Cooling system for a motor vehicle

Abstract

Cooling system for a motor vehicle. The invention relates to a cooling system for an electrically driven motor vehicle (2), which cooling system consists of a chiller circuit (10), a battery circuit (20), a refrigerator circuit (30) and an electronics circuit (40) and a first switching valve, wherein each cooling circuit can be divided into subcircuits.

Description

Technical Field

[0001] The present invention relates to a cooling system, thermal management module for a motor vehicle of the type described in the independent patent claims, and a motor vehicle having such a cooling system or thermal management module. Background Technology

[0002] US 11,807,067 B2 discloses a cooling system for motor vehicles with an eight-way valve that allows different cooling circuits to be interconnected to distribute heat within the vehicle. Summary of the Invention

[0003] The objective of this invention is to design a cooling system for motor vehicles that enables the utilization and distribution of generated heat within the vehicle in an advantageous manner with minimal switching components and small space requirements, and presents different operating states.

[0004] Therefore, a cooling system for an electrically driven motor vehicle is proposed, which conforms to the features of claim 1 and the dependent claims, as well as a thermal management module having such a cooling system, and a motor vehicle having a cooling system or a thermal management module.

[0005] The cooling system for an electrically driven motor vehicle according to the invention has four main cooling circuits, which are interconnected via a first switching valve having eight interfaces. The first switching valve can occupy five different switching positions, and thus enables variable interconnection between the main cooling circuits. Furthermore, the main cooling circuits can be divided into sub-circuits.

[0006] The first switching valve can be shaped, for example, as a ball or cylinder that can rotate about a rotation axis, and includes a corresponding channel guide within the valve body. A fluid connection can be established by rotating the valve body accordingly relative to the interface of the first switching valve. In principle, multiple separate multi-way valves can also be used to achieve the desired function. However, this approach is significantly more costly and expensive than having all necessary switching states presented in a single switching valve.

[0007] Favorable fluid distribution can be achieved in the first switching valve through targeted interface arrangement and internal fluid connections within the valve. Therefore, the main cooling circuit can be arranged to reduce heat loss between coolants that may be at different temperature levels, thereby improving the efficiency of the entire system.

[0008] The main cooling circuit operates using the same coolant, typically a mixture of water and ethylene glycol. However, the use of other coolants, such as low-viscosity oils or specialized media tailored to the application, is also conceivable.

[0009] The main cooling circuit consists of a cooler circuit, a battery circuit, a refrigerator circuit, and an electronic component circuit.

[0010] Here, the cooler circuit, the refrigeration circuit, and the electronic device circuit can be further subdivided into lower-level circuits, which can be either connected, disconnected, operated in a mixed manner, or even operated in isolation.

[0011] In this configuration, the first switching position S1 of the first switching valve connects the first interface to the seventh interface, connects the eighth interface to the second interface, connects the sixth interface to the third interface, and connects the fourth interface to the fifth interface.

[0012] Therefore, in this first switching position, the return flow section of the refrigerator circuit is connected to the inlet flow section of the battery circuit, wherein the return flow section of the battery circuit is connected to the inlet flow section of the refrigerator circuit. The return flow section of the cooler circuit is connected to the inlet flow section of the electronic device circuit, and the return flow section of the electronic device circuit is ultimately connected to the inlet flow section of the cooler circuit. Thus, the battery circuit and the refrigerator circuit are connected to each other, and correspondingly, the cooler circuit is connected to the electronic device circuit.

[0013] The second switching position S2 connects the first interface to the seventh interface, the fourth interface to the third interface, the eighth interface to the fifth interface, and the sixth interface to the second interface.

[0014] Therefore, the coolant is guided from the electronics circuit to the cooler circuit, then from there to the battery circuit, and then back to the entry point of the electronics circuit. The refrigeration circuit is not coupled to any other circuits.

[0015] The third switching position S3 connects the first interface to the fifth interface, the sixth interface to the second interface, the eighth interface to the third interface, and the fourth interface to the seventh interface.

[0016] Therefore, the electronic device circuits and battery circuits are interconnected. The cooler circuits and refrigeration circuits are also fluidly coupled to each other.

[0017] The fourth switching position S4 connects the first interface to the second interface, the fourth interface to the fifth interface, the sixth interface to the third interface, and the eighth interface to the seventh interface.

[0018] Here, the electronic circuit is self-coupled, allowing the coolant to circulate within itself, while the battery circuit and the refrigerator circuit are fluidly coupled to each other. The cooler circuit is non-functional and self-coupled.

[0019] The first switching valve, according to the invention, in another fifth switching position S5, connects the first interface to the third interface, the fourth interface to the second interface, the sixth interface to the fifth interface, and the eighth interface to the seventh interface.

[0020] Through these advantageous switching positions and the corresponding advantageous arrangement of the inlet and outlet ports of the main cooling circuit, optimal separation of different temperature levels in the main cooling circuit is achieved, and heat loss between the main cooling circuits is minimized. This increases the efficiency of the entire system.

[0021] Therefore, the cooler circuit and battery circuit can be decoupled from the cooling system; that is, the inlet and outlet sections of the cooler circuit and battery circuit are self-connected. The refrigeration circuit and electronic device circuit are fluidly coupled to each other.

[0022] In addition to the main cooling circuit, a refrigeration circuit is also required in the cooling system. This refrigeration circuit consists at least of a compressor, an indirect condenser, a refrigeration unit, and at least one (particularly advantageously at least two) adjustable expansion valves arranged in a suitable position within the refrigeration circuit. The refrigeration circuit can operate in heat pump mode and is thus used to generate heat. Heat pump mode utilizes heat from a heat source and, through a circulation process, elevates this heat to a higher energy level. This method of heat generation is highly efficient, meaning that a high heat output can be achieved with very little electrical energy. In modern electric motor vehicles, R290 (propane) or R774 (CO2) is used, for example, in this refrigeration system. 2 However, other known refrigerants such as R1234yf can also be used.

