Description:TECHNICAL FIELD
[001] Embodiments disclosed herein relate to automatic climate control in electric vehicles, and more particularly to performing automatic climate control in electric vehicles using a heat recovery system.
BACKGROUND
[002] Cabin heating in an electric vehicle (EV) is a critical component of the thermal management system. EVs typically use one or more Positive Temperature Coefficient (PTC) heaters for heating the cabin. However, to achieve a set temperature inside the cabin, cold air and hot air has to be mixed in a pre-defined proportion nits. Further, managing the temperature of the battery(ies) and cabin in the EV can consume a lot of energy, which can adversely affect the range of the EV.
[003] Hence, there is a need in the art for solutions which will overcome the above mentioned drawback(s), among others.
OBJECTS
[004] The principal object of the embodiment herein is to disclose systems and methods for achieving automatic climate controlling in an Electric Vehicle (EV), using a heat recovery system, wherein the waste heat from at least one compressor outlet is used to heat air, and the heated air is mixed with cold air to achieve at least one pre-set temperature inside a cabin of the EV.
[005] These and other aspects 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 at least one embodiment 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 FIGURES
[006] Embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the following illustrator drawings. Embodiments herein are illustrated by way of examples in the accompanying drawings, and in which:
[007] FIG. 1 is a block diagram illustrating an automatic climate control system of an electric vehicle, according to embodiments as disclosed herein;
[008] FIG. 2 is a schematic illustration of an automatic climate control system of an electric vehicle, according to embodiments as disclosed herein;
[009] FIG. 3 is a flow diagram illustrating the method for achieving an automatic climate control in an electric vehicle, according to embodiments as disclosed herein;
[0010] FIG. 4 depicts example results of a demist test at -3 degree Celsius with an indirect heat pump, according to embodiments as disclosed herein; and
[0011] FIG. 5 depicts an example power consumption comparison between a PTC heater (as used in currently available solutions), and an indirect heat pump (as disclosed herein).
DETAILED DESCRIPTION
[0012] 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.
[0013] For the purposes of interpreting this specification, the definitions (as defined herein) will apply and whenever appropriate the terms used in singular will also include the plural and vice versa. It is to be understood that the terminology used herein is for the purposes of describing particular embodiments only and is not intended to be limiting. The terms “comprising”, “having” and “including” are to be construed as open-ended terms unless otherwise noted.
[0014] The words/phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” are merely used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein using the words/phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” is not necessarily to be construed as preferred or advantageous over other embodiments.
[0015] Embodiments herein may be described and illustrated in terms of blocks which carry out a described function or functions. These blocks, which may be referred to herein as managers, units, modules, hardware components or the like, are physically implemented by analog and/or digital circuits such as logic gates, integrated circuits, microprocessors, microcontrollers, memory circuits, passive electronic components, active electronic components, optical components, hardwired circuits, and the like, and may optionally be driven by a firmware. The circuits may, for example, be embodied in one or more semiconductor chips, or on substrate supports such as printed circuit boards and the like. The circuits constituting a block may be implemented by dedicated hardware, or by a processor (e.g., one or more programmed microprocessors and associated circuitry), or by a combination of dedicated hardware to perform some functions of the block and a processor to perform other functions of the block. Each block of the embodiments may be physically separated into two or more interacting and discrete blocks without departing from the scope of the disclosure. Likewise, the blocks of the embodiments may be physically combined into more complex blocks without departing from the scope of the disclosure.
[0016] It should be noted that elements in the drawings are illustrated for the purposes of this description and ease of understanding and may not have necessarily been drawn to scale. For example, the flowcharts/sequence diagrams illustrate the method in terms of the steps required for understanding of aspects of the embodiments as disclosed herein. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Furthermore, in terms of the system, one or more components/modules which comprise the system may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
[0017] The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any modifications, equivalents, and substitutes in addition to those which are particularly set out in the accompanying drawings and the corresponding description. Usage of words such as first, second, third etc., to describe components/elements/steps is for the purposes of this description and should not be construed as sequential ordering/placement/occurrence unless specified otherwise.
