Description:TITLE OF THE INVENTION: THERMAL MANAGEMENT SYSTEM FOR A LOCOMOTORY DEVICE
FIELD OF THE INVENTION
The present disclosure is generally related to a thermal management system. Particularly, the present disclosure is related to a thermal management system for a locomotory device.
BACKGROUND OF THE INVENTION
A thermal management system of locomotory devices typically employs a single or a pair of fans to manage cooling demands of an energy storage system and power electronics. In the conventional thermal management system, these fans are controlled by a single controlling mechanism, which engages both fans together all the time and at a same speed, regardless of whether the cooling demands of the energy storage system and the power electronics are different.
However, such conventional systems suffer from at least the following drawbacks: the thermal management system cannot control and/or regulate the fans independently; less airflow to a condenser for cooling the energy storage system, leads to insufficient subcooling, resulting in inadequate cooling for battery cooling unit, which leads to stop the locomotory device; increased power consumption; and/or potential wear on the fans due to constant high-speed operation.
There is, therefore, a need in the art, for: a thermal management system for a locomotory device, which overcomes the aforementioned drawbacks and shortcomings.
SUMMARY OF THE INVENTION
A thermal management system for a locomotory device, is disclosed. Said thermal management system broadly comprises: an at least a condenser; a first air disseminating member; an at least a radiator; a second air disseminating member; an at least an enclosing member; a battery cooling unit; and a power electronic cooling unit.
The at least one enclosing member broadly comprises: a front portion and a rear portion. Said rear portion broadly comprises: an upper section; an intermediate section; and a lower section.
Said at least one condenser and said at least one radiator are disposed (or installed, or mounted, or positioned) inside the front portion of the at least one enclosing member, one over the other.
Said first air disseminating member is disposed (or installed, or mounted, or positioned) on a rear side of the at least one condenser, and within the upper section of the rear portion.
Said second air disseminating member is disposed (or installed, or mounted, or positioned) on a rear side of the at least one radiator, and within the lower section and the intermediate section, of the rear portion.
In an embodiment, the intermediate section is configured to reroute about 10% to about 15% of air sucked by the second air disseminating member to the at least one condenser.
Said first air disseminating member is disposed (or installed, or mounted, or positioned) diagonally to said second air disseminating member on the rear portion of the at least one enclosing member.
In an embodiment, an area occupied by the second air disseminating member in the lower section and the intermediate section is about 85% and about 15%, respectively.
In an embodiment, an area occupied by the second air disseminating member in the lower section and the intermediate section is about 90% and about 10%, respectively.
Said first air disseminating member enabling the ambient air to pass through the at least one condenser fully, whereas the second air disseminating member enables the air to pass through both the at least one radiator and the at least one condenser.
In an embodiment, said first air disseminating member enables the ambient air to pass through the at least one condenser fully, whereas the second air disseminating member enables only about 85% to about 90% of air to pass through the at least one radiator and about 10% to about 15% of air to pass through the at least one condenser.

In an embodiment, said first air disseminating member and said second air disseminating member are Brushless Direct Current fan.
Said battery cooling unit is configured to perform thermal management of an at least an energy storage system. Said battery cooling unit broadly comprises: a first controlling member; a first temperature sensing member; a second temperature sensing member; and a first pump.
The first controlling member monitors and controls the operations of the battery cooling unit.
The first temperature sensing member is disposed (or installed, or mounted, or positioned) on an output port of a chiller, and senses the temperature of coolant comes out from the chiller, with the sensed data being transmitted to the first controlling member.
The second temperature sensing member is disposed (or installed, or mounted, or positioned) on the at least one energy storage system, and senses the temperature of battery cells, with the sensed data being transmitted to the first controlling member.
The first pump is configured to circulate the coolant from the chiller to the at least one energy storage system.
The power electronic cooling unit is configured to perform thermal management of power electronic components. Said power electronic cooling unit broadly comprises: a second controlling member; a third temperature sensing member; and a second pump.
The second controlling member monitors and controls the operations of the power electronic cooling unit.
The third temperature sensing member is disposed (or installed, or mounted, or positioned) between the outlet of the at least one radiator and the second pump, and senses the temperature of coolant comes out from the at least one radiator, with the sensed data being transmitted to the second controlling member.