[0023] To subdivide the main cooling circuit, mixing valves are installed at the nodes. These mixing valves are typically implemented as three-way valves, capable of either fully switching two channels or mixed switching all three. The placement of mixing valves at nodes with at least three interfaces is central to this invention. By strategically positioning these mixing valves within the cooling system, advantages in system operation can be achieved, such as fully utilizing particularly favorable pressure conditions. While the corresponding switching could be implemented with separate valves in lower-level circuits, this would increase the number of parts and thus significantly increase complexity and cost.

[0024] A coolant cooler is arranged in the cooler circuit. The coolant cooler is circulated by ambient air and releases heat from the coolant into the surrounding environment, or absorbs heat from the surrounding environment into the coolant, so that this heat can be utilized in the heat pump process. The coolant cooler is typically located in the front area of ​​the vehicle so that it is subjected to airflow during driving. A fan may also be installed on the coolant cooler, for example, when airflow is insufficient, or when the vehicle is stationary, or when an electrically driven vehicle has increased cooling demand due to ongoing charging; the fan blows air onto the coolant cooler or draws air through it. For further adjustment, openings with adjustable grille blades may also exist in the vehicle's cooler grille. The grille blades can be opened when cooling demand is high, and closed when cooling demand is low or nonexistent. Closed grille blades, in particular, have lower air resistance when the vehicle is in motion, and therefore benefit the vehicle's energy consumption.

[0025] The cooler circuit also includes a first mixing valve, which is implemented as a three-way valve. This three-way valve allows switching of the cooler bypass circuit, which enables all or part of the coolant to be diverted through the coolant cooler.

[0026] Therefore, the cooler circuit consists of two lower-level circuits: the cooler sub-circuit and the cooler bypass circuit.

[0027] Therefore, under certain operating conditions, heat transfer can be regulated or completely shut off via the coolant cooler. The cooler circuit does not have its own pump capable of circulation. Therefore, circulation must be achieved through a separate main cooling circuit or sub-circuit connected via the first switching valve.

[0028] The battery circuit includes a second heat-generating component, typically the vehicle's battery. Heat may be generated in the battery circuit, for example, due to battery charging or discharging, or the second heat-generating component must be heated to achieve an ideal operating point, such as when the ambient temperature is low. Therefore, two distinct operating conditions arise in the battery circuit: cooling or heating within the same main cooling circuit, and these operating conditions must be covered by the cooling system. The battery circuit does not have its own water pump capable of circulation. Therefore, this circulation must be achieved through a separate main cooling circuit or sub-circuit connected via a first switching valve.

[0029] The refrigeration circuit is further divided into three sub-circuits. These three sub-circuits contain two water pumps and two check valves.

[0030] The first refrigeration sub-circuit is formed by a second mixing valve and a first check valve. The second mixing valve is implemented as a three-way valve, which can either operate in two-way mode only or in all three-way mode under mixed operation. The first refrigeration sub-circuit also includes a first refrigeration circuit water pump and connects to the third and fourth interfaces of the first switching valve via its inlet and outlet. Thus, the required coolant volume flow for the coolant circuit and battery circuit can be adjusted in a combined manner, as well as the coolant temperature for the battery circuit can be adjusted, or the battery circuit can be operated in a self-circulating mode.

[0031] The refrigeration circuit also includes two additional lower-level circuits: the second refrigeration sub-circuit and the third refrigeration sub-circuit. The second refrigeration sub-circuit contains the chiller, which is a refrigerant-coolant heat exchanger that performs heat exchange between the coolant and the refrigeration circuit.

[0032] The third refrigeration sub-loop includes the second refrigeration sub-loop water pump, the second check valve, and the first compartment heat exchanger. The second and third refrigeration sub-loops are connected to each other via the first and second refrigeration nodes.

[0033] The first compartment heat exchanger is used to cool incoming air by passing through it and passing it through a coolant. This cooling also allows for the condensation of moisture in the air, enabling dehumidification of the air flowing into the cockpit, depending on operating conditions, or dehumidification of the air inside the cockpit when the cockpit ventilation system is in recirculation mode.

[0034] The second refrigeration unit loop water pump transports the coolant leaving the refrigeration unit to the first compartment heat exchanger, and then returns it to the refrigeration unit via the second check valve and the first refrigeration unit node.

[0035] Therefore, cold coolant can be supplied to the first compartment heat exchanger to cool the cabin air, and / or the compartment heat exchanger can transfer waste heat from the air from the cockpit or the surrounding environment into the coolant and supply it to the refrigeration unit under heat pump operation.

[0036] The second refrigeration sub-circuit does not contain any additional components and is connected to the third and first refrigeration sub-circuit via two refrigeration nodes. Therefore, the refrigeration unit can provide cold coolant to the battery circuit, electronic device circuit, and cooler circuit, or can absorb heat from them.

[0037] The electronic device circuit can be divided into a parallel arrangement of a first heat-generating component (e.g., several power electronic devices, a drive motor, or other heat-generating electronic components, where multiple heat-generating components may be connected) and an indirect condenser, and includes a water pump for the first electronic device circuit. Therefore, a first electronic device circuit section containing the first heat-generating component and a second electronic device circuit section containing the indirect condenser are formed. The indirect condenser is a refrigerant-cooled condenser arranged in the refrigeration circuit. The indirect condenser is traversed by both refrigerant and coolant, allowing heat exchange between the two media.