[0018] The embodiments herein achieve systems and methods for achieving automatic climate controlling in an Electric Vehicle (EV). Referring now to the drawings, and more particularly to FIGS. 1 through 5, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0019] Embodiment herein disclose systems and methods for achieving automatic climate controlling in an Electric Vehicle (EV), using a heat recovery system, wherein the waste heat from at least one compressor outlet is used to heat air, and the heated air is mixed with cold air to achieve at least one pre-set temperature inside a cabin of the EV.
[0020] FIG. 1 is a block diagram illustrating an automatic climate control system of an electric vehicle. In an embodiment herein, the climate control system 100 can be a single zone climate control system, wherein a single pre-set temperature is pre-set for the entire cabin of the vehicle. In an embodiment herein, the climate control system 100 can have climate control zones, wherein one or more pre-set temperatures can be set for one or more cabins of the vehicle and/or zones present in the cabin of the vehicle. The climate control system 100 includes a control unit 101, a drive train coolant loop 102, a battery system coolant loop 103, and a vehicle heat pump system 104. The control unit 101 controls the operation of the components of vehicle thermal management system 100 and the components of the various embodiments of the vehicle thermal management system (as shown in FIG. 2), among others. The components of the vehicle thermal management system 100 are interconnected via tubing and/or piping. In an embodiment herein, tubing describes a structure that supports the transport of refrigerant across the climate control system 100. In an embodiment herein, piping includes structure(s) that support the transport of coolant across the climate control system 100. The control system 101 controls the drive train coolant loop 102, the battery system coolant loop 103, and the vehicle heat pump system 104, via one or more wired and/or wireless communication links. Examples of the wired and/or wireless communication links can be, but not limited to, Near Field Communication (NFC), Bluetooth, Bluetooth Low Energy (BLE), Wi-Fi, Controller Area Network (CAN), LIN, and so on.
[0021] The battery system coolant loop 103 includes a battery system 111. The battery system 111 includes a plurality of individual batteries/battery packs, constructed according to one or more embodiments as disclosed herein. The components of the automatic climate control system 100 can be powered by the battery system 111, and controlled by the control unit 101.
[0022] The vehicle heat pump system 104 includes an electric compressor 112, a condenser 113, an evaporator 114, a 3-way refrigerant flow control valve (RFCV) 115, a coolant flow control valve (CFCV) 116, a chiller 117, a water cooled condenser (WCC) 118, a low capacity coolant heater 119, a solenoid 120, and a cabin heater 121. Each of the components of the automatic climate control system 100 can be powered by the battery system 111, and controlled by the control system 101. When in a heating mode, the coolant flow control valve 116 can serially couple the battery system coolant loop 103 to the cabin heater 121. The automatic climate control system 100 can exchange heating and/or cooling between and among the battery system 111, the at least one drive train component and the cabin of the vehicle.
[0023] The drive train coolant loop 102 may further include a radiator 105, a reservoir 106, an on-board charger 107, an electric power control unit 108, a pump 109 and, a motor 110.
[0024] As depicted in the automatic climate control system 100, the vehicle heat pump system 104 can source heat from at least one of the drive train coolant loop 102, the battery system coolant loop 103, and/or the ambient.
[0025] FIG. 2 is a schematic illustration of an automatic climate control system of an electric vehicle, wherein the automatic climate control system 200 includes a vehicle heat pump system 104, a battery system coolant loop 103, and a drive train coolant loop 102. The automatic climate control system 200 can be in thermal communication with at least one drive train component. The battery system coolant loop 103 can be in thermal communication with the battery system 111. A control system (not shown) can control operation of one or more components of the vehicle thermal management system 200. The components of the automatic climate control system 200 are interconnected via tubing and/or piping.
