) and from the heater (13) to the first pump (P1) by bypassing the battery (11). A second direction control valve (v2) is connected in the refrigerant circuit of the air conditioning system (30), wherein the second direction control valve (v2) is provided in connection with the external condenser (31), the internal condenser (36), and the external refrigerant storage tank (33). In an embodiment, the first and second direction control valves (v1, v2) are 3/2-way direction control valves. The external refrigerant storage tank (33) is connected in the refrigerant circuit and is provided in connection with the heat exchanger (34). Further, a first non-return valve (nrv1) is connected in the refrigerant circuit and is provided in communication with the external refrigerant storage tank (33) and the external condenser (31). A second non-return valve (nrv2) is connected in the refrigerant circuit and is provided in connection with the chiller (12) and the first and second evaporators (37, 38).
[037] Further, in the heat pump system (100), the chiller (12) is configured to receive the battery coolant pumped by the first pump (P1) via the battery coolant circuit and receive the refrigerant from a third expansion valve (xv3) connected with the heat exchanger (34) of the air conditioning system (30), via the refrigerant circuit. Further, the chiller (12) is configured to transfer heat from the coolant to the refrigerant, wherein the refrigerant exiting from the chiller (12) has a higher temperature than the refrigerant entering the chiller (12), therefore reducing the energy required by the compressor (35) of the air conditioning system (30) to convert the refrigerant into the high temperature and high-pressure gaseous refrigerant.
[038] In an embodiment, the heater (13), the battery (11) of the vehicle, and the first pump (P1) are connected in a first battery coolant line (bcl1). The first direction control valve (v1) is connected between the battery (11) and the heater (13) via the first battery coolant line (bcl1). The coolant passing through the first battery coolant line (bcl1) is selectively heated by the heater (13) and the battery (11) before passing through the first pump (P1). In an embodiment, the heater (13) is an electric heater (13). In another embodiment, the heater (13) is a PTC heater (13). The first pump (P1) is configured to pump the heated coolant to the chiller (12) via the battery first coolant line (bcl1). A second battery coolant line (bcl2) is connected between a port of the first direction control valve (v1) and a point between the battery (11) and the first pump (P1), bypassing the battery (11). The coolant passing through the second battery coolant line (bcl2) bypasses the battery (11) and directly supplies the coolant received through the first direction control valve (v1) to the first pump (P1). The first direction control valve (v1) is configured to selectively allow the flow of the coolant through the battery (11) and bypass the battery (11) through the second battery coolant line (bcl2). Further, the chiller (12) is disposed between the first battery coolant line (bcl1) and a third battery coolant line (bcl3). The third battery coolant line (bcl3) connects the chiller (12) to a third direction control valve (v3), wherein the cooled coolant exiting from the chiller (12) flows through the third battery coolant line (bcl3).
[039] Further, the radiator (25) of the vehicle is connected to the third direction control valve (v3) via a first e-drive coolant line (ecl1). A fourth direction control valve (v4) is disposed between the radiator (25) and the third direction control valve (v3) on the first e-drive coolant line (ecl1). A second pump (P2) is disposed on a second e-drive coolant line (ecl2), wherein the second e-drive coolant line (ecl2) connects the second pump (P2) with the third direction control valve (v3) and the front e-drive (24). The third direction control valve (v3) is configured to selectively allow the flow of the coolant through any two of the battery coolant lines (bcl1, bcl3) and the e-drive coolant lines (ecl1, ecl2) connected to the third direction control valve (v3). In an embodiment, the third direction control valve (v3) is a 4/2 direction control valve. The second pump (P2) is configured to pump the coolant received through the third direction control valve (v3) towards the front e-drive (24), whereby the coolant passes through the front e- drive (24) absorbing the heat generated from the front e-drive (24). Further, a third e-drive coolant line (ecl3) connects the onboard charger (21), dc-dc converter (22), and the rear e-drive (23) with the front e-drive (24). A stream of coolant pumped by the second pump (P2) flows through the third e-drive coolant line (ecl3), wherein the heat from the rear e-drive (24) is absorbed by the stream of coolant. A fourth e-drive coolant line (ecl4) connects the rear e- drive (24) with the third e-drive coolant line (ecl3) coming out of the front e-drive (24). A fifth e-drive coolant line (ecl5) diverts a stream of the coolant towards the fourth direction control valve (v4). Furthermore, a sixth e-drive coolant line (ecl6) connects the fourth and third e-drive coolant lines (ecl4, ecl3) with the radiator (25) of the vehicle, wherein the coolant from the fourth and third e-drive coolant lines (ecl4, ecl3) flows through the radiator (25) to absorb the heat dissipated by the radiator (25).