[0038] Therefore, the first electronic device circuit section and the second electronic device circuit section can be supplied with coolant from the coolant cooler in parallel. Thus, although the coolant volume flow is distributed between the two downstream circuits, the coolant temperature and coolant pressure are the same. In the first electronic device circuit section, the coolant flows through the first heating element and carries the heat back to the first switching valve.

[0039] Here, the outflow portion of the electronic device circuit is connected to the first interface of the first switching valve, and the inflow portion of the electronic device circuit is connected to the second interface of the first switching valve. Downstream of the second interface, a first electronic device circuit node is arranged, which divides the electronic device circuit into a first electronic device circuit segment and a second electronic device circuit segment. Downstream of the first electronic device circuit node, in the first electronic device circuit segment, a first electronic device circuit water pump is arranged, and further downstream is a first heating element. Following the first heating element, a third mixing valve with three interfaces is arranged, which is fluidly connected to the first interface.

[0040] The third mixing valve can be configured as a three-way regulating valve, which can either completely switch two channels or switch all three channels under mixed operation.

[0041] A second electronic device loop node is arranged in the second electronic device loop section, and a second electronic device loop water pump is arranged downstream of this second electronic device loop node. An indirect condenser is arranged downstream of the second electronic device loop water pump. A third electronic device loop node is arranged downstream of the indirect condenser, and this third electronic device loop node is fluidly connected to a third mixing valve. Therefore, a third electronic device loop section, including a second compartment heat exchanger, is formed between the third electronic device loop node and the second electronic device loop node.

[0042] The second compartment heat exchanger is a heating element that is circulated by the air arriving in the cabin and can heat the air for use in the cockpit.

[0043] An optional electric coolant heater can be arranged between the indirect condenser and the third electronic device loop node, which can introduce additional heat into the second electronic device loop section.

[0044] The addition of a third electronic circuit section results in a very small cooling circuit with low thermal mass, yet offers greater flexibility in coolant temperature regulation through unique on / off or mixed operation using a third mixing valve. This is particularly advantageous because it reduces heat loss to the surrounding environment caused by unnecessarily heating large surfaces or heavy components (heat that cannot be used to warm the cockpit). It also enables advantageous rapid warming of the cockpit via the second compartment heat exchanger. Mixed operation for coolant temperature regulation becomes necessary when the coolant temperature from the indirect condenser is too high for the compartment heat exchanger.

[0045] Therefore, the first and second electronic device loop water pumps are arranged in parallel within the first and second electronic device loop sections, and due to the fluid connection between the first and second electronic device loop nodes, they achieve nearly identical pressure levels on the suction side. This enables a particularly advantageous and simpler distribution of the coolant volumetric flow rate through the two electronic device loop water pumps, as the pumps can be controlled and regulated more precisely and easily during parallel operation when the same suction pressure is applied. The coolant flow between the first and second electronic device loop sections can thus be advantageously adjusted via the corresponding switching of the third mixing valve. Here, the particularly advantageous arrangement of the third mixing valve downstream of the first heating element is also obtained. Therefore, the first electronic device loop section can be separated from the second electronic device loop section in a particularly efficient manner. For example, if the third mixing valve is arranged at the third electronic device loop node after the indirect condenser, the branch between the third electronic device loop node and the third mixing valve remains part of the thermal mass of the first electronic device loop section, which is not advantageous.

[0046] If excess heat from the second electronic circuit section needs to be released into the first electronic circuit section, this can be advantageously achieved by switching the third mixing valve accordingly, transferring heat to the first electronic circuit section while sufficient heat remains in the second and third electronic circuit sections for heating the cockpit. Therefore, for example, thermal mass, particularly the thermal mass of the first heat-generating component, can be used to absorb heat before it needs to be released to the surrounding environment via the cooler circuit. Thus, for example, the grille blades arranged on the coolant cooler can be opened later, which is advantageous for reducing air resistance in the vehicle, thereby saving energy and making the vehicle more efficient.

[0047] The simple structure of the system, which has a first and second electronic circuit water pump and a three-way valve as a third mixing valve, enables a wide range of favorable possibilities for adjusting the coolant inlet temperature at the second compartment heat exchanger, for example, to prevent excessively high coolant temperatures at the second compartment heat exchanger in an operating mode that is used to dehumidify the cabin air while the ambient temperature is high (e.g., above 15°C).

[0048] In addition to the conventional refrigerant circuit, the refrigerant circuit can also be constructed in particularly advantageous configurations. Vapor injection and hot gas bypass configurations enable particularly efficient heat generation for use in the indirect condenser and subsequently for cabin heating.

[0049] Vapor injection is a functional configuration in a refrigerant circuit used to significantly improve its efficiency and performance. In this method, a portion of the refrigerant liquefied in an indirect condenser is fed to a vapor generator for vaporization and then to the compressor. The remaining mass stream is further cooled and directed to the refrigeration unit.

[0050] The main advantage of vapor injection is increased refrigeration capacity, which allows the refrigerant circuit to more effectively extract heat from the surrounding environment. Another advantage is reduced compressor overheating, which extends its lifespan and lowers maintenance costs.

[0051] Additionally, this technology improves performance at lower ambient temperatures by optimizing the enthalpy of vaporization, thus maintaining the efficiency of the refrigerant circuit even under adverse conditions. Vapor injection also optimizes operation under partial load and partial load conditions, resulting in better overall energy utilization. Since the refrigerant circuit is used to generate heat (e.g., for cabin heating), this efficiency enhancement allows for the generation of more heat and, consequently, the elimination of additional heating devices in the refrigerant circuit if necessary.