[0026] The vehicle heat pump system 104 includes an electric compressor 112, a condenser 113, an evaporator 114, a 3-way refrigerant flow control valve 115, a chiller 117, a water cooled condenser 118, a solenoid 120, a plurality of Thermal expansion valves (TXVs) 201, a plurality of Electronic expansion valves (EXVs) 202, and an orifice 204. The 3-way refrigerant flow control valve 115 can deliver hot, high-pressure refrigerant to the respective condensers 113, 118. The TXVs 201 can actively control the superheat set point of the evaporator 114 by controlling the flow of refrigerant to the evaporator 114. The TXV 201 has a sensing bulb attached to the TXV body (connected with suction line/evaporator outlet), wherein the valve setting in a sensing bulb modulates the flow of refrigerant to the evaporator coil using its pressure. In an embodiment herein, the TXVs 201 can completely block flow of refrigerant to the evaporator 114, when not required. In an embodiment herein, the TXVs 201 can permit flow of refrigerant to the evaporator 114, when required. The EXVs 202 can actively control the superheat set point of the chiller 117 by controlling the flow of refrigerant to the chiller 117. The EXV 202 can use electronic controls, and a stepper motor to precisely regulate the flow of refrigerant flow into the evaporator coil. In an embodiment therein, the EXVs 202 can completely block flow of refrigerant to the chiller 117, when not required. In an embodiment therein, the EXVs 202 can permit flow of refrigerant of refrigerant o the chiller 117, when required.
[0027] The battery system coolant loop 103 includes the pump 112, a reservoir 203, the battery system 111, the chiller 117, the coolant flow control valve 116, the low capacity coolant heater 119, the cabin heater 121, and a T joint and piping, wherein the T joint and piping intercouples these components, and can be used to direct coolant. The drive train coolant loop 102 includes a radiator 105, a reservoir 106, an on-board charger 107, an electric power control unit 108, a pump 109 and, a motor 110. When excess heat is generated by the battery system 111 and/or the drive train components, the coolant can be directed to the radiator 105, wherein the radiator 105 can sink the excess heat from the coolant.
[0028] The on-board charger 107 in the drive train coolant loop 102 is configured to connect to an AC power source to continuously charge the battery system 111. The electric power control unit 108 integrates a number of components (not shown), such as, but not limited to, an inverter, a low voltage converter, and a vehicle control unit to manage the power within the electric vehicle. The components of both the battery system coolant loop 103, and the drive train coolant loop 102 can be filled with a coolant such as, but not limited to, an alcohol based coolant, or any other coolant.
[0029] FIG. 3 is a flow diagram illustrating the method for an automatic climate controlling system of an electric vehicle using heat recovery system. In step 301, the control unit collects the waste heat recovered from the compressor 112. The waste heat recovered from the compressor 112 can be considered as the heat source for performing automatic climate control. In step 302, the refrigerant flow control valve (RFCV) 115 controls the flow of the waste heat and splits the hot refrigerant between the cabin and the battery system coolant loop 103. In step 303, the recovered waste heat passes through the condenser 113 and the plurality of thermal expansion valve (TXVs) 201. In step 304, the hot refrigerant from the electric compressor 112 exchanges heat with the coolant inside the water cooled condenser (WCC) 118 through the refrigerant flow control valve (RFCV) 115. In step 305, the cabin temperature (as set by the user) is achieved and maintained by combining the recovered waste heat (which has been passed through the condenser 113 and the plurality of thermal expansion valve (TXVs) 201 (step 303)) and the refrigerant (which has exchanged heat with the coolant inside the WCC 118). The various actions in method 300 may be performed in the order presented, in a different order or simultaneously. Further, in some embodiments, some actions listed in FIG. 3 may be omitted.
[0030] FIG. 4 depicts example results of a demist test at -3 degree Celsius with an indirect heat pump, wherein the test comprises performing demisting with the WCC 118, and a 1kW heater and meets the demist requirements as per the AIS 084 requirement.