[040] A first refrigerant line (rl1) connects the chiller (12) with the heat exchanger (34), wherein the heated refrigerant exiting from the chiller (12) flows into the heat exchanger (24) through the first refrigerant line (rl1). A second refrigerant line (rl2) connects the heat exchanger (24) with the compressor (35) and the internal condenser (36). The second refrigerant line (rl2) also includes the second direction control valve (v2) disposed between the internal condenser (36) and the external condenser (31). The second refrigerant line (rl2) extends up to the external condenser (31). A fourth refrigerant line (rl4) is disposed between the second direction control valve (v2) and the external refrigerant storage tank (33). The second direction control valve (v2) is configured to selectively direct the flow of the refrigerant in any two of the three refrigerant lines (rl2, rl4, rl6) connected to the ports of the second direction valve (v2). Furthermore, a third refrigerant line (rl3) is connected between the heat exchanger (34) and the chiller (12). The third expansion valve (xv3) is connected between the chiller (12) and the heat exchanger (34) on the third refrigerant line (rl3). The third expansion valve (xv3) is configured to control the flow of the refrigerant entering the chiller (12). A fifth refrigerant line (rl5) connects the external condenser (31) with the heat exchanger (34). The first non-return valve (nrv1) and the external refrigerant storage tank (33) are disposed on the fifth refrigerant line (rl5) between the external condenser (31) and the heat exchanger (34). The first non-return valve (nrv1) is configured to restrict the flow of the refrigerant from the external refrigerant storage tank (33) to the external condenser (31). Further, a sixth refrigerant line (rl6) is provided between the first and the third refrigerant line (rl1, rl3). The second non-return valve (nrv2), the first and second evaporator (37, 38), the first and second expansion valves (xv1, xv2), and the fifth direction control valve (v5) are disposed on the sixth refrigerant line (rl6). A stream of the refrigerant from the heat exchanger (34) is diverted to the sixth refrigerant line (rl6), wherein the fifth direction control valve (v5) comprising of a solenoid valve is configured to selectively allow the flow of refrigerant through the first and second expansion valves (xv1, xv2). The first and second expansion valves (xv1, xv2) are configured to control the amount of refrigerant flowing into the first and second evaporators (37, 38) respectively. In an embodiment, the first and second expansion valves (xv1, xv2) are thermal expansion valves. In an embodiment, the first and second evaporators (37, 38) are arranged parallel with the blower (39) disposed between the first and second evaporators (37, 38). The second non-return valve (nrv2) is configured to restrict the flow of the refrigerant from the first refrigerant line (rl1) to the evaporators (37, 38).
[041] The heat pump system (100) is configured to operate in a plurality of modes, wherein the heat from the ambient, the battery (11) and the heater (13), and the electric drive/ power train is selectively utilized to heat the coolant flowing through the battery coolant circuit and the e-drive coolant circuit, and the heat from the coolant is transferred to the refrigerant in the chiller (12) of the battery cooling system (10).
Operation in first mode:
[042] In one embodiment, the heat pump system (100) is configured to operate in a first mode when the coolant exiting from the chiller (12) has a lower temperature than the ambient temperature and the vehicle is in any one of an idle condition or low-speed condition. In the first mode of operation of the heat pump system (100), as shown in Figure 2, the coolant exiting from the chiller (12) and the coolant flowing in the e-drive coolant circuit is diverted towards the radiator (25) of the vehicle. In an embodiment, the third direction control valve (v3) is actuated to allow the flow of the coolant from the third battery coolant line (bcl3) to the second e-drive coolant line (ecl2), wherein the coolant from the third and fourth e-drive coolant lines (elc3, ecl4) is directed towards the radiator (25) of the vehicle through the sixth e-drive coolant line (ecl6). The coolant is heated in the radiator (25) by the ambient air. The heated coolant exiting from the radiator (25) is then diverted towards the chiller (12), wherein the fourth direction control valve (v4) is actuated to allow the flow of the heated coolant from the radiator (25) to a coolant inlet of the chiller (12) via the first e-drive coolant line (ecl1). Further, the third direction control valve (v3) is actuated to allow the flow of the heated coolant from the first e-drive coolant line (ecl1) to the first battery coolant line (bcl1), bypassing the heater (13). The first direction control valve (v1) is actuated to pass the coolant through the battery (11) via the first battery coolant line (bcl1). The heat from the coolant is transferred to the refrigerant. This heated refrigerant is then diverted into the refrigerant circuit, wherein the air conditioning system (30) is operated to provide heated air into the cabin of the vehicle.
Operation in second mode:
[043] In an embodiment, the heat pump system (100) is configured to operate in a second mode when the temperature of the coolant exiting from the chiller (12) is lower than a temperature of the coolant exiting from the rear e-drive (23) and the front e-drive (24). In the second mode, as shown in Fig.3, the heat pump system (100) is configured to divert the flow of the coolant exiting from the chiller (12) towards the front e-drive (24) and the rear e-drive (23), wherein the heat dissipated from the e-drives/powertrain is utilized to heat the coolant flowing through the e-drive coolant circuit. In an embodiment, in the second mode of operation of the heat pump system (100), the third valve (v3) is actuated to allow the flow of the low-temperature coolant exiting from the chiller (12) through the third battery coolant line (bcl3) to the second e-drive coolant line (ecl2). The coolant is passed through the rear e-drive (24) via the third e-drive coolant line (ecl3), wherein the heat dissipated from the rear e-drive (23) is absorbed by the coolant, and the heated coolant exits from the rear e-drive (23) via the fourth e-drive coolant line (ecl4). Further, the stream of coolant flowing through the front e-drive (25) is also heated and this stream combines with the coolant from the fourth e-drive coolant line (ecl4) and flows through the fifth e-drive coolant line (ecl5) towards the third direction control valve (v3). The fourth direction control valve (v4) is actuated to connect the fifth e-drive coolant line (ecl5) with the first e-drive coolant line (ecl1). Further, the third direction control valve (v3) is actuated to divert the flow of the heated coolant from the first e-drive coolant line (ecl1) to the first battery coolant line (bcl1). The first direction control valve (v1) is actuated to bypass the flow of coolant through the battery (11), passing the coolant via the second battery coolant line (bcl2) towards the first pump (P1) and into the chiller (12), wherein the heat from the heated coolant is transferred to the refrigerant in the chiller (12).
