DESC:METHOD AND SYSTEM FOR OPERATING COOLING PUMP OF AN ACTIVE COOLING SYSTEM OF ELECTRIC VEHICLE
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202521000479 filed on 02/01/2025, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to a cooling system for electric vehicles. Particularly, the present disclosure relates to a system and a method of operating a cooling pump of an active cooling system of an electric vehicle.
BACKGROUND
Electric vehicles (EVs) incorporate multiple high-power vehicle subsystems such as traction battery packs, electric motors, DC-DC converters, and onboard chargers. The subsystems generate substantial heat during operation, and excess heat, if not dissipated effectively, adversely impacts performance, efficiency, and the lifecycle of the components. As a result, efficient thermal management is critical to ensure safe and reliable operation of the electric vehicle.
Conventional approaches of active cooling arrangements in electric vehicles are classified into three main types, namely fixed-speed cooling pumps, fixed-speed fans, and combined pump-fan circulation. In fixed-speed cooling pump operation, the coolant is circulated continuously despite the thermal load, resulting in constant energy usage. Further, in fixed-speed fan cooling, airflow is provided uniformly across the heat exchanger, without adjustment to changing subsystem temperatures. Furthermore, in combined pump-fan circulation, both coolant and airflow are delivered simultaneously to manage heat dissipation during vehicle operation.
There are certain problems associated with the existing above-mentioned methods of active cooling of an electric vehicle. Specifically, the combined pump-fan circulation lacks integrated sensing of both coolant temperature and subsystem temperature, limiting the ability to adapt cooling dynamically. As a result, cooling devices such as pumps and fans are controlled in an on-off manner, without modulation based on actual operating conditions, which leads to overcooling that reduces efficiency and undercooling that compromises safety.
Therefore, there exists a need for a system and method of active cooling of an electric vehicle that is efficient and overcomes one or more of the problems mentioned above.
SUMMARY
An object of the present disclosure is to provide a system for active cooling of an electric vehicle.
Another object of the present disclosure is to provide a method of active cooling of an electric vehicle.
Yet another object of the present disclosure is a system and method of active cooling with an integrated control unit that dynamically regulates the operation of a cooling pump and modulates a fan airflow based on sensed temperatures of vehicle subsystems and coolant.
In accordance with a first aspect of the present disclosure, there is provided a system for active cooling of an electric vehicle, the system comprises:
- at least one temperature sensor configured to sense the temperature of a plurality of vehicle subsystems;
- a cooling pump operatively connected to the plurality of vehicle subsystems and a heat exchanger;
- at least one coolant temperature sensor configured to sense coolant temperature;
- at least one fan configured to provide airflow to the heat exchanger; and
- a control unit operatively connected to the at least one temperature sensor, the cooling pump, the at least one coolant temperature sensor, and the at least one fan, wherein the control unit is configured to:
- control the operation of the cooling pump based on the sensed temperature of the plurality of vehicle subsystems and the sensed temperature of the coolant; and
- modulate the airflow of the at least one fan based on the operation of the cooling pump.
The system and method of active cooling of an electric vehicle, as described in the present disclosure, are advantageous in terms of improved thermal management, subsystem reliability, and operational efficiency by real-time monitoring of temperatures of vehicle subsystems and coolant via integrated temperature sensors. Further, in response to the sensed temperature values, the control unit dynamically regulates the operation of the cooling pump and modulates the airflow of the fan, thereby optimizing cooling performance under varying thermal loads. Furthermore, protective operation is reinforced by continuous evaluation of the vehicle subsystem and coolant temperature deviations, enabling immediate mitigation of overheating risks and ensuring safe operating limits for critical components such as the battery pack, electric motor, DC-DC converter, and charger. Consequently, the risks of thermal runaway, efficiency losses, and premature degradation of components in electric vehicles are reduced, further improving operational safety, energy efficiency, and overall vehicle performance.
In accordance with another aspect of the present disclosure, there is provided a method of active cooling of an electric vehicle, the method comprising:
- sensing the temperature of a plurality of vehicle subsystems via at least one temperature sensor;
- sensing a coolant temperature via at least one coolant temperature sensor;
- comparing the sensed temperature values of the plurality of vehicle subsystems with a predefined threshold temperature values via a control unit;
- modulating the cooling pump speed based on a generated activation signal via the control unit; and
- controlling the fan speed based on a pulse-width modulation via the control unit.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Figure 1 illustrates a block diagram of a system for active cooling of an electric vehicle, in accordance with an embodiment of the present disclosure.
