Vehicle HVAC and RESS Thermal Management

• US 20100012295A1
• Filed: 07/21/2008
• Published: 01/21/2010
• Est. Priority Date: 07/21/2008
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations Incorporated (Motors Liquidation Co. GUC Trust)
• Inventors: Martinchick, Matthew J., Ibri, Wissam, Nemesh, Mark D., Singh, Kulwinder
• Granted Patent: US 7,975,757 B2
• Time in Patent Office: Days
• US Class Current: 165/104.190
• CPC Class Codes: B60H 1/00278 for the battery arrangement of batteries B60R16/04
• CPC Class Codes: B60H 1/004 for vehicles having a combustion engine and electric drive means, e.g. hybrid electric vehicles
• CPC Class Codes: B60H 1/32281 comprising a single secondary circuit, e.g. at evaporator or condenser side
• CPC Class Codes: B60H 2001/00307 Component temperature regulation using a liquid flow
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60L 58/27 by heating
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/615 Heating or keeping warm
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/6568 characterised by flow circuits, e.g. loops, located externally to the cells or cell casings
• CPC Class Codes: H01M 10/657 by electric or electromagnetic means
• CPC Class Codes: H01M 10/663 the system being an air-conditioner or an engine
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A HVAC and RESS thermal management system and a method of operation for a vehicle having a passenger compartment, a power plant and a battery pack is disclosed. The system comprises a RESS coolant circuit and a power plant coolant circuit. The RESS coolant circuit directs a coolant through the battery pack and includes a pump, a coolant heating branch has a coolant-to-coolant heat exchanger, and a coolant routing valve that will selectively direct the coolant through the coolant heating branch. The power plant coolant circuit includes a heater core branch having a HVAC pump, a coolant heater, a heater core located in a HVAC module to provide heat to the passenger compartment, and the coolant-to-coolant heat exchanger, with the coolant-to-coolant heat exchanger providing heat transfer between the coolant in the coolant heating branch and the coolant in the heater core branch.

Claims

1. A HVAC and RESS thermal management system for a vehicle having a passenger compartment, a power plant and a battery pack, the system comprising:

a RESS coolant circuit configured to direct a coolant through the battery pack and including a pump for pumping the coolant through the RESS coolant circuit, a coolant heating branch having a coolant-to-coolant heat exchanger, and a controllable coolant routing valve that is actuatable to selectively direct the coolant through the coolant heating branch; and

a power plant coolant circuit including a heater core branch, the heater core branch having a HVAC pump for pumping the coolant through the heater core branch, a coolant heater, a heater core configured to be located in a HVAC module to provide heat to the passenger compartment, and the coolant-to-coolant heat exchanger, the coolant-to-coolant heat exchanger configured to provide heat transfer between the coolant in the coolant heating branch and the coolant in the heater core branch.

2. The system of claim 1 wherein the power plant coolant circuit includes a power plant branch configured to direct the coolant through the power plant and a controllable heating circuit coolant routing valve that is actuatable to selectively direct the coolant through the power plant branch and to selectively bypass the power plant branch.

3. The system of claim 2 wherein the RESS coolant circuit includes a chiller branch including a chiller, with the controllable coolant routing valve actuatable to selectively direct the coolant through the chiller branch, bypassing the coolant-to-coolant heat exchanger, and actuatable to selectively direct the coolant through the coolant heating branch.

4. The system of claim 3 wherein the chiller is configured to accept a refrigerant flow therethrough that is adapted to absorb heat from the coolant flowing through the chiller.

5. The system of claim 1 wherein the RESS coolant circuit includes a chiller branch including a chiller, with the controllable coolant routing valve actuatable to selectively direct the coolant through the chiller branch, bypassing the coolant-to-coolant heat exchanger, and actuatable to selectively direct the coolant through the coolant heating branch.

6. The system of claim 5 wherein the RESS coolant circuit includes a RESS radiator branch including a RESS radiator, with the controllable coolant routing valve actuatable to selectively direct the coolant through the RESS radiator branch, bypassing the coolant-to-coolant heat exchanger, actuatable to selectively direct the coolant through the chiller branch, and actuatable to selectively direct the coolant through the coolant heating branch.

7. The system of claim 6 wherein the RESS coolant circuit includes an air separator that is in fluid communication with at least one of the RESS radiator branch and the chiller branch.

8. The system of claim 1 wherein the RESS coolant circuit includes a RESS radiator branch including a RESS radiator, with the controllable coolant routing valve actuatable to selectively direct the coolant through the RESS radiator branch, bypassing the coolant-to-coolant heat exchanger, and actuatable to selectively direct the coolant through the coolant heating branch.

9. The system of claim 1 including a first coolant temperature sensor configured to measure a coolant temperature just upstream of the battery pack and a second coolant temperature sensor configured to measure the coolant temperature just downstream of the battery pack.

10. A method of thermally controlling a passenger compartment and a battery pack of a vehicle having a power plant, the method comprising the steps of:

(a) detecting if a battery warming load is requested for the battery pack;

(b) if the battery warming load is requested, activating a HVAC coolant pump to pump a coolant through a heater core branch of a power plant coolant circuit including a coolant heater and a coolant-to-coolant heat exchanger and activating the coolant heater to warm the coolant flowing therethrough; and

(c) if the battery warming load is requested, activating a pump and setting a controllable coolant routing valve to direct the coolant through a coolant heating branch of a RESS coolant circuit including the battery pack and the coolant-to-coolant heat exchanger, whereby the coolant flowing through the coolant heating branch will absorb heat from the coolant flowing through the heater core branch in the coolant-to-coolant heat exchanger.

