EV Battery Thermal Management

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EV Battery Thermal Management

 

 

 

Model	NFEHP6.0-1	Refrigeration capacity	7kW
Rated Voltage	600V DC	Communication method	CAN2.0
Control Voltage	24V	Refrigerant	R134a
Heating capacity	8kW	working temperature	-40℃～50℃
Overvoltage protection /recovery voltage	750/720V DC	Weight	＜55KG
Undervoltage protection /recovery	400/430V DC	Color	White

 

 

It presents the schematic diagram of our EV Battery Thermal Management. In this diagram, the solid red line indicates the refrigeration cycle, while the dashed blue line represents the coolant cycle. The system features three operating modes-cooling, heating, and self-circulation-and switches between them based on feedback parameters received from the battery pack's BMS.

 

① Cooling Mode

 

In cooling mode, the fan and compressor are activated. High-temperature, high-pressure refrigerant discharged from the compressor flows into the condenser, where it releases heat and is cooled. The refrigerant is then throttled and depressurized through a thermal expansion valve (TXV) to achieve the cooling effect. The resulting low-pressure, low-temperature refrigerant enters the battery cooler (chiller) and performs heat exchange with the high-temperature coolant exiting the battery pack. After absorbing heat, the refrigerant returns to the compressor suction port, thereby completing the refrigeration cycle.

 

Simultaneously, the high-temperature coolant leaving the battery pack outlet passes through the water pump and flows into the chiller, where it is cooled. The now low-temperature coolant then enters the battery pack inlet to cool the battery, completing the water circuit cycle.

 

This cooling mode is designed for operating conditions with a high thermal load on the battery pack.

 

② Heating Mode

 

In heating mode, the fan and compressor are turned off, while the water pump and electric heater are turned on. The low-temperature coolant is heated by the electric heater, then flows through the chiller (without active refrigeration) and enters the battery pack to warm the battery.

 

This heating mode is suitable for conditions where the battery temperature is too low.

 

③ Self-Circulation Mode

 

In self-circulation mode, the compressor and electric heater are turned off, while the water pump and fan are turned on. The coolant circulates solely between the thermal management unit and the battery pack, dissipating heat from the battery pack without active refrigeration or heating.

 

This self-circulation mode is intended for operating conditions with a low thermal load on the battery pack.

 

 

 

 

 

 

 

 

1. Q: What are the main functions of the EV Battery Thermal Management ?

A: The EV Battery Thermal Management maintains the battery pack within an optimal temperature range during vehicle operation, charging, or parking. It provides three operating modes – cooling, heating, and self-circulation– to handle different thermal loads and ambient conditions, thereby ensuring battery performance, safety, lifespan, and driving range.

2. Q: What are the key advantages of this system?
A: The EV Battery Thermal Management offers:
- High thermal efficiency
- Enhanced safety
- CAN2.0 communication for real-time BMS integration
- Fault self-diagnosis with error code reporting
- Fast heat dissipation and stable temperature control

3. Q: Which components are included in the standard system?
A: The standard system includes:
- Electric compressor
- Condenser with fan
- Thermal expansion valve (TXV)
- Chiller (refrigerant-to-coolant heat exchanger)
- Electronic water pump
- Radiator with fan
- Electric heater (NF 8KW PTC coolant heater)
- Control valve (e.g., 3-way or 4-way)
- Temperature/pressure sensors

 

4. Q: How does the system communicate with the vehicle's BMS?

A: Our system uses CAN2.0 protocol to exchange real-time data with the BMS, including battery temperature, requested mode, coolant temperature setpoint, fault status, and diagnostic codes. The thermal management unit automatically switches modes based on BMS feedback.

 

5. Q: What fault self-diagnosis functions are available?

A: The system continuously monitors critical parameters such as refrigerant pressure, coolant temperature, compressor current, pump speed, sensor continuity, and communication status. Detected faults trigger error codes stored in the unit and transmitted via CAN. Examples: sensor failure, compressor overcurrent, pump stall, low refrigerant charge, or PTC overheat.

 

6. Q: What are the required electrical and coolant specifications?

A: Typical requirements:
- Voltage: 400-750 V DC (for compressor and PTC) / 24 V DC (for control board, electronic water pump, fans)
- Coolant type:50/50 water-glycol mixture
- Nominal cooling capacity:7kW (depending on battery pack size)
- Heating capacity (PTC):8kW

 

7. Q: Is the system suitable for both commercial and passenger EVs?

A: This product is mainly used for commercial vehicles ,such as electric buses.

 

8. Q: What documentation and support are provided with the RFQ?
A: Upon RFQ confirmation, we provide:
- Technical datasheet (cooling/heating capacity curves, power consumption, dimensions)
- CAN communication protocol (DBC file)
- 3D CAD model (STEP)
- Installation and maintenance manual
- Sample test report (performance, vibration, thermal shock)
- Warranty terms and spare parts list

 

 

Electric air conditioning compressor	Electronic water pump	PTC coolant heater	4 way valve

 

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