Operation in third mode:
[044] In an embodiment, the heat pump system (100) is configured to operate in a third mode when the temperature exiting the chiller (12) is lower than the temperature of the coolant in the e-drive coolant circuit and the temperature of the coolant in the e-drive coolant circuit is lower than the temperature of the battery coolant circuit. In the third mode of operation as depicted in Fig.4, the coolant exiting from the chiller (12) is passed through the e-drive coolant circuit, wherein the heat from the rear e-drive (23) and the front e-drive (24) is utilized to heat the coolant and the coolant is then passed through the battery (11) of the vehicle, wherein the heat from the battery (11) is utilized to heat the coolant at a higher temperature and the heat from the coolant is transferred to the refrigerant in the chiller (12). In an embodiment, wherein the heat pump system (100) operates in the third mode, the third direction control valve (v3) is actuated to allow the flow of the coolant from the third battery coolant line (bcl3) to the second e-drive coolant line (ecl2). The fourth direction control valve (v4) is actuated to allow the flow of the heated coolant from the fifth e-drive coolant line (ecl5) to the first e-drive coolant drive (ecl5). Further, the third direction control valve (v3) is actuated to allow the flow of the heated coolant from the first e-drive coolant line (ecl1) to the first coolant drive, wherein the first direction control valve (v1) is actuated to pass the coolant through the battery (11).
Operation in fourth mode:
[045] In an embodiment, the heat pump system (100) is configured to operate in a fourth mode when the temperature of the battery (11) and the e-drive are low i.e., no heat is dissipated from the battery (11) and the powertrain of the vehicle, and the ambient temperature is low. In the fourth mode of operation, as shown in Fig.5, the heat pump system (100) is configured to divert the flow of the coolant exiting from the chiller (12) to the heater (13) of the battery cooling system (10), wherein the heater (13) is operated to heat the coolant to a predetermined temperature. The heated coolant exiting from the heater (13) is diverted towards the chiller (12), wherein the heat from the coolant is transferred to the refrigerant. In an embodiment, wherein the heat pump system (100) operates in the fourth mode the third direction control valve (v3) is actuated to allow the flow of the coolant exiting from the chiller (12) through the third battery coolant line (bcl3) to the first battery coolant line (bcl1) and the first direction control valve (v1) is actuated to divert the flow of the heated coolant to the second battery coolant line (bcl2) by bypassing the battery (11).
Operation in fifth mode:
[046] In an embodiment, the heat pump system (100) is configured to operate in fifth mode when the heat generated/ dissipated by the battery (11) is above a predetermined threshold value, wherein the heat dissipated by the battery (11) is sufficient to heat the coolant exiting from the chiller (12). In the fifth mode of operation of the heat pump system (100), as shown in Fig.6, the coolant exiting from the chiller (12) is directed towards the battery (11), wherein the coolant passing through the battery (11) absorbs the heat dissipated from the battery (11) and the heated coolant then transfers the heat to the refrigerant in the chiller (12). In an embodiment, in the fifth mode of operation of the heat pump system (100), the third direction control valve (v3) is actuated to connect the third battery coolant line (bcl3) with the first battery coolant line (bcl1) so that the coolant exiting from the chiller (12) is diverted to the battery (11) of the vehicle. In this mode of operation of the heat pump system (100), the heater (13) is in an OFF condition. The coolant passing through the battery (11) gets heated due to the absorption of heat dissipated from the battery (11). The heated coolant exiting from the battery (11) is then pumped by the first pump (P1) into the chiller (12), wherein the heat from the coolant is transferred to the refrigerant.
Operation in sixth mode:
[047] In an embodiment, the heat pump system (100) is configured to operate in a sixth mode of operation when the heat dissipated by the battery (11) is within a predefined range and below the predetermined threshold level such that the heat dissipated from the battery (11) is not sufficient to heat the coolant to the predetermined temperature, and the coolant from the e-drive coolant circuit is not flowing through the battery coolant circuit.
In the sixth mode of operation of the heat pump system (100), the coolant exiting from the chiller (12) is diverted towards the heater (13) of the battery cooling system (10), wherein the heater (13) heats the coolant to a predefined temperature. The heated coolant is then passed through the battery (11), wherein the heat dissipated by the battery (11) is absorbed by the coolant which further heats the coolant. The heated coolant exiting from the battery (11) is pumped by the first pump (P1) into the chiller (12), wherein the heat from the coolant is transferred to the refrigerant, heating the refrigerant. In an embodiment, in the sixth mode of operation of the heat pump system (100), the third direction control valve (v3) is actuated to divert the flow of the coolant exiting from the chiller (12) via the third battery coolant line (bcl3) to the first battery coolant line (bcl1), wherein the heater (13) is actuated to an ON condition. The heated coolant is diverted to the battery (11) by actuating the first direction control valve (v1) to close the flow of the coolant through the second battery coolant line (bcl2).
Operation in seventh mode:
[048] In an embodiment, the heat pump system (100) is configured to operate in a seventh mode (not shown in Figures), wherein the coolant is heated by passing the coolant via the radiator (25) and the battery cooling system (10), and the heater (13) is actuated to the ON condition to further heat the coolant.
Operation in eighth mode:
[049] In an embodiment, the heat pump system (100) is configured to operate in an eighth mode, wherein the coolant exiting from the chiller (12) is heated by passing the coolant through the e-drive coolant circuit, wherein the heat dissipated from the motors is absorbed by the coolant, and the heated coolant is further heated by passing the coolant via the heater (13), wherein the heater (13) is actuated to the ON condition to further heat the coolant.
[050] The embodiments herein disclose methods for heating the coolant in the heat pump system (100) for pre-heating the refrigerant of the air-conditioning system (30) of the electric/hybrid vehicle.