Figure 2 illustrates a flow chart of a method for active cooling of an electric vehicle, in accordance with another embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
As used herein, the term “active cooling” refers to a process of actively regulating the temperature of an electric vehicle’s subsystems via devices such as pumps, fans, and sensors to remove heat and maintain safe operating conditions. Specifically, the active cooling employs a plurality of temperature sensors to monitor the thermal state of vehicle subsystems, a coolant temperature sensor to monitor coolant temperature, a cooling pump operatively connected to the subsystems and a heat exchanger, and at least one fan to provide airflow across the heat exchanger. The types of active cooling, such as, but not limited to, liquid cooling, air cooling, and hybrid cooling. Each active cooling type is configured to meet specific thermal management requirements of the vehicle subsystems. The active cooling enhances safety, improves energy efficiency, and prolongs the operational life of vehicle subsystems.
As used herein, the terms “electric vehicle”, “EV”, and “battery electric vehicle” are used interchangeably and refer to a vehicle configured to operate using electrical energy stored in rechargeable batteries. Specifically, the electric vehicle integrates key subsystems such as, but not limited to, a battery pack for energy storage, an electric motor for propulsion, power electronics for energy conversion, and auxiliary units for charging and thermal management. The types of electric vehicles are classified into, such as but not limited to, battery electric vehicles, plug-in hybrid electric vehicles, and hybrid electric vehicles, with each type featuring distinct energy storage capacities, charging requirements, and power management strategies. Advantageously, the electric vehicle promotes reduced dependency on fossil fuels, supports efficient energy utilization, and enhances environmental sustainability across residential, commercial, and public transportation applications.
As used herein, the terms “temperature sensor”, “thermal sensor”, and “subsystem temperature sensor” are used interchangeably and refer to a device configured to detect and measure the temperature of a vehicle subsystem within an electric vehicle. Specifically, the temperature sensor generates electrical signals corresponding to the sensed subsystem temperature, which are transmitted to a control unit for monitoring and regulation of thermal conditions. The types of temperature sensors are thermistors, thermocouples, resistance temperature detectors (RTDs), and semiconductor-based sensors, with each type providing distinct accuracy, response time, and measurement range. Advantageously, the temperature sensor enables precise thermal management, enhances the safety and reliability of vehicle subsystems, and improves energy efficiency under varying operating and environmental conditions.
As used herein, the terms “vehicle subsystems”, “electrical subsystems”, and “EV subsystems” are used interchangeably and refer to the components of an electric vehicle that generate heat during operation and require thermal management. Specifically, the vehicle subsystems such as, but not limited to, the battery pack, electric motor, DC-DC converter, onboard charger, and power electronics. The vehicle subsystems have distinct thermal characteristics and operational requirements, which are monitored and managed by the active cooling system. Advantageously, the vehicle subsystems ensure precise temperature regulation, enhance safety, and improve energy efficiency under varying driving conditions, load scenarios, and environmental temperatures.
As used herein, the terms “cooling pump”, “circulation pump”, and “coolant pump” are used interchangeably and refer to a device configured to circulate coolant through the vehicle subsystems and heat exchanger to remove heat. Specifically, the cooling pump is operatively connected to the subsystems and is controlled by the control unit to vary the flow rate of coolant based on real-time temperature measurements. The types of cooling pumps comprise, but are not limited to, centrifugal pumps, positive displacement pumps, and electrically driven pumps, each providing distinct flow characteristics and response times. Advantageously, the cooling pump within the active cooling system ensures precise thermal regulation, enhances the safety and reliability of the vehicle subsystems, and optimizes energy efficiency under varying operating and environmental conditions.
As used herein, the terms “heat exchanger”, “cooling exchanger”, and “thermal exchanger” are used interchangeably and refer to a device configured to transfer heat from the vehicle subsystems and circulating coolant to a secondary medium, such as but not limited to air, to maintain safe operating temperatures. Specifically, the heat exchanger is operatively connected to the cooling pump and a fan. Further, the heat exchanger works in conjunction with the active cooling system to remove heat from the battery pack, electric motor, power electronics, and other vehicle subsystems. The types of heat exchangers comprise, but are not limited to, air-cooled radiators, liquid-to-liquid exchangers, and hybrid exchangers, each providing distinct heat transfer efficiency and flow characteristics. Advantageously, the heat exchanger ensures effective thermal management, enhances the safety and reliability of vehicle subsystems, and improves energy efficiency under varying load conditions and environmental temperatures.