The second pump is configured to direct the coolant comes out from the at least one radiator to the power electronic components.
Said first controlling member is communicatively associated with the second controlling member, and the first controlling member is configured to control the second air disseminating member through the second controlling member.
In an embodiment, the first controlling member and the second controlling member are Electronic Control Units (ECUs).
The system further comprises an at least a deaeration tank. Said at least one deaeration tank is disposed (or installed, or mounted, or positioned) on the upper section and over the at least one condenser. The at least one deaeration tank is configured to store the coolant and releases pressure to the atmosphere when the pressure exceeds a threshold.
In an embodiment, the threshold pressure is about 1.4 bar.
The method of working of the thermal management system is also disclosed.
The disclosed thermal management system for a locomotory device offers at least the following advantages: can control and/or regulate the air disseminating members and their speeds independently; allowing of about 10% to about 15% atmospheric air drawn by the second air disseminating member to flow through the at least one condenser, thereby enabling enhanced subcooling and prioritized BCU cooling; decreased power consumption; improved durability and lifespan by reducing frequent high-speed operation and activation.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 and Figure 1a illustrate a thermal management system for a locomotory device, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates an upper section, an intermediate section, and a lower section of a thermal management system for a locomotory device, in accordance with an embodiment of the present disclosure;
Figure 3 and Figure 3a illustrate a 3D isometric view of a thermal management system for a locomotory device, in accordance with an embodiment of the present disclosure; and
Figure 4 illustrates a flow chart of a thermal management for a locomotory device, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
Throughout this specification, the use of the words “comprise” and “include”, and variations, such as “comprises”, “comprising”, “includes”, and “including”, may imply the inclusion of an element (or elements) not specifically recited. Further, the disclosed embodiments may be embodied, in various other forms, as well.
Throughout this specification, the use of the word “system” is to be construed as: “a set of technical components (also referred to as “members”) that are communicatively and/or operably associated with each other, and function together, as part of a mechanism, to achieve a desired technical result”.
Throughout this specification, the use of the words “communication”, “couple”, and their variations (such as communicatively), is to be construed as being inclusive of: one-way communication (or coupling); and two-way communication (or coupling), as the case may be, irrespective of the directions of arrows, in the drawings.
Throughout this specification, where applicable, the use of the phrase “at least” is to be construed in association with the suffix “one” i.e. it is to be read along with the suffix “one”, as “at least one”, which is used in the meaning of “one or more”. A person skilled in the art will appreciate the fact that the phrase “at least one” is a standard term that is used, in Patent Specifications, to denote any component of a disclosure, which may be present (or disposed) in a single quantity, or more than a single quantity.
Throughout this specification, the use of the word “plurality” is to be construed as being inclusive of: “at least one”.
Throughout this specification, where applicable, the use of the phrase “at least one” is to be construed in association with a succeeding component name.
Throughout this specification, the phrases “at least a”, “at least an”, and “at least one” are used interchangeably.
Throughout this specification, the disclosure of a range is to be construed as being inclusive of: the lower limit of the range; and the upper limit of the range.
Throughout this specification, the words “the” and “said” are used interchangeably.
Throughout this specification, the use of the acronym “PWM”, is to be constructed as: “Pulse Width Modulation”.
Throughout this specification, the use of the acronym “TXV”, is to be constructed as: “Thermal Expansion Value”.
Throughout this specification, the use of the phrase “energy storage system”, the word “battery”, the acronym “ESS”, and their variations, is to be construed as being inclusive of: “battery modules; battery packs; battery systems; and/or the like”.
Throughout this specification, where applicable, the phrase “energy storage system”, the acronym “ESS”, and the word “battery” are used interchangeably.
Throughout this specification, the use of the acronyms “BCU” is to be constructed as: “Battery Cooling Unit”.
Throughout this specification, the use of the phrase “power electronic components”, and their variations, is to be construed as being inclusive of: “traction motor, motor control unit, direct current motor, and/or the like”.
Throughout this specification, the use of the acronyms “PECU” is to be constructed as: “Power Electronics Cooling Unit”.
Throughout this specification, the use of the phrase “locomotory device”, and its variations, is to be construed as: “electric vehicles; battery powered vehicles; and/or the like”.