Method 1:
[051] In an embodiment, a method for heating a coolant in the heat pump system (100), as depicted in Fig. 2, includes diverting the coolant exiting from the chiller (12) of the battery cooling system (10) to the radiator (25) of the vehicle via the e-drive coolant circuit, when a temperature of the coolant exiting from the chiller (12) is lower than an ambient temperature and the vehicle is in any one of an idle condition and low-speed condition, wherein the coolant absorbs the heat dissipated by the radiator (25). The method further includes diverting the heated coolant exiting from the radiator (25) to a coolant receiving inlet of the chiller (12) via the battery coolant circuit, wherein the heat from the coolant is absorbed by the refrigerant flowing into the chiller (12) through heat exchange. In an embodiment, the method includes actuating the third direction control valve (v3) to allow the flow of the coolant from the third battery coolant line (bcl3) to the second e-drive coolant line (ecl2). The method further includes actuating the fourth directional valve (v4) to allow the flow of the heated coolant from the radiator (25) to the coolant inlet of the chiller (12) via the first e-drive coolant line (ecl1). The method also includes actuating the third direction control valve (v3) to allow the flow of the heated coolant from the first e-drive coolant line (ecl1) to the first battery coolant line (bcl1).
Method 2:
[052] In another embodiment, a method for heating a coolant in a heat pump system (100), as depicted in Fig. 3, includes diverting the flow of the coolant exiting from the chiller (12) to the power train of the vehicle comprising a rear e-drive (23) and a front e-drive (24) via the e-drive coolant circuit, when the temperature of the coolant exiting from the chiller (12) is lower than the temperature of coolant exiting from the powertrain, wherein the heat dissipated from the powertrain is absorbed by the coolant, heating the coolant to a higher temperature. The method further includes diverting the flow of the heated coolant to the first pump (P1) via the battery coolant circuit, wherein the pump (P1) pumps the heated coolant into the chiller (12) coolant inlet, whereby the refrigerant flowing into the chiller (12) absorbs the heat from the coolant in the chiller (12).
[053] In an embodiment, the method includes actuating the third direction control valve (v3) to allow the flow of the low-temperature coolant exiting from the chiller (12) through the third battery coolant line (bcl3) to the second e-drive coolant line (ecl2). Further, the method includes actuating the fourth direction control valve (v4) to connect the fifth e-drive coolant line (ecl5) with the first e-drive coolant line (ecl1) and actuating the third direction control valve (v3) to divert the flow of the heated coolant from the first e-drive coolant line (ecl1) to the first battery coolant line (bcl1). The method also includes actuating the first direction control valve (v1) to bypass the flow of coolant through the battery (11).
Method 3:
[054] In an embodiment, a method for heating the coolant with a heat pump system (100), as depicted in Fig. 4, includes diverting the flow of the coolant exiting from the chiller (12) to the e-drive coolant circuit, when the temperature exiting the chiller (12) is lower than the temperature of the coolant in the e-drive coolant circuit and the temperature of the coolant in the e-drive coolant circuit is lower than the temperature of the battery coolant circuit, wherein the heat from the rear e-drive and the front e-drive is utilized to heat the coolant. Further, the method includes diverting the coolant from the e-drive coolant circuit to the battery (11) of the vehicle via the battery coolant circuit, wherein the heat from the battery (11) is utilized to heat the coolant at a higher temperature. The method also includes diverting the heated coolant from the battery (11) to the chiller (12) wherein the heat from the coolant is transferred to the refrigerant in the chiller (12). In an embodiment, the method includes actuating the third direction control valve (v3) to allow the flow of the coolant from the third battery coolant line (bcl3) to the second e-drive coolant line (ecl2) and actuating the fourth direction control valve (v4) to allow the flow of the heated coolant from the fifth e-drive coolant line (ecl5) to the first e-drive coolant drive (ecl5). Further, the method includes actuating the third direction control valve (v3) to allow the flow of the heated coolant from the first e-drive coolant line (ecl1) to the first battery coolant line (bcl1) and actuating the first direction control valve (v1) to pass the coolant through the battery (11).
Method 4:
[055] In an embodiment, a method for heating a coolant in a heat pump system (100), Fig.5, includes diverting the flow of the coolant exiting from the chiller (12) to the heater (13) of the battery cooling system (10), when the temperature of the battery (11) and the e-drive are low and the ambient temperature is low, wherein the heater (13) is operated to heat the coolant to a predetermined temperature. The method further includes diverting the heated coolant exiting from the heater (13) to the chiller (12), wherein the heat from the coolant is transferred to the refrigerant in the chiller (12). In an embodiment, the method includes actuating the third direction control valve (v3) to allow the flow of the coolant exiting from the chiller (12) through the third battery coolant line (bcl3) to the first battery coolant line (bcl1) and actuating the first direction control valve (v1) to divert the flow of the heated coolant to the second battery coolant line (bcl2) by bypassing the battery (11).
Method 5:
[056] In an embodiment, a method for heating the coolant in the heat pump system (100), as depicted in Fig.6, includes diverting the coolant exiting from the chiller (12) towards the battery (11), when heat dissipated from the battery (11) is sufficient to heat the coolant, wherein the coolant passing through the battery (11) absorbs the heat dissipated from the battery (11). The method further includes diverting the heated coolant exiting from the battery (11) to the chiller (12), wherein the heat from the coolant is transferred to the refrigerant in the chiller (12). In an embodiment, the method includes actuating the third direction control valve to connect the third battery coolant line with the first battery coolant line so that the coolant exiting from the chiller (12) is diverted to the battery (11) of the vehicle. The method also includes actuating the first pump (P1) to pump the heated coolant to the chiller (12).
Method 6:
[057] In an embodiment, a method for heating a coolant in a heat pump system (100), as shown in Fig. 7, includes diverting the coolant exiting from the chiller (12) towards the heater (13) of the battery cooling system (10), when the heat dissipated from the battery (11) is not sufficient to heat the coolant to the predetermined temperature, and the coolant from the e-drive coolant circuit is not flowing through the battery coolant circuit, wherein the heater (13) heats the coolant to a predefined temperature. Further, the method includes passing the heated coolant through the battery (11), wherein the heat dissipated by the battery (11) is absorbed by the coolant which further heats the coolant. The method also includes pumping the heated coolant exiting from the battery (11) by the first pump (P1) into the chiller (12), wherein the heat from the coolant is transferred to the refrigerant, heating the refrigerant.