As used herein, the terms “coolant temperature sensor”, “coolant sensor”, and “thermal fluid sensor” are used interchangeably and refer to a device configured to detect and measure the temperature of the coolant circulating through the vehicle subsystems and the heat exchanger. Specifically, the coolant temperature sensor generates electrical signals corresponding to the sensed coolant temperature, which are transmitted to the control unit to regulate the operation of the cooling pump and the fan for optimal thermal management. The types of coolant temperature sensors include, but are not limited to, thermistors, thermocouples, resistance temperature detectors (RTDs), and semiconductor-based sensors, each providing varying accuracy, response time, and measurement range. Advantageously, the coolant temperature sensor ensures precise monitoring of coolant conditions, enhances the safety and reliability of vehicle subsystems, and improves energy efficiency under varying load conditions and environmental temperatures.
As used herein, the terms “fan”, “cooling fan”, and “airflow fan” are used interchangeably and refer to a device configured to generate airflow across the heat exchanger to remove heat. Specifically, the fan operates under the control of the control unit, which modulates the fan speed based on the sensed temperatures of the subsystems and coolant to maintain optimal thermal conditions. The types of fans include, but are not limited to, axial fans, centrifugal fans, and electronically commutated (EC) fans, each providing distinct airflow characteristics and response times. Advantageously, the fan enhances the safety and reliability of vehicle subsystems, improving energy efficiency under varying load conditions and environmental temperatures.
As used herein, the terms “control unit”, “controller”, and “thermal management controller” are used interchangeably and refer to an electronic module configured to monitor, analyze, and regulate the operation of components within the active cooling architecture of an electric vehicle. Specifically, the control unit receives input signals from the temperature sensors and the coolant temperature sensor, processes the data, and dynamically adjusts the cooling pump speed and the fan airflow to maintain optimal vehicle subsystem and coolant temperatures. The types of control units comprise, but are not limited to, microcontroller-based units, Programmable Logic Controllers (PLC), Application-Specific Integrated Circuits (ASIC), and System-on-Chip (SoC) modules, each providing distinct levels of processing capability, flexibility, and integration for thermal management tasks. Advantageously, the control unit enables intelligent and adaptive cooling, enhances subsystem safety and reliability, and improves energy efficiency across varying operating conditions and environmental scenarios.
As used herein, the terms “battery pack”, “energy storage module”, and “traction battery” are used interchangeably and refer to a system of interconnected rechargeable battery cells configured to store electrical energy for powering an electric vehicle. Specifically, the battery pack provides energy to the electric motor, while generating heat during charge and discharge cycles that require thermal management. The types of battery packs comprise, but are not limited to, lithium-ion, nickel-metal hydride, and solid-state battery assemblies, each offering distinct energy density, power output, and thermal characteristics. Advantageously, the battery pack enhances performance and reliability, and prolongs the operational life of the battery cells under varying load conditions and environmental temperatures.
As used herein, the terms “electric motor”, “traction motor”, and “drive motor” are used interchangeably and refer to a device configured to convert electrical energy from the battery pack into mechanical energy to propel an electric vehicle. Specifically, the electric motor operates under varying load conditions, generating heat during operation that requires thermal management by the active cooling. The types of electric motors comprise, but are not limited to, permanent magnet synchronous motors (PMSMs), induction motors, and switched reluctance motors, each offering distinct efficiency, torque characteristics, and thermal behaviour. Advantageously, the electric motor enhances reliability and performance and prolongs motor life under varying driving conditions and environmental temperatures.
As used herein, the terms “DC-DC converter unit”, “DC-DC converter”, and “power conversion module” are used interchangeably and refer to a device configured to convert electrical energy from one DC voltage level to another within an electric vehicle to supply power to various subsystems. Specifically, the DC-DC converter unit regulates voltage for components such as the auxiliary systems, battery management system, and onboard electronics, while generating heat during operation that requires thermal management by the active cooling system. The types of DC-DC converter units comprise, but are not limited to, isolated converters, non-isolated converters, and bidirectional converters, each providing distinct efficiency, voltage regulation capabilities, and thermal characteristics. Advantageously, the DC-DC converter unit enhances reliability and energy efficiency and prolongs the operational life of the converter under varying load conditions and environmental temperatures.