[0052] In terms of specific implementation schemes, the refrigerant circuit includes additional valve devices, refrigerant lines, and additional evaporators in necessary sections. These additional evaporators serve as vapor generators, which enables the corresponding adjustment and construction of the refrigerant circuit.

[0053] Hot gas recirculation bypass is another special regulation strategy in the refrigerant circuit, used to optimize compressor operation under specific operating conditions. Here, a portion of the hot refrigerant from the compressor is bypassed and diverted directly into the suction circuit before the compressor, instead of flowing through the indirect condenser located after the compressor. Hot gas recirculation bypass allows for pressure regulation in the refrigerant circuit, which is particularly useful when load conditions fluctuate. It helps increase the compressor's mass flow and thus effectively releases more electrical power into the refrigerant, and consequently releases more heat to the cooling circuit in the indirect condenser. Since this also addresses cabin heating, additional heating devices in the refrigerant circuit can be eliminated if necessary. In specific implementations, the refrigerant circuit includes at least one additional valve device and refrigerant line in the necessary sections, enabling appropriate regulation and configuration of the refrigerant circuit.

[0054] It is conceivable that feasible solutions for vapor injection and hot gas recirculation bypass can be integrated simultaneously in the refrigeration loop. Therefore, either vapor injection or hot gas recirculation bypass can be operated, or both can be operated simultaneously when efficiency is desired. However, it is also conceivable that only one of the two feasible solutions can be implemented in the refrigeration loop, allowing for the use of only one of the two solutions at a time.

[0055] Heat exchangers arranged in cooling and refrigerant circuits can be constructed in a variety of different ways and methods in their design. Thus, a heat exchanger can be constructed from individual tubes, with fins arranged between the tubes to transfer heat, for example, to the air flowing through the fins, or to absorb heat from the air. Heat exchangers in a stacked structure are also particularly useful in indirect condensers and refrigerators, in which individual plates are alternately stacked, thus increasing the flow path for at least two fluids. These are known design structures and need to be selected and designed appropriately according to the desired application and the refrigerant or coolant used.

[0056] In a particularly advantageous improvement of the invention, at least a first switching valve, a refrigeration circuit, a first refrigeration circuit water pump, a second refrigeration circuit water pump, a refrigeration unit, an indirect condenser, a first mixing valve, a second mixing valve, and a third mixing valve form a structural unit as a thermal management module. Integrating the aforementioned components into the thermal management module offers advantages in terms of structural space. Because the components are arranged closely together, long wiring paths between the components are eliminated. The thermal management module can be placed in a suitable location within the vehicle and includes only interfaces for connecting heat-generating components or heat exchangers that require cooling. The disclosed thermal management module is also referred to as an indirect system because, for example, the refrigeration circuit is limited by the structural space of the thermal management module, and therefore cooling and heating of components connected to the cooling system are achieved solely through the refrigerant. Therefore, it is no longer necessary to introduce refrigerant into the cabin and direct it to the evaporator to provide cooling power there. This also allows the refrigeration circuit to be constructed quite small and requires only a small amount of refrigerant. This is particularly advantageous when using R290 (propane) as a refrigerant, as it is desirable to avoid the presence of flammable gases (such as propane) in the passenger compartment. Especially in the event of a motor vehicle accident, potential ignition sources are positioned outside the passenger compartment, giving passengers time to ensure their safety. The relatively small amount of propane used as a refrigerant also generally reduces the fire load.

[0057] The feasibility of flexibly arranging thermal management modules in motor vehicles is also a major advantage, because electric motor vehicles no longer place a large internal combustion engine in the front area, and therefore have more continuous structural space available compared to conventional motor vehicles with internal combustion engines (in which the various units must be placed in the remaining structural space around the internal combustion engine).

[0058] The possible design and implementation schemes of the cooling circuit and its components, as well as the switching locations and implementation schemes of the thermal management module, cannot be fully listed here.

[0059] The control device can be located inside the vehicle or in the thermal management module. The control device can receive signals from temperature sensors and, according to its function, drive various components of the cooling system, such as the first switching valve, mixing valve, water pump, and components of the refrigeration circuit, thus enabling on-demand control and regulation of the cooling system according to the invention and reflecting various operating points according to the invention. Other requirements of the vehicle or driver can also be considered accordingly. These requirements may be specific driving conditions, ongoing charging processes, or additional actual temperature signals from the cabin or surrounding environment, or even a target temperature for the cabin.

[0060] In a particularly advantageous manner, a first temperature sensor can be arranged at the output end of the refrigeration unit. A second temperature sensor can be arranged between the indirect condenser and the third electronic device loop node. A third temperature sensor can be arranged between the water pump in the first electronic device loop and the first heating element. A fourth temperature sensor can be arranged between the second port of the first switching valve and the first electronic device loop node. A fifth temperature sensor can be arranged between the bypass section in the refrigeration unit loop and the fourth port of the first switching valve. It should be noted that the temperature sensors can also be arranged in other suitable locations, therefore, the final performance of all possible assembly parts cannot be described here.