Throughout this specification, the use of the phrase “thermal management system for a locomotory device” and its variations, is to be construed as: “thermal management system for an electric vehicle”.
Also, it is to be noted that embodiments may be described as a method. Although the operations, in a method, are described as a sequential process, many of the operations may be performed in parallel, concurrently, or simultaneously. In addition, the order of the operations may be re-arranged. A method may be terminated, when its operations are completed, but may also have additional steps.
A thermal management system for a locomotory device (also referred to as “system”), is disclosed. In an embodiment of the present disclosure, as illustrated in Figure 1, and Figure 1a, said thermal management system broadly comprises: an at least a condenser (1); a first air disseminating member (2); an at least a radiator (3); a second air disseminating member (4); an at least an enclosing member (5); a battery cooling unit (6); and a power electronic cooling unit (9).
In another embodiment of the present disclosure, said at least one condenser (1), said first air disseminating member (2), said at least one radiator (3), and said second air disseminating member (4), are disposed (or installed, or mounted, or positioned) within the at least one enclosing member (5).
In yet another embodiment of the present disclosure, said at least one enclosing member (5) broadly comprises: a front portion and a rear portion. Said rear portion broadly comprises: an upper section (14); an intermediate section (13); and a lower section (15), as illustrated in Figure 2 and Figure 3a.
In yet another embodiment of the present disclosure, said at least one enclosing member (5) is a shroud.
In yet another embodiment of the present disclosure, the at least one condenser (1) and the at least one radiator (3) are disposed (or installed, or mounted, or positioned) inside the front portion of the at least one enclosing member (5), one over the other.
In yet another embodiment of the present disclosure, a gap between the at least one condenser (1) and the at least one radiator (3) is filled with a seal.
In yet another embodiment of the present disclosure, said at least one condenser (1) is disposed (or installed, or mounted, or positioned) above the at least one radiator (3). The at least one condenser (1) receives refrigerant from a compressor as a high pressure and high temperature gas. Said at least one condenser (1) is configured to transfer heat from refrigerant to ambient (or atmospheric) air through forced convection and causing the refrigerant to change into a high-pressure and low/medium temperature liquid. Then said high-pressure and low/medium temperature liquid passes through a TXV, and exits as a low-pressure and low-temperature liquid before entering a chiller, and exists the chiller as a low pressure and low temperature gas.
In yet another embodiment of the present disclosure, said chiller is configured as a heat exchanger, which facilitates heat transfer from the hot coolant exiting an at least an energy storage system (7) with the help of the low-temperature refrigerant.
Said at least one radiator (3) is configured as a cross-flow heat exchanger, to transfer heat from a hot coolant, which circulates the power electronic components (10), to the ambient air through forced convection. Once the coolant is cooled, it flows from the at least one radiator (3) to a second pump (12B) that subsequently directs the coolant to the power electronic components (10) to maintain their optimal operating temperature.
In yet another embodiment of the present disclosure, the optimal operating temperature of the power electronic components (10) is about 65 degrees Centigrade.
In yet another embodiment of the present disclosure, said first air disseminating member (2) is disposed (or installed, or mounted, or positioned) on a rear side of the at least one condenser (1), and within the upper section (14) of the rear portion, whereas said second air disseminating member (4) is disposed (or installed, or mounted, or positioned) on a rear side of the at least one radiator (3), and within the lower section (15) and the intermediate section (13), of the rear portion. Said first air disseminating member (2), and said second air disseminating member (4) are configured to pull (or suck, or draw) the ambient air to optimize effective heat transfer.
In yet another embodiment of the present disclosure, an area occupied by the second air disseminating member (4) in the lower section (15) and the intermediate section (13) is about 85% and about 15%, respectively.
In yet another embodiment of the present disclosure, an area occupied by the second air disseminating member (4) in the lower section (15) and the intermediate section (13) is about 90% and about 10%, respectively.
The first air disseminating member (2) enables the ambient air to pass through the at least one condenser (1) fully (or alone), whereas the second air disseminating member (4) enables only about 85% to about 90% of air to pass through the at least one radiator (3) and the remaining about 10% to about 15% of air to pass through the at least one condenser (1), as illustrated in Figure 1a and Figure 2.