As used herein, the terms “charger”, “onboard charger”, and “battery charger” are used interchangeably and refer to a device configured to convert electrical energy from an external power source into a form suitable for charging the battery pack of an electric vehicle. Specifically, the charger controls voltage and current supplied to the battery while generating heat during operation, which requires thermal management by the active cooling system. The types of chargers comprise, but are not limited to, AC chargers, DC fast chargers, and bidirectional chargers, each providing distinct charging rates, efficiency, and thermal characteristics. Advantageously, the charger enhances charging reliability and energy efficiency, and prolongs the service life of both the charger and the battery pack under varying load conditions and environmental temperatures.
As used herein, the terms “coolant lines” and “coolant pipes” are used interchangeably and refer to channels or tubes configured to transport coolant between the vehicle subsystems, the cooling pump, and the heat exchanger within an electric vehicle. Specifically, the coolant lines form a closed-loop path to facilitate continuous circulation of the coolant for heat removal from the vehicle subsystems, such as but not limited to the battery pack, the electric motor. The types of coolant lines comprise, but are not limited to, flexible hoses, rigid tubes, and hybrid conduit assemblies, each providing distinct flow characteristics, thermal conductivity, and durability. Advantageously, the coolant lines ensure efficient heat transfer, support precise thermal management, enhance the safety and reliability of vehicle subsystems, and optimize energy efficiency under varying operating and environmental conditions.
As used herein, the terms “predefined threshold temperature”, “temperature setpoint”, and “thermal threshold” are used interchangeably and refer to a predetermined temperature value used by the control unit to regulate the operation of the active cooling in an electric vehicle. Specifically, the predefined threshold temperature serves as a reference for comparing sensed temperatures of the vehicle subsystems and the coolant, enabling the control unit to generate activation signals for controlling the cooling pump and the fan. The types of predefined threshold temperatures comprise, but are not limited to, fixed thresholds, adjustable thresholds, and dynamically calculated thresholds based on operating conditions, each providing distinct control characteristics and safety margins. Advantageously, the use of the predefined threshold temperature ensures precise thermal management, prevents overheating of the vehicle subsystems, enhances safety, and improves energy efficiency under varying load and environmental conditions.
As used herein, the terms “activation signal”, “control signal”, and “actuation signal” are used interchangeably and refer to an electrical or electronic signal generated by the control unit to initiate, modulate, or terminate the operation of components within the active cooling of an electric vehicle. Specifically, the activation signal is generated based on comparisons between sensed vehicle subsystem and coolant temperatures and predefined threshold temperatures, and is transmitted to devices such as the cooling pump and the fan to regulate thermal management. The types of activation signal comprise, but are not limited to, binary on/off signals, analog signals, and pulse-width modulated signals, each providing distinct control precision and response characteristics. Advantageously, the generation and use of the activation signal ensures timely and accurate regulation of subsystem temperatures, enhances safety, improves reliability, and optimizes energy efficiency under varying operating and environmental conditions.
As used herein, the terms “pulse-width modulation”, “PWM”, and “modulation signal” are used interchangeably and refer to a technique in which the duty cycle of a periodic electrical signal is varied to control the operation of components within the active cooling of an electric vehicle. Specifically, the pulse-width modulation is applied by the control unit to regulate the speed of the cooling pump and the fan based on deviations between sensed vehicle subsystem temperatures, coolant temperature, and predefined threshold temperatures. The types of pulse-width modulation comprise, but are not limited to, fixed-frequency PWM, variable-frequency PWM, and multi-level PWM, each providing distinct control resolution, efficiency, and response time. Advantageously, the use of PWM ensures precise and efficient thermal regulation, enhances the safety and reliability of vehicle subsystems, and optimizes energy consumption under varying operating conditions and environmental temperatures.
In accordance with a first aspect of the present disclosure, there is provided a system for controlling charging of an electric vehicle, the system comprises:
- at least one temperature sensor configured to sense the temperature of a plurality of vehicle subsystems;
- a cooling pump operatively connected to the plurality of vehicle subsystems and a heat exchanger;
- at least one coolant temperature sensor configured to sense coolant temperature;
- at least one fan configured to provide airflow to the heat exchanger; and
- a control unit operatively connected to the at least one temperature sensor, the cooling pump, the at least one coolant temperature sensor, and the at least one fan, wherein the control unit is configured to:
- control the operation of the cooling pump based on the sensed temperature of the plurality of vehicle subsystems and the sensed temperature of the coolant; and
- modulate the airflow of the at least one fan based on the operation of the cooling pump.