[0061] The cooling system implemented according to the invention can operate under different advantageous and inventive operating methods, thus covering many daily conditions of a motor vehicle through different operating points. Here, the cooling system according to the invention and its components (especially the reversing valve and pump) are switched on or off as needed. Sensors, especially temperature sensors and control devices, along with corresponding control circuitry, are used to implement the appropriate switching process. The cooling system also responds to the vehicle's requirements (based on current driving conditions or the driver's specific demands). Based on these values, a suitable operating point is selected, and the cooling system is adjusted accordingly. Attached Figure Description

[0062] Another advantageous design of the present invention is described in the following figures. Wherein:

[0063] Figure 1 A schematic diagram of the cooling circuit according to the present invention is shown;

[0064] Figure 2 The first switching valve with five different switching positions is shown;

[0065] Figure 3 A schematic diagram of the thermal management module is shown;

[0066] Figure 4 A schematic diagram of a refrigeration circuit for a cooling system with a hot gas circulation and steam injection configuration is shown. Detailed Implementation

[0067] Figure 1A schematic structure of a cooling system 1 according to the invention in a motor vehicle 2 is shown. The cooling system 1 consists of four main cooling circuits 10, 20, 30, and 40, which are divided or can be divided into sub-circuits. The main cooling circuits 10, 20, 30, and 40 are respectively a cooler circuit 10, a battery circuit 20, a refrigerator circuit 30, and an electronic device circuit 40. A central first switching valve 200 has eight ports 201, 202, 203, 204, 205, 206, 207, and 208, and can connect the main cooling circuits 10, 20, 30, and 40 to each other. For this purpose, the first switching valve 200 can be placed in five different switching positions, in which different main cooling circuits 10, 20, 30, and 40 can be fluidly connected respectively. The first switching valve 200 is electrically operated using a corresponding actuator and can therefore be placed in the desired position. The first switching valve 200 can be shaped, for example, as a sphere or cylinder that can rotate about a rotation axis, and includes a corresponding channel guide within the valve body. By rotating the valve body accordingly relative to the interface of the first switching valve 200, a fluid connection can be established.

[0068] The inlet of cooler circuit 10 is connected to the seventh port 207 of the first switching valve 200. The outlet of cooler circuit 10 is connected to the eighth port 208 of the first switching valve 200. Cooler circuit 10 has a first mixing valve 213, which is configured as a three-way valve and can divide cooler circuit 10 into cooler sub-circuit 111 and cooler bypass circuit 112. The first mixing valve 213 can either fully switch between the two circuits or operate by mixing via all three ports, thus simultaneously directing coolant to cooler sub-circuit 111 and cooler bypass circuit 112. Therefore, variable drive control of cooler circuit 10 can be achieved to cover all necessary operating states. A coolant cooler 210 is arranged in cooler sub-circuit 111, which is circulated by ambient air. Therefore, coolant cooler 210 can dissipate heat or, in possible heat pump operation modes, absorb heat from ambient air. To support or control heat transfer, a fan 211 is typically provided at the front of the cooler, and optionally, grille blades 212 are also provided. These grille blades direct more or less air onto the coolant cooler 210 depending on operating requirements. Therefore, for example, when the vehicle is stationary and charging, the fan 211 can draw air from the surrounding environment and direct it through the coolant cooler 210 to expel the waste heat generated during charging from the coolant. In driving conditions, the driving airflow is sufficient, where the optional grille blades 212 can be opened or closed accordingly to regulate airflow. This also applies if there is a higher cooling demand when the vehicle 2 is stationary.

[0069] The inlet of the battery circuit 20 is connected to the fifth port 205 of the first switching valve 200, and the outlet of the battery circuit 20 is connected to the sixth port 206 of the first switching valve 200. A second heating element 220, which is typically the battery of the electrically driven motor vehicle 2, is also arranged in the battery circuit 20.

[0070] The outlet of the refrigeration circuit 30 is connected to the fourth port 204 of the first switching valve 200, and the inlet of the refrigeration circuit 30 is connected to the third port 203 of the first switching valve 200. Downstream of the third port 203, a first refrigeration circuit water pump 233 is arranged, and further downstream, a second mixing valve 232 with three ports is arranged. The second mixing valve 232 is configured as a three-way valve, which can either completely switch any two ports or mix via all three ports. The first refrigeration circuit water pump 233 is used to circulate the coolant in the refrigeration circuit 30. Depending on the switching position of the first switching valve 200, the first refrigeration circuit water pump 233 can also be used to circulate the coolant in other main cooling circuits 10, 20, 30, and 40. Therefore, the battery circuit 20 does not have its own water pump and must circulate the coolant, for example, by means of the first refrigeration circuit water pump 233, wherein the refrigeration circuit 20 must then be connected to the battery circuit 20 via the first switching valve 200.

[0071] A second mixing valve 232, located downstream of the first refrigeration circuit pump 233, is connected to the outlet of the refrigeration circuit 30 via a bypass section 237 and a third refrigeration node 134 upstream of the fourth interface 204. A first check valve 234 is located upstream of the bypass section 237. Here, a first refrigeration sub-circuit 131 is formed. When the second mixing valve 232 is switched accordingly and the battery circuit 20 is fluidly connected to the refrigeration circuit 30 via the first switching valve 200, the refrigeration sub-circuit 131 can circulate the battery circuit 20. The first check valve 234 here prevents coolant from flowing back upstream of the refrigeration circuit 30.

[0072] A second refrigeration sub-circuit 133 is formed downstream of the second mixing valve 232 and upstream of the first check valve 234. Downstream of the second mixing valve 232, a first refrigeration node 238 is arranged in the second refrigeration sub-circuit 133, which connects to the input end of the refrigeration unit 230 and the return section of the third refrigeration sub-circuit 132. The third refrigeration sub-circuit 132 includes a second refrigeration sub-circuit water pump 235 and a first compartment heat exchanger 231. The first compartment heat exchanger 231 is a cooling body, preferably circulated by cooled coolant, and is used for air conditioning the cockpit. The first compartment heat exchanger 231 is circulated either by air from the cockpit or by air from the surrounding environment, and mixing is also conceivable. Cooling is preferably achieved during the flow, thus cooling the cockpit. A second check valve 236 is arranged between the first compartment heat exchanger 231 and the first refrigeration unit node 238 to prevent the coolant from flowing back towards the second refrigeration unit circuit water pump 235.