Said intermediate section (13) is configured in such a way that, as illustrated in Figure 2, to reroute about 10% to about 15% of air sucked by the second air disseminating member (4) to the at least one condenser (1).
The first air disseminating member (2) works 100% (fully) for the at least one condenser (1), whereas the working of the second air disseminating member (4) is shared between the at least one radiator (3) and the at least one condenser (1) in the ratio of about 85:15 (or 90:10).
In yet another embodiment of the present disclosure, as illustrated in Figure 2 and Figure 3, said first air disseminating member (2) is disposed diagonally (or installed, or positioned) to said second air disseminating member (4) on the rear portion of the at least one enclosing member (5).
In yet another embodiment of the present disclosure, said first air disseminating member (2) and said second air disseminating member (4) are BLDC fan (Brushless Direct Current fan).
In yet another embodiment of the present disclosure, said battery cooling unit (6) is configured to perform thermal management of the at least one energy storage system (7), whereas said power electronics cooling unit (9) is configured to perform thermal management of power electronic components (10).
Said battery cooling unit (6) is an active cooling system and is configured to receive low-temperature refrigerant from the at least one condenser (1). The battery cooling unit (6) facilitates to remove heat from the coolant that exits from the at least one energy storage system (7).
Since the operating temperature of the at least one energy storage system (7) is to be lower than the ambient temperature, the coolant at a temperature below the ambient temperature is used to be circulating on the at least one energy storage system (7) to maintain the operating temperature. To lower the coolant temperature below the ambient temperature the refrigerant is used, which operates in a Rankine cycle that uses the refrigerant to transfer heat and cool the at least one energy storage system (7).
In yet another embodiment of the present disclosure, as illustrated in Figure 1, the battery cooling unit (6) broadly comprises: a first temperature sensing member (6a); a second temperature sensing member (7a); a first controlling member (8); and a first pump (12A).
Said first temperature sensing member (6a) is disposed (or positioned, or installed) on an output port of the chiller, and senses the temperature of coolant comes out from the chiller, with the sensed data being transmitted to the first controlling member (8).
In yet another embodiment of the present disclosure, the first controlling member (8) monitors and controls the operations of the battery cooling unit (6).
The first pump (12A) is configured to circulate the coolant from the chiller to the at least one energy storage system (7).
Said second temperature sensing member (7a) is disposed (or positioned, or installed) on the at least one energy storage system (7), and senses the temperature of battery cells, with the sensed data being transmitted to the first controlling member (8).
In yet another embodiment of the present disclosure, said first air disseminating member (2), said first temperature sensing member (6a), said second temperature sensing member (7a), and said first pump (12A) are associated (i.e. operatively associated) with the first controlling member (8).
Said first controlling member (8) is configured to perform the thermal management of the at least one energy storage system (7) and also responsible to switch ON and/or switch OFF the first air disseminating member (2), as per requirement.
Said power electronic cooling unit (9) is a passive cooling system and is configured to receive hot coolant from the power electronic components (10), which is cooled through the at least one radiator (3) and the second air disseminating member (4). Said second air disseminating member (4) ensures the required airflow over the at least one radiator (3).
In yet another embodiment of the present disclosure, as illustrated in Figure 1, the power electronic cooling unit (9) broadly comprises: a third temperature sensing member (9a); and a second controlling member (11).
In yet another embodiment of the present disclosure, the second controlling member (11) monitors and controls the operations of the power electronic cooling unit (9).
Said third temperature sensing member (9a) is disposed (or installed, or positioned, or mounted) between the outlet of the at least one radiator (3) and the second pump (12B), and senses the temperature of coolant comes out from the at least one radiator (3), with the sensed data being transmitted to the second controlling member (11).
Said second controlling member (11) is configured to perform the thermal management of the power electronic components (10), also responsible to switch ON and/or switch OFF the second air disseminating member (4), as per requirement.
In yet another embodiment of the present disclosure, said first controlling member (8) is communicatively (and/or operatively) associated with the second controlling member (11), and the first controlling member (8) is configured to control the operations of the second air disseminating member (4) through the second controlling member (11), as per requirement.