[058] In an embodiment, the method includes actuating the third direction control valve (v3) to divert the flow of the coolant exiting from the chiller (12) via the third battery coolant line (bcl3) to the first battery coolant line (bcl1), wherein the heater (13) is actuated to an ON condition. The method also includes actuating the first direction control valve (v1) to close the flow of the coolant through the second battery coolant line (bcl2).
[059] The technical advantages achieved by the embodiments disclosed herein include increased efficiency due to utilization of the heat wasted in the vehicle, reduction in power consumption therefore increasing the range of the vehicle, elimination of additional heater thus reducing the cost of the system, utilizing existing components of the battery cooling system such as the chiller thus reducing cost of plumbing and additional components, using internal condenser instead of an air PTC heater which leads to cutting down of cost, reduction in consumption of energy, elimination of high voltage component in cabin and reduction in weight of the system, and independent of ambient conditions for providing heating effect in the cabin.
[060] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
, Claims:1. A heat pump system (100) of an electric vehicle, comprising:
a battery cooling system (10) comprising a battery (11), a chiller (12), a heater (13), and a first pump (P1), connected in a battery coolant circuit comprising a plurality of battery coolant lines (bcl1, blc2, blc3), and configured to circulate the coolant for cooling the battery (11);
an electric drive cooling system (20) integrated with the battery cooling system (10), comprising an onboard charger (21), a dc-dc converter (22), a powertrain of the vehicle comprising a front e-drive (24) and a rear e-drive (23), a radiator (25), and a second pump (P2), connected in an e-drive coolant circuit comprising a plurality of e-drive coolant lines (ecl1, ecl2, ecl3, ecl4, ecl5, ecl6), and configured to circulate the coolant for cooling the powertrain of the vehicle;
an air conditioning system (30) of the vehicle integrated with the battery cooling system (10) of the vehicle comprising a compressor (35), an external condenser (31), a first evaporator (37), a second evaporator (38), a first expansion valve (xv1), a second expansion valve (xv2), and a heat exchanger (34) connected in a refrigerant circuit comprising a plurality of refrigerant lines (rl1, rl2, rl3, rl4, rl5, rl6), and configured to circulate the refrigerant to cool and heat an interior of the vehicle;
an internal condenser (36) connected in the refrigerant circuit, provided in communication with the compressor (35) and the first evaporator (37);
a plurality of direction control valves (v1, v2, v3, v4, v5) disposed at predetermined positions in the battery coolant circuit, the e-drive coolant circuit, and the refrigerant coolant circuit, configured to selectively regulate a direction of flow of the coolant and the refrigerant in the heat pump system (100); and
a plurality of non-return valves (nrv1, nrv2) disposed in the refrigerant circuit, configured to restrict a flow of the refrigerant in a predetermined direction,
wherein
the chiller (12) is configured to:
receive the coolant pumped by the first pump (P1) via the battery coolant circuit, and receive the refrigerant from a third expansion valve (xv3) connected with the heat exchanger (34) via the refrigerant circuit; and
transfer heat from the coolant to the refrigerant, wherein the refrigerant exiting from the chiller (12) has higher temperature than the refrigerant entering the chiller (12),
wherein the heat pump system (100) is configured to selectively heat the coolant flowing through the battery cooling system (10) and the electric drive cooling system (20) for pre- heating the refrigerant flowing through the air conditioning system (30) by heat exchange in the chiller (34) to circulate heated air in a cabin of the vehicle.
2. The heat pump system (100) as claimed in claim 1, wherein,
a first direction control valve (v1) is connected in the battery coolant circuit, provided in communication with the heater (13) and battery (11) of the battery cooling system (10), and configured to selectively direct the flow of the coolant from the heater (13) to the battery (11) and from the heater (13) to the first pump (P1) bypassing the battery (11);
a second direction control valve (v2) is connected in the refrigerant circuit of the air conditioning system (30), provided in communication with the external condenser (31), the internal condenser (36), and the external refrigerant storage tank (33);
a first non-return valve (nrv1) connected in the refrigerant circuit; and
a second non-return valve (nrv2) connected in the refrigerant circuit and provided in communication with the chiller (12) and the first and second evaporators (37, 38),
wherein
the first and second direction control valves (v1, v2) are 3/2 direction control valves.
3. The heat pump system (100) as claimed in claim 2, wherein the heat pump system (100) comprises an external refrigerant storage tank (33) connected in the refrigerant circuit and provided in communication with the heat exchanger (34); and
the first non-return valve (nrv1) is provided in communication with the external refrigerant storage tank (33) and the external condenser (31).
4. The heat pump system (100) as claimed in claim 2, wherein,
a first battery coolant line connects the heater (13), the battery (11), the first pump (P1), and the first direction control valve (v1), wherein the coolant passing through the first battery coolant line (bcl1) is selectively heated by the heater (13) and the battery (11) before passing through the first pump (P1);
a second battery coolant line (bcl2) is connected between a port of the first direction control valve (v1) and a point between the battery (11) and the first pump (P1), bypassing the battery (11), wherein the coolant passing through the second battery coolant line (bcl1) bypasses the battery (11) and directly supplies the coolant received through the first direction control valve (v1) to the first pump (P1);
a third battery coolant line (bcl3) connects the chiller (12) to a third direction control valve (v3), wherein the coolant exiting from the chiller (12) flows through the third battery coolant line (bcl3); and
the first direction control valve (v1) is configured to selectively allow the flow of the coolant through the battery (11) and bypass the battery (11) through the second battery coolant line (bcl2).