[0073] The output end of the refrigeration unit 230 is connected to the second refrigeration unit node 239, which is connected to the return section of the second refrigeration unit sub-circuit 133 and the inlet section of the third refrigeration unit sub-circuit 132.

[0074] The outflow portion of the electronic device circuit 40 is connected to the first interface 201 of the first switching valve 200, and the inflow portion of the electronic device circuit 40 is connected to the second interface 202 of the first switching valve 200.

[0075] Downstream of the second interface 202, a first electronic device loop node 248 is arranged, which divides the electronic device loop 40 into a first electronic device loop segment 141 and a second electronic device loop segment 142.

[0076] Downstream of the first electronic device loop node 248, in the first electronic device loop section 141, a first electronic device loop water pump 247 is arranged, which is responsible for circulating the coolant in the first electronic device loop section 141. Downstream of the first electronic device loop water pump 247, a first heat-generating component 240 is arranged, and further downstream, a third mixing valve 244 with three ports is arranged, which is fluidly connected to the first port 201. The first heat-generating component 240 is, for example, a drive motor or power electronics of the motor vehicle 2 that requires cooling. These could also be multiple components that are sequentially flowed through and typically generate heat during operation. The third mixing valve 244 can either fully connect two paths or, in mixed operation, connect all three ports to each other.

[0077] A second electronic device loop node 250 is arranged in the second electronic device loop section 142. Downstream of the second electronic device loop node 250, a second electronic device loop water pump 245 is arranged, which is responsible for circulating the coolant in the second and third electronic device loop sections 142 and 143. The second electronic device loop water pump 245 is connected to an indirect condenser 241, followed by a third electronic device loop node 249, which is fluidly connected to a third mixing valve 244 and marks the beginning of the third electronic device loop section 143, which is formed between the third electronic device loop node 249 and the second electronic device loop node 250.

[0078] The indirect condenser 241 is arranged together with the refrigerator 230 in the refrigeration circuit 50. The indirect condenser 241 is a refrigerant-cooled condenser that typically releases heat from the refrigeration circuit 50 to the refrigerant flowing through it.

[0079] The third electronic circuit section 143 has a second compartment heat exchanger 243. The second compartment heat exchanger 243 is subjected to the airflow into the cockpit, just like the first compartment heat exchanger 231.

[0080] Typically, air first flows through the first compartment heat exchanger 231 and may be cooled, then flows through the second compartment heat exchanger 243, which can selectively heat the air to a target temperature. In winter, when only air heating is required, the second compartment heat exchanger 243 performs the function of heating the cockpit. When dehumidification of the air is also required, or when air cooling is necessary in high outside temperatures, the air is pre-cooled in the first compartment heat exchanger 231.

[0081] The second electronic device circuit pump 245 here undertakes the circulation in the third electronic device circuit section 143. The reconnection of the third electronic device circuit section 143 is achieved at the second electronic device circuit node 250.

[0082] To support the heating of the coolant circulating in the electronic circuit 40 and to rapidly heat the cockpit via the second compartment heat exchanger 243 when the outside temperature is low, a coolant heater 242 can be arranged after the indirect condenser 241 and before the second compartment heat exchanger 243. However, it is also conceivable that the coolant heater 242 could also be arranged at other locations in the third electronic circuit section 143, even where its placement before the second compartment heat exchanger 243 and after the indirect condenser 241 would be considered particularly advantageous. Furthermore, the coolant heater 242 could also be divided into two self-contained components to efficiently transfer heat to desired locations, such as the second compartment heat exchanger 243 and the second heating element 220, with minimal loss. To regulate and control the cooling system 1, a control device 400 may be provided. This control device receives signals from temperature sensors 401 to 405 and forwards control signals to the first switching valve 200, mixing valves 206, 232, and 244, water pumps 233, 247, 235, and 245, and components in the refrigeration circuit 50. Additional sensor signals (such as ambient temperature and commands and statuses from the vehicle) may also be used as the basis for control.

[0083] In a particularly preferred embodiment, a first temperature sensor 401 is arranged at the output of the refrigerator 230. A second temperature sensor 402 is arranged between the indirect condenser 241 and the third electronic circuit node 249. A third temperature sensor 403 is arranged in front of the first heating element 240 and after the first electronic circuit pump 247. A fourth temperature sensor 404 is arranged after the second port 208 of the first switching valve 200 and in front of the first electronic circuit node 148. A fifth temperature sensor 405 is arranged between the third refrigerator node 134 and the fourth port 204 of the first switching valve 200. It should be noted that the temperature sensors 401 to 405 can also be arranged in other suitable locations, therefore, the final performance of all possible assembly parts cannot be described here.

[0084] exist Figure 1 In the illustrated embodiment, a refrigerator 230 and an indirect condenser 241 are arranged in a refrigerant circuit 50. This refrigerant circuit may consist of a compressor 251, multiple expansion valves 253, 254, 255, and a collector 252. The refrigerant circuit system operates using common refrigerants such as R290, R1234yf, or R744, and is capable of heat exchange between the refrigerator 230 and the indirect condenser 241 depending on the operating mode.

[0085] Figure 2The first switching valve 200 is shown in five different switching positions a), b), c), d), and e). In the first switching position S1 a), the first interface 201 is connected to the seventh interface 207, the eighth interface 208 is connected to the second interface 202, the sixth interface 206 is connected to the third interface 203, and the fourth interface 204 is connected to the fifth interface 205.

