An electric bus battery cooling system refers to a liquid cooling system that regulates the temperature of the battery pack carried by an electric bus. The purpose is to prevent the battery pack from overheating during operation, causing performance degradation, damage, or even safety problems. Our professional engineers design the battery cooling system to keep the battery pack within its optimal temperature range. Its existence effectively prolongs battery life, improves energy efficiency, and ensures vehicle safety.
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Specifically, electric bus cooling systems usually use liquid cooling for batteries. It mainly consists of cooling media (such as water, cooling oil, etc.), radiators, water pumps, pipes, and temperature control units. The cooling medium circulates between the battery pack and the radiator. The heat generated by the battery pack is taken away through the principle of heat exchange. The temperature control unit is responsible for monitoring the battery temperature and adjusting the flow and temperature of the cooling medium as needed. This is an important component for achieving precise temperature control.
The main types of battery cooling systems include natural air cooling, forced air cooling, liquid cooling and refrigerant direct cooling. Each method has its advantages and disadvantages. Our experts will recommend the most suitable solution for you based on your actual situation.
For commercial electric vehicles such as electric buses, liquid cooling for batteries is the most stable and cost-effective method.
The battery cooling system also goes by names such as battery thermal management system or EV battery chiller.
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In order to ensure the safe and efficient operation of the battery, the following are several key battery chiller characteristics:
1, Cooling efficiency:
EV battery chiller must be designed to quickly and efficiently remove heat generated by the battery. If cooling is inefficient, it may cause battery performance degradation or even damage. This part requires comprehensive cooling capacity, coolant flow, battery heat generation and other specific parameters.
2, System reliability:
The EV battery chiller should have high reliability and be able to operate stably for a long time. If the system fails, it may cause safety problems. Therefore, we attach great importance to reliability. In addition, the chiller for batteries needs to be maintained and inspected regularly.
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3, Fully automatic intelligent system:
Through intelligent management, the temperature of the battery and the operating status of the cooling system can be monitored. Once an abnormal situation occurs, the system can automatically adjust the cooling strategy or issue an alarm to ensure the safe operation of the battery.
4, Safety protection:
TKT liquid cooling for batteries is designed with a variety of safety protection measures. Such as overheating protection, overvoltage protection, undervoltage protection, overcurrent protection, coolant leakage protection, etc. Prevent battery safety problems caused by cooling system failure.
At the same time, considering that some vehicle companies may design the chiller for batteries outside when designing new electric commercial vehicles. For longer service life and stability. We design its protection to IP67.
The expansion tank is an important component in liquid cooling for batteries. Because the coolant has the characteristics of thermal expansion and contraction, it will discharge or replenish the coolant in the chiller for batteries pipeline in time. Its important function is to ensure the normal pressure of the pipeline and the sufficient amount of coolant.
We have designed a water level switch on the expansion tank. Through it, you can observe the coolant condition to ensure the stable operation of the system.
The water tank self-exhaust system ensures it removes all gas from the coolant before it enters the chiller for batteries. If the coolant in the water tank or pipeline contains too much gas, this may cause the following problems:
1, Gas blockage: The gas forms bubbles in the coolant flow, hindering the effective flow of the coolant and reducing the heat dissipation efficiency.
2, Corrosion: Oxygen in the air may cause corrosion of multiple related components.
3, Pressure fluctuation: The compressibility and expansion of the gas may cause fluctuations in the pressure of the cooling system, affecting the stability of the system.
1, Battery Management System (BMS): This is the core part of the thermal management system and belongs to the commander. It is responsible for monitoring and managing the battery thermal management system (BTMS). It can collect information such as battery voltage, current and temperature, and issue instructions based on this information to control the battery thermal management system (BTMS). Ensure that the battery operates within a safe and efficient range.
2, Battery cooling plate: This is a device for battery heat dissipation. It is usually installed on the surface of the battery. It transfers the heat generated by the battery to the cooling plate through thermal conductive materials, and then releases the heat by air convection or liquid cooling.
3, Battery thermal management system (BTMS): This is a more efficient battery heat dissipation device. It is combined with a coolant circulation system to quickly take away the heat from the cooling plate.
4, High-voltage PTC electric heater: This is a device for battery heating. It is mainly used to increase the battery temperature in a low temperature environment. The PTC electric heater has the characteristics of automatic constant temperature, and can automatically adjust the heating power according to the ambient temperature and battery requirements to ensure that the battery operates at a suitable temperature.
The battery thermal management system uses PTC heating instead of reverse operation for heating, mainly based on the following reasons:
1, Safety and stability: PTC heating elements have self-limiting temperature characteristics. That is, when the temperature rises to a certain value, its resistance will increase sharply, thereby limiting the passage of current and preventing overheating and safety accidents. In contrast, reverse operation requires a more complex control system to ensure safety.
2, Energy efficiency: PTC heating method performs well in energy conversion efficiency. It can effectively convert electrical energy into thermal energy, thereby quickly increasing the battery temperature. Reverse operation requires more energy to achieve the same heating effect.
3, Heating speed and control accuracy: PTC heating elements can respond quickly to temperature changes and provide fast heating speed. At the same time, by adjusting the power and layout of the PTC element, precise control of the battery temperature can be achieved.
In summary, the PTC heating method is selected in the battery thermal management system because it has greater advantages in safety, energy efficiency, heating speed, and control accuracy.
Over the past 10 years, TKT has developed rapidly and has become the top 3 battery cooling system manufacturers in China. With rich OEM experience, we have cooperated with many world-famous vehicle manufacturers.
Further Reading: How Does BTMS Work?
Case Story: TKT Integrated Battery Cooling and Air Conditioning System for BYD Electric Buses
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