In yet another embodiment of the present disclosure, the first controlling member (8) and the second controlling member (11) are Electronic Control Units (ECUs).
In yet another embodiment of the present disclosure, as illustrated in Figure 3 and Figure 3a, said thermal management system further comprises: an at least a deaeration tank (16).
In yet another embodiment of the present disclosure, said at least one deaeration tank (16) is disposed (or installed, or positioned, or mounted) on the upper section (14) and over the at least one condenser (1). Said at least one deaeration tank (16) is configured to store the coolant and releases pressure to the atmosphere when the pressure exceeds a threshold.
In yet another embodiment of the present disclosure, the threshold pressure is about 1.4 bar.
The method of working of the thermal management system for a locomotory device, shall now be explained.
As illustrated in Figure 4, when the locomotory device is turned ON and the at least one energy storage system (7) is either under charging or discharging, both the battery cooling unit (6) and the power electronic cooling unit (9) will become active.
The first controlling member (8) start receiving data continuously, in real-time, from the first temperature sensing member (6a), and the second temperature sensing member (7a), and the second controlling member (11) start receiving data continuously, in real-time, from the third temperature sensing member (9a).
The battery cooling unit (6) shall work normally until the temperature data (i.e. battery cell temperature and coolant temperature) received from the first temperature sensing member (6a), and the second temperature sensing member (7a) are above or below a first threshold and a second threshold, respectively, and the temperature data received from the first temperature sensing member (6a) is above the first threshold but below a fourth threshold.
In yet another embodiment of the present disclosure, the first threshold, the second threshold, and the fourth threshold are about 35 degrees Centigrade, about 20 degrees Centigrade, and about 42 degrees Centigrade, respectively.
For example, if the first threshold and the second threshold are below 35 degrees Centigrade and 20 degrees Centigrade, respectively, the battery cooling unit (6) shall switch OFF the chiller and the first air disseminating member (2), and if the first threshold and the second threshold are above 35 degrees Centigrade (but below the fourth threshold) and 20 degrees Centigrade, respectively, the battery cooling unit (6) shall switch ON the chiller and the first air disseminating member (2).
Similarly, the power electronic cooling unit (9) shall also work normally until the temperature data (i.e. coolant temperature) received from the third temperature sensing member (9a) is above or below a third threshold.
In yet another embodiment of the present disclosure, the third threshold is about 50 degrees Centigrade.
For example, if the third threshold is below 50 degrees Centigrade, the power electronic cooling unit (9) shall switch OFF the second air disseminating member (4), and if the third threshold is above 50 degrees Centigrade, the power electronic cooling unit (9) shall switch ON the second air disseminating member (4).
However, if the temperature data received from the first temperature sensing member (6a) is above the fourth threshold (i.e. near the battery derating temperature), the battery cooling unit (6) shall instruct the power electronic cooling unit (9) switch ON the second air disseminating member (4), apart from switching ON the first air disseminating member (2), thereby enabling additional suction of about 10% to about 15% of air by the second air disseminating member (4) through the at least one condenser (1). Hence, allowing to perform thermal management of the at least one energy storage system (7) effectively during critical conditions.
The disclosed thermal management system for a locomotory device offers at least the following advantages: can control and/or regulate the air disseminating members and their speeds independently; allowing of about 10% to about 15% atmospheric air drawn by the second air disseminating member (4) to flow through the at least one condenser (1), thereby enabling enhanced subcooling and prioritized BCU cooling; decreased power consumption; and improved durability and lifespan by reducing frequent high-speed operation and activation.
It will be apparent to a person skilled in the art that the above description is for illustrative purposes only and should not be considered as limiting. Various modifications, additions, alterations, and improvements without deviating from the spirit and the scope of the disclosure may be made by a person skilled in the art. Such modifications, additions, alterations, and improvements should be construed as being within the scope of this disclosure.