Referring to figure 1, in accordance with an embodiment, there is described a system for controlling charging of an electric vehicle. The system comprises at least one temperature sensor 102 is configured to sense temperature of a plurality of vehicle subsystems 104, a cooling pump 106 is operatively connected to the plurality of vehicle subsystems 104 and a heat exchanger 108, at least one coolant temperature sensor 110 is configured to sense coolant temperature, at least one fan 112 is configured to provide airflow to the heat exchanger 108 and a control unit 114 is operatively connected to the at least one temperature sensor 102, the cooling pump 106, the at least one coolant temperature sensor 102, and the at least one fan 112. Further, the control unit is configured to control the operation of the cooling pump based on the sensed temperature of the plurality of vehicle subsystems and the sensed temperature of the coolant, and modulate the airflow of the at least one fan based on the operation of the cooling pump.
The system 100 for active cooling of an electric vehicle operates by integrating at least one temperature sensor 102, a cooling pump 106, a heat exchanger 108, at least one coolant temperature sensor 110, at least one fan 112, and a control unit 114. Further, the temperature sensor 102 is configured to sense the temperature of a plurality of vehicle subsystems 104, which comprise but are not limited to a battery pack, an electric motor, a DC-DC converter unit, and a charger. Furthermore, the cooling pump 106 is operatively connected to the vehicle subsystems 104 and the heat exchanger 108 through coolant lines forming a closed-loop path, thereby enabling continuous circulation of coolant. Furthermore, the coolant temperature sensor 110 is positioned to sense the temperature of the coolant flowing through the coolant lines. Furthermore, the fan 112 is mounted to direct airflow across the heat exchanger 108, thereby dissipating heat from the coolant. Furthermore, the control unit 114 is operatively connected to the temperature sensor 102, the coolant temperature sensor 110, the cooling pump 106, and the fan 112, and is configured to process temperature signals received from both the vehicle subsystems and the coolant. Subsequently, the control unit 114 controls the operation of the cooling pump 106 based on the sensed temperature of the vehicle subsystems 104 and the coolant temperature, and modulates the airflow generated by the fan 112 in response to the operation of the cooling pump 106. Specifically, the dynamic coordination between the cooling pump 106 and the fan 112 ensures that both coolant flow rate and airflow are proportionally adjusted to thermal demand. Consequently, efficient dissipation of heat from the subsystems 104 is achieved, maintaining subsystem and coolant temperatures within safe operating limits. Furthermore, the integrated sensing and control mechanism eliminates redundant energy consumption by preventing overcooling or delayed activation of the cooling components. Advantageously, the system 100 enhances thermal management efficiency, extends the lifespan of critical subsystems such as the battery pack and power electronics, improves vehicle reliability, and reduces overall energy usage, thereby contributing to extended driving range and improved safety in electric vehicles.
In an embodiment, the plurality of vehicle subsystems 104 comprises at least one of a battery pack, an electric motor, a DC-DC converter unit, and a charger. The temperature sensor 102, positioned in thermal communication with the battery pack, continuously monitors cell surface temperature to detect heat generated during charging and discharging, thereby preventing thermal runaway and capacity degradation. In the electric motor, the temperature sensor 102 is arranged near the stator windings or casing to capture copper and iron loss heating, ensuring torque efficiency and preventing demagnetization of permanent magnets. In the DC–DC converter unit, the temperature sensor 102 is located adjacent to the semiconductor devices to sense the junction heating caused by switching and conduction losses, enabling timely cooling to sustain voltage conversion efficiency. In the charger, the temperature sensor 102 tracks thermal buildup in the power electronics during AC–DC conversion, thereby securing stable charging performance and protecting sensitive components from overstress. Subsequently, the control unit 114 receives the sensed temperature values from the plurality of vehicle subsystems 104 and processes the data to determine the thermal state of each subsystem 104. Furthermore, based on the relative heating levels of the subsystems 104, the control unit 114 regulates the cooling pump 106 and the fan 112 to ensure that coolant flow and airflow are directed to maintain each subsystem within a predefined safe operating range. Consequently, uniform thermal stability across the vehicle subsystems 104 is achieved, preventing overheating, thermal runaway, or performance degradation.