11. The method of claim 10 wherein step (b) is further defined by:

if the battery warming load is requested, then pumping the coolant through a heater core that is in the heater core branch and is located in a HVAC module.

12. The method of claim 10 including:

(d) detecting if a battery cooling load is requested for the battery pack;

(e) if a battery cooling load is detected and the battery cooling load is a relatively lower amount of cooling, activating the pump, and setting the controllable coolant routing valve to bypass the coolant heating branch and direct the coolant through a RESS radiator in a RESS radiator branch of the RESS coolant circuit; and

(f) if battery cooling load is detected and the battery cooling load is a relatively higher amount of cooling, activating the pump, setting the controllable coolant routing valve to bypass the coolant heating branch and direct the coolant through a chiller in a chiller branch of the RESS coolant circuit, and activating a refrigerant compressor to cause cooled refrigerant to flow through the chiller to thereby absorb heat from the coolant flowing through the chiller.

13. The method of claim 10 including:

(d) detecting if a coolant temperature in the power plant is above a predetermined temperature threshold; and

(e) if the coolant temperature in the power plant is equal to or greater than the predetermined temperature threshold and the battery warming load is requested, activating the HVAC coolant pump to pump the coolant through a heater core branch of a power plant coolant circuit including a coolant-to-coolant heat exchanger, setting a valve to direct the coolant from the heater core branch through the power plant in a power plant branch and back to the heater core branch, and activating the pump and setting the controllable coolant routing valve to direct the coolant through the coolant heating branch, whereby the coolant flowing through the coolant heating branch will absorb heat from the coolant flowing through the heater core branch in the coolant-to-coolant heat exchanger.

14. The method of claim 13 including:

(f) detecting if a passenger compartment warming load is requested for the passenger compartment; and

(g) if the coolant temperature in the power plant is equal to or greater than the predetermined temperature threshold and the passenger compartment warming load is requested, activating the HVAC coolant pump to pump the coolant through the heater core branch, setting a valve to direct the coolant from the heater core branch through the power plant in a power plant branch and back to the heater core branch, and activating the blower to cause air flow through the heater core.

15. A method of thermally controlling a passenger compartment and a battery pack of a vehicle having a power plant, the method comprising the steps of:

(a) detecting if a battery warming load is requested for the battery pack;

(b) detecting if a coolant temperature in the power plant is above a predetermined temperature threshold;

(c) detecting if a passenger compartment warming load is requested for the passenger compartment;

(d) if the coolant temperature in the power plant is not above the predetermined temperature threshold and the passenger compartment warming load is requested, activating a HVAC coolant pump to pump a coolant through a heater core branch of a power plant coolant circuit including a coolant heater, a heater core in a HVAC module and a coolant-to-coolant heat exchanger, activating the coolant heater to warm the coolant flowing therethrough, and activating a blower to cause air flow through the heater core;

(e) if the coolant temperature in the power plant is equal to or greater than the predetermined temperature threshold and the passenger compartment warming load is requested, activating the HVAC coolant pump to pump the coolant through the heater core branch, setting a valve to direct the coolant from the heater core branch through the power plant in a power plant branch and back to the heater core branch, and activating the blower to cause air flow through the heater core; and

(f) if the coolant temperature in the power plant is equal to or greater than the predetermined temperature threshold, the passenger compartment warming load is requested, and the battery warming load is requested, activating the HVAC coolant pump to pump the coolant through the heater core branch, setting a valve to direct the coolant from the heater core branch through the power plant in a power plant branch and back to the heater core branch, activating the blower to cause air flow through the heater core, activating a pump and setting a controllable coolant routing valve to direct the coolant through a coolant heating branch of a RESS coolant circuit including the battery pack and the coolant-to-coolant heat exchanger, whereby the coolant flowing through the coolant heating branch will absorb heat from the coolant flowing through the heater core branch in the coolant-to-coolant heat exchanger.

16. The method of claim 15 wherein step (f) is further defined by cycling the controllable coolant routing valve between directing the coolant through the coolant heating branch and through a branch of the RESS coolant circuit that bypasses the coolant-to-coolant heat exchanger.

17. The method of claim 15 wherein step (f) is further defined by setting the controllable coolant routing valve to direct a first portion of the coolant flowing therethrough into the coolant heating branch and directing a remaining portion of the coolant flowing therethrough into a branch of the RESS coolant circuit that bypasses the coolant-to-coolant heat exchanger.

18. The method of claim 15 wherein step (e) is further defined by selectively activating the coolant heater to produce supplemental coolant heating if the coolant temperature in the power plant is equal to or greater than the predetermined temperature threshold, the passenger compartment warming load is requested, and an ambient air temperature is below a predetermined ambient temperature threshold.

19. The method of claim 15 including:

(g) if the passenger compartment warming load is not detected and the battery warming load is requested, activating the HVAC coolant pump to pump the coolant through the heater core branch, activating the coolant heater to warm the coolant flowing therethrough, activating the pump and setting the controllable coolant routing valve to direct the coolant through the coolant heating branch, whereby the coolant flowing through the coolant heating branch will absorb heat from the coolant flowing through the heater core branch in the coolant-to-coolant heat exchanger.

20. The method of claim 15 including:

(g) detecting if passenger compartment preconditioning is requested;

(h) if the passenger compartment preconditioning is requested, activating the HVAC coolant pump to pump the coolant through the heater core branch, activating the coolant heater to warm the coolant flowing therethrough, and activating a blower to cause air flow through the heater core;

(i) detecting how long the passenger compartment preconditioning is activated; and

(k) ceasing the passenger compartment preconditioning when the passenger compartment preconditioning has been activated for greater than a predetermined time period.