[0086] Therefore, in this first switching position, the return section of the refrigerator circuit 30 is connected to the inlet section of the battery circuit 20, wherein the return section of the battery circuit 20 is connected to the inlet section of the refrigerator circuit 30. The return section of the cooler circuit 10 is connected to the inlet section of the electronic device circuit 40, and the return section of the electronic device circuit 40 is ultimately connected to the inlet section of the cooler circuit 10. Thus, the battery circuit 20 and the refrigerator circuit 30 are connected to each other, and therefore the cooler circuit 10 is connected to the electronic device circuit 40. The coolant is thus guided from the electronic device circuit 40 to the cooler circuit 10, where it can be cooled by the coolant cooler 210. For this purpose, the first electronic device circuit water pump 247 is used, because the cooler circuit 10 does not have its own water pump. The coolant in the battery circuit 20 is circulated by the first refrigerator circuit water pump 233 and guided to the refrigerator circuit 30. Depending on the switching positions of the first and second mixing valves 213 and 232, redistribution or reflux circulation is achieved in their respective sub-circuits 111, 112, 131, and 133 in the cooler circuit 10 or the refrigeration circuit 30.

[0087] Second switching position S2 b) Connect the first interface 201 to the seventh interface 207, connect the fourth interface 204 to the third interface 203, connect the eighth interface 208 to the fifth interface 205, and connect the sixth interface 206 to the second interface 202.

[0088] Therefore, the coolant is guided from the electronic device circuit 40 to the cooler circuit 10, and then from there transferred to the battery circuit 20, and then back to the inlet of the electronic device circuit 40. The circulation is therefore primarily carried out by the first electronic device circuit pump 247, wherein, depending on the switching position of the third mixing valve 244, either the third electronic device circuit section 143 or the second electronic device circuit section 142 may also be connected, and thus the second electronic device circuit pump 245 may also cooperate.

[0089] In the third switching position S3 c), the first interface 201 is connected to the fifth interface 205, the sixth interface 206 is connected to the second interface 202, the eighth interface 208 is connected to the third interface 203, and the fourth interface 204 is connected to the seventh interface 207. Therefore, the electronic device circuit 40 and the battery circuit 20 are connected to each other. The cooler circuit 10 and the refrigerator circuit 30 are also fluidly coupled to each other.

[0090] In the fourth switching position S4 d), the first interface 201 is connected to the second interface 202, the fourth interface 204 is connected to the fifth interface 205, the sixth interface 206 is connected to the third interface 203, and the eighth interface 208 is connected to the seventh interface 207.

[0091] At this point, the electronic device circuit 40 is coupled to itself, allowing the coolant to circulate within it, while the battery circuit 20 and the refrigerator circuit 30 are fluidly coupled to each other.

[0092] In the fifth switching position S5 e), the first interface 201 is connected to the third interface 203, the fourth interface 204 is connected to the second interface 202, the sixth interface 206 is connected to the fifth interface 205, and the eighth interface 208 is connected to the seventh interface 207.

[0093] Therefore, the cooler circuit 10 and the battery circuit 20 are decoupled from the cooling system 1, meaning that the inlet and outlet of the cooler circuit 10 and the battery circuit 20 are connected to each other. The refrigerator circuit 30 and the electronic device circuit 40 are fluidly coupled to each other.

[0094] Figure 3 The structure of the thermal management module 3 in the vehicle 2 is schematically shown, reflecting the cooling system 1. All components for switching and transporting the cooling circuit, as well as the complete refrigeration circuit 50, are integrated into the thermal management module 3, so that only the first and second heat-generating components 220, 240, the first and second compartment heat exchangers 231, 243, and the coolant cooler must be connected to the thermal management module 3 via connecting lines. This enables a compact structure of the cooling system 1 and flexible placement within the vehicle 2.

[0095] Figure 4 The refrigeration circuit 50 of a cooling system 1 with a hot gas circulation and steam injection configuration is schematically shown.

[0096] The refrigeration circuit 50 operates using a compressor 251, wherein heat is released to the refrigerant in an indirect condenser 241 and absorbed from the refrigerant at the refrigerator 230. A collector 252 serves as a storage medium for the refrigerant. In the illustrated embodiment, the collector is positioned on the indirect condenser 241. However, the collector 252 may also be positioned at other locations within the refrigeration circuit 50. Refrigerant exiting from either the indirect condenser 241 or the collector 252 reaches a first refrigerant node 260, where the refrigerant line is divided into two branches. The first branch is regulated by a second expansion valve 254 and directed to a vapor generator 256, from where it is directed to the compressor via a refrigerant injection line 257. An adjustable second expansion valve 254 allows a certain amount of refrigerant to be directed via the vapor generator 256 to the compressor 251, where it is again fed into the refrigerant circuit. Refrigerant not directed to compressor 251 but instead destined for refrigerator 230 is guided in a second branch through a separate fluid path via vapor generator 256, and then via a first expansion valve to refrigerator 230. After passing through refrigerator 230, the refrigerant reaches second refrigerant node 261, where the refrigerant line is divided into two branches, one of which leads to compressor 251, where the refrigerant is compressed. The second branch is then guided past compressor 251 via an adjustable fourth expansion valve 259, and then merges again with third refrigerant node 262 from compressor 251. An adjustable third expansion valve 255 is arranged after the third refrigerant node and before indirect condenser 241. By adjusting expansion valves 253, 254, 255, and 259 accordingly, refrigeration circuit 50 can be selectively switched to vapor injection mode and / or hot gas circulation mode. Alternatively, refrigeration circuit can also operate without using vapor injection mode and / or hot gas circulation.