In an embodiment, the cooling pump 106 is operatively connected to the plurality of vehicle subsystems 104 and the heat exchanger 108 via a plurality of coolant lines, and wherein the plurality of coolant lines is configured to form a closed-loop path with the plurality of vehicle subsystems 104 and the heat exchanger 108. The cooling pump 106 actively drives coolant through the closed-loop, directing the coolant sequentially through each vehicle subsystem 104, with the coolant absorbing heat generated during operation. As the heated coolant exits the vehicle subsystems, the coolant flows into the heat exchanger 108, with the fan 112 forcing air across the heat exchanger surfaces to dissipate the thermal energy to the surrounding environment. The cooled coolant returns to the cooling pump 106, completing the closed-loop cycle and ensuring continuous, uninterrupted circulation. The control unit 114 monitors coolant and subsystem temperatures in real time and dynamically adjusts the pump 106 and fan 112 speeds to match thermal demand, thereby maintaining precise flow rates and optimal heat transfer. Consequently, the closed-loop configuration maintains stable thermal regulation of all vehicle subsystems 104, prevents overheating, and ensures the coolant remains within the desired temperature range. Advantageously, the closed-loop design enhances energy efficiency, minimizes coolant loss, enables precise control of subsystem temperatures, and improves the overall reliability and performance of the electric vehicle.
In an embodiment, the control unit 114 is configured to receive the sensed temperature of the plurality of vehicle subsystems 104 from the at least one temperature sensor 102 and the sensed temperature of the coolant from the at least one coolant temperature sensor 110. The temperature sensor 102 continuously monitors the operating temperature of each vehicle subsystem 104 and transmits the digitized values to the control unit 114 in real time. Simultaneously, the coolant temperature sensor 110 measures the temperature of the coolant circulating through the plurality of coolant lines and communicates the readings to the control unit 114. The control unit 114 processes both sets of temperature data to determine the current thermal state of the vehicle subsystem 104 by calculating deviations from predefined thresholds and quantifying the relative thermal loads of each subsystem. Based on the assessment, the control unit 114 generates control signals, which are implemented as pulse-width modulation (PWM) outputs, to dynamically adjust the speeds of the cooling pump 106 and the fan 112, ensuring coolant circulation and airflow are proportional to the instantaneous thermal demand. Consequently, the control unit 114 maintains precise thermal management, prevents overheating of the vehicle subsystems 104, and keeps the coolant within optimal temperature ranges. Advantageously, the control unit 114 allows accurate load-based cooling, improves energy efficiency, enhances the system 100 reliability, and ensures safe operation of the electric vehicle under varying operating conditions.
In an embodiment, the control unit 114 is configured to compare the sensed temperature values of the plurality of vehicle subsystems 104 with a predefined threshold temperature value and generate an activation signal based on the comparison. The control unit 114 continuously receives temperature readings from the temperature sensors 102 associated with each vehicle subsystem 104 and digitizes the incoming signals for processing. The control unit 114 evaluates each sensed temperature against the predefined threshold stored in the control unit memory to determine the thermal deviation of each subsystem. As the deviation exceeds the safe limit for a subsystem, the control unit 114 generates an activation signal, which is communicated to the cooling pump 106 and the fan 112. The activation signal is further processed using a proportional control algorithm, where the magnitude of the deviation determines the duty cycle of a pulse-width modulation (PWM) signal, thereby adjusting pump and fan speeds proportionally to the thermal demand. Consequently, the system 100 responds dynamically to temperature changes, increasing coolant circulation and airflow when the vehicle subsystem 104 temperatures rise and reducing flow when temperatures approach nominal levels. Advantageously, the control unit 114 provides precise, real-time thermal management, enhancing the efficiency, reliability, and operational safety of the electric vehicle.
In an embodiment, the control unit 114 is configured to modulate the cooling pump 106 speed based on the generated activation signal. The control unit 114 receives the activation signal, which is derived by comparing real-time temperatures of the plurality of vehicle subsystems 104 and sensed by temperature sensors 102, with predefined safe operating thresholds. The control unit 114 calculates the thermal deviation from the thresholds and processes it using a proportional control algorithm to determine the required adjustment to the pump speed. A corresponding drive signal, such as a pulse-width modulation (PWM) signal, is generated where the duty cycle is proportional to the calculated deviation, thereby controlling the electrical power supplied to the cooling pump 106. As a result, the pump speed increases progressively when subsystem temperatures exceed safe limits, enhancing coolant circulation, and decreases when temperatures approach nominal levels, avoiding unnecessary energy consumption. The continuous, real-time modulation ensures optimal coolant flow through the plurality of vehicle subsystems 104, maintaining thermal stability, preventing overheating, and reducing energy waste. Advantageously, the control unit 114 improves thermal management efficiency, reduces mechanical stress on the cooling pump 106, prolongs operational life, and enhances the overall reliability and safety of the electric vehicle.