LIST OF REFERENCE NUMERALS
1 – At Least One Condenser
2 – First Air Disseminating Member
3 – At Least One Radiator
4 – Second Air Disseminating Member
5 – At Least One Enclosing Member
6 – Battery Cooling Unit
6a – First Temperature Sensing Member
7 – At Least One Energy Storage System
7a - Second Temperature Sensing Member
8 – First Controlling Member
9 –Power Electronic Cooling Unit
9a – Third Temperature Sensing Member
10 –Power Electronic Components
11 – Second Controlling Member
12A – First Pump
12B – Second Pump
13 – Intermediate Section
14 – Upper Section
15 – Lower Section
16 – At Least One Deaeration Tank , Claims:1. A thermal management system for a locomotory device, comprising:
an at least an enclosing member (5) that comprises: a front portion and a rear portion, with: said rear portion comprising an upper section (14); an intermediate section (13); and a lower section (15);
an at least a condenser (1) and an at least a radiator (3) that are disposed inside the front portion of the at least one enclosing member (5), one over the other;
a first air disseminating member (2) that is disposed on a rear side of the at least one condenser (1), and within the upper section (14) of the rear portion;
a second air disseminating member (4) that is disposed on a rear side of the at least one radiator (3), and within the lower section (15) and the intermediate section (13), of the rear portion;
a battery cooling unit (6) that is configured to perform thermal management of an at least an energy storage system (7), said battery cooling unit (6) comprising:
a first controlling member (8) that monitors and controls the operations of the battery cooling unit (6);
a first temperature sensing member (6a) that is disposed on an output port of a chiller, and senses the temperature of coolant comes out from the chiller, with the sensed data being transmitted to the first controlling member (8);
a second temperature sensing member (7a) that is disposed on the at least one energy storage system (7), and senses the temperature of battery cells, with the sensed data being transmitted to the first controlling member (8); and
a first pump (12A) that is configured to circulate coolant from the chiller to the at least one energy storage system (7);
a power electronic cooling unit (9) that is configured to perform thermal management of power electronic components (10), said power electronic cooling unit (9) comprising:
a second controlling member (11) that monitors and controls the operations of the power electronic cooling unit (9);
a third temperature sensing member (9a) that is disposed between the outlet of the at least one radiator (3) and a second pump (12B), and senses the temperature of coolant comes out from the at least one radiator (3), with the sensed data being transmitted to the second controlling member (11); and
the second pump (12B) that is configured to direct the coolant comes out from the at least one radiator (3) to the power electronic components (10); and
an at least a deaeration tank (16) that is disposed on the upper section (14) and over the at least one condenser (1), and is configured to store the coolant and releases pressure to the atmosphere when the pressure exceeds a threshold, with:
said first controlling member (8) being communicatively associated with the second controlling member (11), and the first controlling member (8) being configured to control the second air disseminating member (4) through the second controlling member (11);
said first air disseminating member (2) being disposed diagonally to said second air disseminating member (4) on the rear portion of the at least one enclosing member (5); and
said first air disseminating member (2) enabling the ambient air to pass through the at least one condenser (1) fully, whereas the second air disseminating member (4) enables the air to pass through both the at least one radiator (3) and the at least one condenser (1).
2. The thermal management system for a locomotory device, as claimed in claim 1, wherein: an area occupied by the second air disseminating member (4) in the lower section (15) and the intermediate section (13) is 85% and 15%, respectively.
3. The thermal management system for a locomotory device, as claimed in claim 1, wherein: an area occupied by the second air disseminating member (4) in the lower section (15) and the intermediate section (13) is 90% and 10%, respectively.
4. The thermal management system for a locomotory device, as claimed in claim 1, wherein: the intermediate section (13) is configured to reroute 10% to 15% of air sucked by the second air disseminating member (4) to the at least one condenser (1).
5. The thermal management system for a locomotory device, as claimed in claim 1, wherein: said first air disseminating member (2) enables the ambient air to pass through the at least one condenser (1) fully, whereas the second air disseminating member (4) enables only 85% to 90% of air to pass through the at least one radiator (3) and 10% to 15% of air to pass through the at least one condenser (1).
6. The thermal management system for a locomotory device, as claimed in claim 1, wherein: said first air disseminating member (2) and said second air disseminating member (4) are Brushless Direct Current fan.
7. The thermal management system for a locomotory device, as claimed in claim 1, wherein: the threshold pressure is 1.4 bar.
8. The thermal management system for a locomotory device, as claimed in claim 1, wherein: the first controlling member (8) and the second controlling member (11) are Electronic Control Units.