5. The heat pump system (100) as claimed in claim 2, wherein,
a first e-drive coolant line (ecl1) connects the radiator (25), a third direction control valve (v3), and a fourth direction control valve (v4);
a second e-drive coolant line (ecl2) connects the second pump (P2) with the third direction control valve (v3) and the front e-drive (24);
a third e-drive coolant line (ecl3) connects the onboard charger (21), the dc-dc converter (22), and the rear e-drive (23) with the front e-drive (24), wherein a stream of the coolant pumped by the second pump (P2) flows through the third e-drive coolant line (ecl3);
a fourth e-drive coolant line (ecl4) connects the rear e- drive (24) with the third e-drive coolant line (ecl3);
a fifth e-drive coolant line (ecl5) diverts a stream of the coolant towards the fourth direction control valve (v4);
a sixth e-drive coolant line (ecl6) connects the fourth and third e-drive coolant lines (ecl4, ecl3) with the radiator (25) of the vehicle; and
the third direction control valve (v3) is configured to selectively allow the flow of the coolant through any two of the battery coolant lines (bcl1, bcl3) and the e-drive coolant lines (ecl1, ecl2) connected to the third direction control valve (v3),
wherein
the third direction control valve (v3) is a 4/2 direction control valve, and the fourth direction control valve (v4) is a 3/2 direction control valve.
6. The heat pump system (100) as claimed in claim 2, wherein,
a first refrigerant line connects the chiller (12) with the heat exchanger (34), wherein the heated refrigerant exiting from the chiller (12) flows into the heat exchanger (24) through the first refrigerant line (rl1);
a second refrigerant line connects the heat exchanger (24) with the compressor (35) and the internal condenser (36) and the second direction control valve (v2) disposed between the internal condenser (36) and the external condenser (31);
a third refrigerant line (rl3) connects the heat exchanger (34) and the chiller (12), and the third expansion valve (xv3) disposed between the chiller (12) and the heat exchanger (34);
a fourth refrigerant line (rl4) connects the second direction control valve (v2) and the external refrigerant storage tank (33);
a fifth refrigerant line (rl5) connects the external condenser (31) with the heat exchanger (34), wherein the first non-return valve (nrv1) and the external refrigerant storage tank (33) are disposed on the fifth refrigerant line (rl5) between the external condenser (31) and the heat exchanger (34);
a sixth refrigerant line (rl6) is connected between the first and the third refrigerant line (rl1, rl3), wherein the second non-return valve (nrv2), the first and second evaporator (37, 38), the first and second expansion valves (xv1, xv2), and a fifth direction control valve (v5) are disposed on the sixth refrigerant line (rl6);
the second direction control valve (v2) is configured to selectively direct the flow of the refrigerant in any two of the three refrigerant lines (rl2, rl4, rl6) connected to a plurality of ports of the second direction valve (v2);
the first non-return valve (nrv1) is configured to restrict the flow of the refrigerant from the external refrigerant storage tank (33) to the external condenser (31); and
the second non-return valve (nrv2) is configured to restrict the flow of the refrigerant from the first refrigerant line (rl1) to the evaporators (37, 38).
7. The heat pump system as claimed in claim 1, wherein,
the heat pump system (100) is configured to operate in a first mode when the coolant exiting from the chiller (12) has a lower temperature than the ambient temperature and the vehicle is in any one of an idle condition or low-speed condition,
wherein
the coolant exiting from the chiller (12) and the coolant flowing in the e-drive coolant circuit is diverted towards the radiator (25) of the vehicle; and
the coolant absorbs the heat from the radiators and the heat is transferred to the refrigerant in the chiller (12).
8. The heat pump system (100) as claimed in claim 1, wherein, the heat pump system (100) is configured to operate in a second mode when a temperature of the coolant exiting from the chiller (12) is lower than a temperature of the coolant exiting from the rear e-drive (23) and the front e-drive (24),
wherein
the heat pump system (100) is configured to divert the flow of the coolant exiting from the chiller (12) towards the front e-drive (24) and the rear e-drive (23);
the heat dissipated from the powertrain of the vehicle is utilized to heat the coolant flowing through the e-drive coolant circuit; and
the heat absorbed by the coolant from the powertrain is transferred to the refrigerant in the chiller (12).

9. The heat pump system (100) as claimed in claim 1, wherein the heat pump system (100) is configured to operate in a third mode when a temperature of the coolant exiting the chiller (12) is lower than a temperature of the coolant in the e-drive coolant circuit and the temperature of the coolant in the e-drive coolant circuit is lower than a temperature of the battery coolant circuit,
wherein
the coolant exiting from the chiller (12) is passed through the e-drive coolant circuit, wherein the heat from the rear e-drive (23) and the front e-drive (24) is utilized to heat the coolant and the coolant is then passed through the battery (11) of the vehicle;
the heat from the battery (11) is utilized to heat the coolant at a higher temperature; and
the heat from the coolant is transferred to the refrigerant in the chiller (12).
10. The heat pump system as claimed in claim 1, wherein the heat pump system (100) is configured to operate in a fourth mode when a temperature of the battery (11) and the powertrain of the vehicle are below a threshold value,
wherein
the coolant exiting from the chiller (12) is diverted to the heater (13) of the battery cooling system (10), and the heater (13) is operated to heat the coolant to a predetermined temperature; and
the heated coolant exiting from the heater (13) is diverted towards the chiller (12), wherein the heat from the coolant is transferred to the refrigerant.
11. The heat pump system (100) as claimed in claim 1, wherein the heat pump system (100) is configured to operate in a fifth mode when the heat dissipated by the battery (11) is above a predetermined threshold value,
wherein
the coolant exiting from the chiller (12) is directed towards the battery (11);
the coolant passing through the battery (11) absorbs the heat dissipated from the battery (11); and
the heated coolant transfers the heat to the refrigerant in the chiller (12).