In an embodiment, the control unit 114 is configured to apply a pulse-width modulation, wherein the pulse-width modulation is proportional to a deviation in the coolant temperature. The control unit 114 continuously acquires real-time temperature values from the coolant temperature sensor 110 and computes the deviation by subtracting a predefined threshold value stored in memory from the measured coolant temperature. Further, a proportional control algorithm processes the deviation by multiplying the deviation by a proportional gain constant (Kp) to generate the PWM duty cycle. For instance, the threshold temperature is 60 °C and the sensor measures 65 °C, the deviation is 5 °C; with a proportional gain constant of 10, the control unit 114 calculates a PWM duty cycle of 50%, which is applied to the power stage of the cooling pump 106. As the deviation increases, the duty cycle rises proportionally, resulting in faster pump operation and higher coolant flow, whereas smaller deviations generate proportionally lower duty cycles and reduced pump speed. The PWM output is continuously updated with each new sensor reading, ensuring that the cooling pump 106 responds immediately to changes in coolant temperature and avoids oscillations or abrupt speed variations. Consequently, the system 100 maintains precise thermal regulation across the plurality of vehicle subsystems 104, prevents overheating, and reduces unnecessary energy consumption. Advantageously, the proportional control algorithm ensures effective dynamic actuation of the cooling pump 106, enhances reliability, and extends the service life of both the pump and thermally sensitive subsystems.
In an embodiment, the control unit 114 is configured to control the fan 112 speed based on the pulse-width modulation. Specifically, the procedure involves the control unit 114 receiving real-time coolant temperature data from the coolant temperature sensor 110, computing the deviation from a predefined threshold, and converting the deviation into a PWM duty cycle. The generated PWM signal is applied to a fan drive circuitry, where the duty cycle directly controls the rotational speed of the fan 112, such that higher coolant temperature deviations correspond to a higher duty cycle and faster fan operation, while lower deviations correspond to a reduced duty cycle and slower fan speed. Furthermore, the control unit 114 continuously updates the PWM output to reflect instantaneous thermal conditions, ensuring smooth acceleration and deceleration of the fan without abrupt transitions. The proportional modulation mechanism directs the airflow through the heat exchanger 108 precisely in line with thermal demand, thereby maintaining stable coolant temperature and consistent subsystem cooling. Advantageously, PWM-based fan speed control not only improves thermal management efficiency but also reduces redundant energy consumption, minimizes mechanical wear on the fan 112, and enhances overall reliability and safety of the electric vehicle.
In accordance with a second aspect, there is described a method of active cooling of an electric vehicle, the method comprising:
- sensing the temperature of a plurality of vehicle subsystems via at least one temperature sensor ;
- sensing a coolant temperature via at least one coolant temperature sensor;
- comparing the sensed temperature values of the plurality of vehicle subsystems with a predefined threshold temperature values via a control unit;
- modulating the cooling pump speed based on a generated activation signal via the control unit; and
- controlling the fan speed based on a pulse-width modulation via the control unit.
Figure 2 describes a method 200 of active cooling of an electric vehicle. The method 200 starts at step 202. At step 202, the method 200 comprises sensing the temperature of a plurality of vehicle subsystems 104 via at least one temperature sensor 102. At step 204, the method 200 comprises sensing a coolant temperature via at least one coolant temperature sensor 110. At step 206, the method 200 comprises comparing the sensed temperature values of the plurality of vehicle subsystems 104 with a predefined threshold temperature value via a control unit 114. At step 208, the method 200 comprises modulating the cooling pump speed based on a generated activation signal via the control unit 114. At step 210, the method 200 comprises modulating an airflow of at least one fan 112 via the control unit 114. The method 200 ends at step 210.
In an embodiment, the method 200 comprises receiving the sensed temperature of the plurality of vehicle subsystems 104 from the at least one temperature sensor 102 and the sensed temperature of the coolant from the at least one coolant temperature sensor 110.
In an embodiment, the method 200 comprises applying a pulse-width modulation and wherein the pulse-width modulation is proportional to a deviation in the coolant temperature, via the control unit 114.