[0031] FIG. 5 depicts an example power consumption comparison between a PTC heater (as used in currently available solutions), and an indirect heat pump (as disclosed herein). From the graph, it can be seen that there is a 3% range improvement for a vehicle equipped with an indirect heat pump for performing automatic climate control (as disclosed herein), as compared to a vehicle equipped with a PTC heater and an AC compressor for performing automatic climate control (as used in currently available vehicles).
[0032] The embodiments disclosed herein can be implemented through at least one software program running on at least one hardware device and performing network management functions to control the network elements. The elements include blocks which can be at least one of a hardware device, or a combination of hardware device and software module.
[0033] The embodiment disclosed herein describes systems and methods to achieve automatic climate controlling in an Electric Vehicle (EV), using a heat recovery system. Therefore, it is understood that the scope of the protection is extended to such a program and in addition to a computer readable means having a message therein, such computer readable storage means contain program code means for implementation of one or more steps of the method, when the program runs on a server or mobile device or any suitable programmable device. The method is implemented in at least one embodiment through or together with a software program written in e.g., Very high speed integrated circuit Hardware Description Language (VHDL) another programming language, or implemented by one or more VHDL or several software modules being executed on at least one hardware device. The hardware device can be any kind of portable device that can be programmed. The device may also include means which could be e.g., hardware means like e.g., an ASIC, or a combination of hardware and software means, e.g., an ASIC and an FPGA, or at least one microprocessor and at least one memory with software modules located therein. The method embodiments described herein could be implemented partly in hardware and partly in software. Alternatively, the invention may be implemented on different hardware devices, e.g., using a plurality of CPUs.
[0034] 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 embodiments and examples, those skilled in the art will recognize that the embodiments and examples disclosed herein can be practiced with modification within the scope of the embodiments as described herein.
, Claims:We claim:
1. An automatic climate control system (100) for an Electric Vehicle (EV) comprising:
a control unit (101) configured to:
heat air using waste heat from at least one outlet of at least one compressor (112); and
achieve at least one pre-set temperature inside a cabin of the EV by mixing the heated air with cold air.
2. The automatic climate control system, as claimed in claim 1, wherein the system (100) further comprises a vehicle heat pump system (104), a battery system coolant loop (103), a water cooled condenser (WCC) (118), and a drive train coolant loop (102).
3. The automatic climate control system, as claimed in claim 2, wherein the vehicle heat pump system (104) comprises the compressor (112), a condenser (113), an evaporator (114), and a chiller (117).
4. The automatic climate control system, as claimed in claim 2, wherein the control unit (101) is further configured to:
split the waste heat from the compressor (112) between the cabin of the EV, and the battery system coolant loop (103) using a refrigerant flow control valve (RFCV) (115);
pass the waste heat through the condenser (113) and the plurality of thermal expansion valve (TXVs) (201);
exchange heat from hot refrigerant from the compressor (112) with coolant inside the WCC (118); and
achieve and maintain the at least one pre-set temperature by combining
the waste heat from the condenser (113) and the plurality of thermal expansion valve (TXVs) (201); and
the refrigerant which has exchanged heat with the coolant inside the WCC (118).
5. A method for achieving automatic climate control system (100) in an Electric Vehicle (EV), the method comprises:
heating air, by a control module (101), using waste heat from at least one outlet of at least one compressor (112); and
achieving, by the control module (101), at least one pre-set temperature inside a cabin of the EV by mixing the heated air with cold air.
6. The method, as claimed in claim 5, wherein the method further comprises:
splitting, by the control module (101), the waste heat from the compressor (112) between the cabin of the EV, and a battery system coolant loop (103) using a refrigerant flow control valve (RFCV) (115);
passing, by the control module (101), the waste heat through a condenser (113) and a plurality of thermal expansion valve (TXVs) (201);
exchanging heat, by the control module (101), from hot refrigerant from the compressor (112) with coolant inside a water-cooled condenser (WCC) (118); and
achieving and maintaining, by the control module (101), the at least one pre-set temperature by combining
the waste heat from the condenser (113) and the plurality of thermal expansion valve (TXVs) (201), and
the refrigerant which has exchanged heat with the coolant inside the WCC (118).