12. The heat pump system (100) as claimed in claim 1, wherein the heat pump system (100) is configured to operate in a sixth mode of operation when the heat dissipated by the battery (11) is within a predefined range and below a predetermined threshold level,
wherein
the coolant exiting from the chiller (12) is diverted towards the heater (13) of the battery cooling system (10), wherein the heater (13) heats the coolant to a predefined temperature;
the heated coolant is passed through the battery (11), wherein the heat dissipated by the battery (11) is absorbed by the coolant; and
the heated coolant exiting from the battery (11) is pumped by the first pump (P1) into the chiller (12), wherein the heat from the coolant is transferred to the refrigerant, heating the refrigerant.
13. The heat pump system (100) as claimed in claim 1, wherein the heat pump system (100) is configured to operate in a seventh mode, wherein the coolant is heated by passing the coolant via the radiator (25) and the battery cooling system (10), and the heater (13) is actuated to the ON condition to further heat the coolant.
14. The heat pump system (100) as claimed in claim 1, wherein the heat pump system (100) is configured to operate in an eighth mode, wherein the coolant exiting from the chiller (12) is heated by passing the coolant through the e-drive coolant circuit,
wherein
the heat dissipated from the powertrain of the vehicle is absorbed by the coolant, and the heated coolant is heated by passing the coolant via the heater (13); and
the heater (13) is actuated to an ON condition to heat the coolant.
15. A method for heating a coolant in a heat pump system (100) comprising a battery cooling system (10), an e-drive cooling system (20) and an air conditioning system (30) of the vehicle integrated with the battery cooling system (10), an internal condenser (36) provided in communication with a first evaporator (37) of the air conditioning system (30), a plurality of direction control valves (v1,v2,v3,v4,v5) disposed at predetermined positions and configured to selectively direct flow of the coolant and a refrigerant in the heat pump system (100), a plurality of non-return valves (nrv1, nrv2) provided in a refrigerant circuit of the air conditioning system (30), and an external refrigerant storage tank (33), the method comprising:
diverting the coolant exiting from a chiller (12) of the battery cooling system (10) to a radiator (25) of the vehicle via a e-drive coolant circuit, when a temperature of the coolant exiting from the chiller (12) is lower than an ambient temperature and the vehicle is in any one of an idle condition and low-speed condition, wherein the coolant absorbs the heat dissipated by the radiator (25); and
diverting the heated coolant exiting from the radiator (25) to a coolant receiving inlet of the chiller (12) via a battery coolant circuit, wherein the heat from the coolant is absorbed by the refrigerant flowing into the chiller (12) through heat exchange.
16. The method as claimed in claim 15, wherein the method comprises,
actuating a third direction control valve (v3) to allow the flow of the coolant from a third battery coolant line (bcl3) to a second e-drive coolant line (ecl2);
actuating a fourth directional valve (v4) to allow the flow of the heated coolant from the radiator (25) to the coolant inlet of the chiller (12) via a first e-drive coolant line (ecl1); and
actuating the third direction control valve (v3) to allow the flow of the heated coolant from the first e-drive coolant line (ecl1) to a first battery coolant line (bcl1).
17. A method for heating a coolant in a heat pump system comprising a battery cooling system (10), an e-drive cooling system (20) and an air conditioning system (30) of the vehicle integrated with the battery cooling system (10), an internal condenser (36) provided in communication with a first evaporator (37) of the air conditioning system (30), a plurality of direction control valves (v1,v2,v3,v4,v5) disposed at predetermined positions and configured to selectively direct flow of the coolant and a refrigerant in the heat pump system (100), a plurality of non-return valves (nrv1, nrv2) provided in a refrigerant circuit of the air conditioning system (30), and an external refrigerant storage tank (33); the method comprising:
diverting the flow of the coolant exiting from the chiller (12) to a power train of the vehicle comprising a rear e-drive (23) and a front e-drive (24) via a e-drive coolant circuit, when the temperature of the coolant exiting from the chiller (12) is lower than the temperature of coolant exiting from the powertrain;
wherein the heat dissipated from the power train is absorbed by the coolant, heating the coolant to a higher temperature; and
diverting the flow of the heated coolant to a first pump (P1) via a battery coolant circuit, wherein the first pump (P1) pumps the heated coolant into the chiller (12) coolant inlet, whereby the refrigerant flowing into the chiller (12) absorbs the heat from the coolant in the chiller (12).
18. The method as claimed in claim 17, wherein the method comprises:
actuating a third direction control valve (v3) to allow the flow of the low-temperature coolant exiting from the chiller (12) through a third battery coolant line (bcl3) to a second e-drive coolant line (ecl2);
actuating a fourth direction control valve (v4) to connect a fifth e-drive coolant line (ecl5) with a first e-drive coolant line (ecl1); and
actuating the third direction control valve (v3) to divert the flow of the heated coolant from the first e-drive coolant line (ecl1) to a first battery coolant line (bcl1); and
actuating a first direction control valve (v1) to bypass the flow of coolant through a battery (11) of the vehicle.