In an embodiment, the method 200 comprises sensing the temperature of a plurality of vehicle subsystems 104 via at least one temperature sensor 102. Further, the method 200 comprises sensing a coolant temperature via at least one coolant temperature sensor 110. Further, the method 200 comprises receiving the sensed temperature of the plurality of vehicle subsystems 104 from the at least one temperature sensor 102 and the sensed temperature of the coolant from the at least one coolant temperature sensor 110. Furthermore, the method 200 comprises comparing the sensed temperature values of the plurality of vehicle subsystems with a predefined threshold temperature value via a control unit 114. Furthermore, the method 200 comprises applying a pulse-width modulation and wherein the pulse-width modulation is proportional to a deviation in the coolant temperature, via the control unit 114. Furthermore, the method 200 comprises modulating the cooling pump 106 speed based on a generated activation signal via the control unit 114, based on the sensed temperatures of the plurality of vehicle subsystems 104 and the coolant. Furthermore, the method 200 comprises modulating an airflow of at least one fan 112, based on the operation of the cooling pump 106 via the control unit 114.
The system and method of active cooling of an electric vehicle, as described in the present disclosure, are advantageous in terms of improved thermal management, subsystem reliability, and operational efficiency through real-time monitoring of temperatures of vehicle subsystems and coolant via integrated temperature sensors.
It would be appreciated that all the explanations and embodiments of the system 100 also apply mutatis-mutandis to the method 200.
In the description of the present disclosure, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may, for example, be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present disclosure can be understood in specific cases by those skilled in the art.
Modifications to embodiments and combinations of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, and “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components, or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art. ,CLAIMS:WE CLAIM:
1. A system (100) for active cooling of an electric vehicle, the system (100) comprises:
- at least one temperature sensor (102) configured to sense the temperature of a plurality of vehicle subsystems (104);
- a cooling pump (106) operatively connected to the plurality of vehicle subsystems and a heat exchanger (108);
- at least one coolant temperature sensor (110) configured to sense coolant temperature;
- at least one fan (112) configured to provide airflow to the heat exchanger (108); and
- a control unit (114) operatively connected to the at least one temperature sensor (102), the cooling pump (106), the at least one coolant temperature sensor (102), and the at least one fan (112), wherein the control unit (114) is configured to:
- control the operation of the cooling pump (106) based on the sensed temperature of the plurality of vehicle subsystems (104) and the sensed temperature of the coolant; and
- modulate the airflow of the at least one fan (112) based on the operation of the cooling pump (106).

2. The system as claimed in claim 1, wherein the plurality of vehicle subsystems (104) comprises at least one of a battery pack, an electric motor, a DC-DC converter unit, and a charger.

3. The system as claimed in claim 1, wherein the cooling pump (106) is operatively connected to the plurality of vehicle subsystems (104) and the heat exchanger (108) via a plurality of coolant lines, and wherein the plurality of coolant lines is configured to form a closed-loop path with the plurality of vehicle subsystems (104) and the heat exchanger (108).

4. The system as claimed in claim 1, wherein the control unit (114) is configured to receive the sensed temperature of the plurality of vehicle subsystems (104) from the at least one temperature sensor (102) and the sensed temperature of the coolant from the at least one coolant temperature sensor (110).

5. The system as claimed in claim 1, wherein the control unit (114) is configured to compare the sensed temperature values of the plurality of vehicle subsystems (104) with a predefined threshold temperature value and generate an activation signal based on the comparison.

6. The system as claimed in claim 1, wherein the control unit (114) is configured to modulate the cooling pump (106) speed based on the generated activation signal.

7. The system as claimed in claim 1, wherein the control unit (114) is configured to apply a pulse-width modulation and wherein the pulse-width modulation is proportional to a deviation in the coolant temperature.

8. The system as claimed in claim 1, wherein the control unit (114) is configured to control the fan (112) speed based on the pulse-width modulation.

9. The method (200) of active cooling of an electric vehicle, the method (200) comprising:
- sensing temperature of a plurality of vehicle subsystems (104) via at least one temperature sensor (102);
- sensing a coolant temperature via at least one coolant temperature sensor (110);
- comparing the sensed temperature values of the plurality of vehicle subsystems (104) with a predefined threshold temperature values via a control unit (114);
- modulating the cooling pump (106) speed based on a generated activation signal via the control unit (114); and
- controlling the fan (112) speed based on a pulse-width modulation via the control unit (114).