19. A method for heating a coolant in a heat pump system comprising a battery cooling system (10), an e-drive cooling system (20) and an air conditioning system (30) of the vehicle integrated with the battery cooling system (10), an internal condenser (36) provided in communication with a first evaporator (37) of the air conditioning system (30), a plurality of direction control valves (v1,v2,v3,v4,v5) disposed at predetermined positions and configured to selectively direct flow of the coolant and a refrigerant in the heat pump system (100), a plurality of non-return valves (nrv1, nrv2) provided in a refrigerant circuit of the air conditioning system (30), and an external refrigerant storage tank (33); the method comprising:
diverting a flow of the coolant exiting from the chiller (12) to a e-drive coolant circuit, when a temperature of the coolant exiting the chiller (12) is lower than a temperature of the coolant in the e-drive coolant circuit and the temperature of the coolant in the e-drive coolant circuit is lower than the temperature of a battery coolant circuit, wherein the heat from a powertrain of the vehicle is utilized to heat the coolant;
diverting the coolant from the e-drive coolant circuit to a battery (11) of the vehicle via the battery coolant circuit, wherein the heat from the battery (11) is utilized to heat the coolant at a higher temperature; and
diverting the heated coolant from the battery (11) to the chiller (12) wherein the heat from the coolant is transferred to the refrigerant in the chiller (12).
20. The method as claimed in claim 19, wherein the method comprises:
actuating a third direction control valve (v3) to allow the flow of the coolant from a third battery coolant line (bcl3) to a second e-drive coolant line (ecl2);
actuating a fourth direction control valve (v4) to allow the flow of the heated coolant from a fifth e-drive coolant line (ecl5) to a first e-drive coolant drive (ecl5);
actuating a third direction control valve (v3) to allow the flow of the heated coolant from a first e-drive coolant line (ecl1) to a first battery coolant line (bcl1); and
actuating a first direction control valve (v1) to pass the coolant through the battery (11).
21. A method for heating a coolant in a heat pump system comprising a battery cooling system (10), an e-drive cooling system (20) and an air conditioning system (30) of the vehicle integrated with the battery cooling system (10), an internal condenser (36) provided in communication with a first evaporator (37) of the air conditioning system (30), a plurality of direction control valves (v1,v2,v3,v4,v5) disposed at predetermined positions and configured to selectively direct flow of the coolant and a refrigerant in the heat pump system (100), a plurality of non-return valves (nrv1, nrv2) provided in a refrigerant circuit of the air conditioning system (30), and an external refrigerant storage tank (33); the method comprising:
diverting a flow of the coolant exiting from the chiller (12) to a heater (13) of the battery cooling system (10), when the temperature of the battery (11) and a powertrain of the vehicle are below a predetermined threshold value and an ambient temperature is below a predetermined threshold temperature, wherein the heater (13) is operated to heat the coolant to a predetermined temperature;
diverting the heated coolant exiting from the heater (13) to the chiller (12), wherein the heat from the coolant is transferred to the refrigerant in the chiller (12).
22. The method as claimed in claim 21, wherein the method comprises:
actuating a third direction control valve (v3) to allow the flow of the coolant exiting from the chiller (12) through a third battery coolant line (bcl3) to a first battery coolant line (bcl1); and
actuating a first direction control valve (v1) to divert a flow of the heated coolant to a second battery coolant line (bcl2) by bypassing a battery (11) of the vehicle.
23. A method for heating a coolant in a heat pump system comprising a battery cooling system (10), an e-drive cooling system (20) and an air conditioning system (30) of the vehicle integrated with the battery cooling system (10), an internal condenser (36) provided in communication with a first evaporator (37) of the air conditioning system (30), a plurality of direction control valves (v1,v2,v3,v4,v5) disposed at predetermined positions and configured to selectively direct flow of the coolant and a refrigerant in the heat pump system (100), a plurality of non-return valves (nrv1, nrv2) provided in a refrigerant circuit of the air conditioning system (30), and an external refrigerant storage tank (33); the method comprising:
diverting the coolant exiting from the chiller (12) towards a battery (11) of the vehicle, when heat dissipated from the battery (11) is within a threshold value to heat the coolant, wherein the coolant passing through the battery (11) absorbs the heat dissipated from the battery (11); and
diverting the heated coolant exiting from the battery (11) to the chiller (12), wherein the heat from the coolant is transferred to the refrigerant in the chiller (12).
24. The method as claimed in claim 23, the method comprising:
actuating a third direction control valve (v3) to connect a third battery coolant line (bcl3) with a first battery coolant line (bcl1), diverting the coolant exiting from the chiller (12) to the battery (11) of the vehicle; and
actuating a first pump (P1) to pump the heated coolant to the chiller (12).
25. A method for heating a coolant in a heat pump system comprising a battery cooling system (10), an e-drive cooling system (20) and an air conditioning system (30) of the vehicle integrated with the battery cooling system (10), an internal condenser (36) provided in communication with a first evaporator (37) of the air conditioning system (30), a plurality of direction control valves (v1,v2,v3,v4,v5) disposed at predetermined positions and configured to selectively direct flow of the coolant and a refrigerant in the heat pump system (100), a plurality of non-return valves (nrv1, nrv2) provided in a refrigerant circuit of the air conditioning system (30), and an external refrigerant storage tank (33); the method comprising:
diverting the coolant exiting from the chiller (12) towards a heater (13) of the battery cooling system (10), when the heat dissipated from the battery (11) is below a predefined threshold value, and the coolant from an e-drive coolant circuit is not flowing through the battery coolant circuit, wherein the heater (13) heats the coolant to a predefined temperature;
passing the heated coolant through the battery (11), wherein the heat dissipated by the battery (11) is absorbed by the coolant;
pumping the heated coolant exiting from the battery (11) by a first pump (P1) into the chiller (12), wherein the heat from the coolant is transferred to the refrigerant, heating the refrigerant.
26. The method as claimed in claim 25, wherein the method comprises:
actuating a third direction control valve (v3) to divert a flow of the coolant exiting from the chiller (12) via a third battery coolant line (bcl3) to a first battery coolant line (bcl1), wherein the heater (13) is actuated to an ON condition; and
actuating a first direction control valve (v1) to close the flow of the coolant through a second battery coolant line (bcl2).