[0097] List of reference numerals

[0098] 1 Cooling System

[0099] 2 Motor vehicles

[0100] 3 Thermal Management Module

[0101] 10 Cooler Circuit

[0102] 20 Battery Circuit

[0103] 30 Refrigeration circuit

[0104] 40 Electronic device circuits

[0105] 50 Refrigeration circuit

[0106] 111 Cooler Sub-Circuit

[0107] 112 Cooler bypass circuit

[0108] 131 First Refrigeration Unit Sub-circuit

[0109] 132 Third Refrigeration Unit Sub-circuit

[0110] 133 Second Refrigeration Unit Sub-circuit

[0111] 134 Third Refrigeration Unit Node

[0112] 141 First Electronic Device Circuit Section

[0113] 142 Second Electronic Device Circuit Section

[0114] 143 Third Electronic Device Circuit Section

[0115] 200 First switching valve

[0116] 201 First Interface

[0117] 202 Second Interface

[0118] 203 Third Interface

[0119] 204 Fourth Interface

[0120] 205 Fifth Interface

[0121] 206 Sixth Interface

[0122] 207 Seventh Interface

[0123] 208 Eighth Interface

[0124] 210 Coolant Cooler

[0125] 211 Fan

[0126] 212 Grid Blade

[0127] 213 First mixing valve

[0128] 220 Second heating element

[0129] 230 Refrigeration unit

[0130] 231 First compartment heat exchanger

[0131] 232 Second mixing valve

[0132] 233 First Refrigeration Unit Circuit Water Pump

[0133] 234 First check valve

[0134] 235 Second Refrigeration Unit Circuit Water Pump

[0135] 236 Second check valve

[0136] 237 Bypass Section

[0137] 238 First Refrigeration Unit Node

[0138] 239 Second Refrigeration Unit Node

[0139] 240 First heating element

[0140] 241 Indirect Condenser

[0141] 242 Electric coolant heater

[0142] 243 Second compartment heat exchanger

[0143] 244 Third mixing valve

[0144] 245 Second Electronic Components Circuit Water Pump

[0145] 247 First Electronic Device Circuit Water Pump

[0146] 248 First Electronic Device Circuit Node

[0147] 249 Third Electronic Device Circuit Node

[0148] 250 Second Electronic Device Circuit Node

[0149] 251 compressor

[0150] 252 collectors

[0151] 253 First expansion valve

[0152] 254 Second Expansion Valve

[0153] 255 Third Expansion Valve

[0154] 256 Steam Generator

[0155] 257 Refrigerant Injection Circuit

[0156] 258 Refrigerant Bypass Route

[0157] 259 Fourth Expansion Valve

[0158] 260 First Refrigerant Node

[0159] 261 Second Refrigerant Node

[0160] 262 Third Refrigerant Node

[0161] 400 control equipment

[0162] Temperature sensors 401 to 405 (first to fifth temperature sensors)

[0163] L - Inflow of external air

[0164] CA cabin air inflow

Claims

1. A cooling system (1) for an electrically driven motor vehicle (2), the cooling system comprising a cooler circuit (10), a battery circuit (20), a refrigeration circuit (30), and an electronic device circuit (40), in, A first switching valve (200) is provided, having a first port (201), a second port (202), a third port (203), a fourth port (204), a fifth port (205), a sixth port (206), a seventh port (207), and an eighth port (208). The first switching valve (200) enables fluid connection of the cooler circuit (10), the battery circuit (20), the refrigerator circuit (30), and the electronic device circuit (40). The inlet of the cooler circuit (10) is connected to the seventh port (207), and the outlet of the cooler circuit (10) is connected to the eighth port (208). The circuit (10) is equipped with a first mixing valve (213) with three ports, which divides the cooler circuit (10) into a cooler sub-circuit (111) and a cooler bypass circuit (112). The cooler sub-circuit (111) includes a coolant cooler (210). The inlet of the battery circuit (20) is connected to the fifth port (205), and the outlet of the battery circuit (20) is connected to the sixth port (206). A second heating element (220) is arranged in the battery circuit (20). The outlet of the refrigerator circuit (30) is connected to the fourth port (204), and the inlet of the refrigerator circuit (30) is connected to the sixth port (206). A three-port connection (203) is provided, wherein a first chiller circuit water pump (233) is arranged downstream of the third port (203), and a second mixing valve (232) with three ports is arranged downstream of the first chiller circuit water pump (233). A bypass section (237) connects the second mixing valve (232) to a third chiller node (134). The third chiller node (134) has a connection to the fourth port (204), forming a first chiller sub-circuit (131). The third chiller node (134) has another port connected to a first check valve (234). The second mixing valve (232) is connected to the third port (203). Downstream of the third refrigeration sub-circuit (133), a second refrigeration sub-circuit (133) is formed, wherein, in the second refrigeration sub-circuit (133), a first refrigeration node (238) is arranged downstream of the second mixing valve (232), the first refrigeration node is connected to the input end of the refrigeration unit (230) and the return section of the third refrigeration sub-circuit (132), wherein, the output end of the refrigeration unit (230) is connected to the second refrigeration node (239), the second refrigeration node is connected to the inlet section of the third refrigeration sub-circuit (132) and the first check valve (234), wherein, in the third refrigeration sub-circuit (132), a second refrigeration circuit water pump (235) is arranged downstream of the second refrigeration node (239).A first compartment heat exchanger (231) is arranged further downstream, and a second check valve (236) is arranged downstream of it. The second check valve (236) is connected to the first refrigeration unit (238). The outflow portion of the electronic device circuit (40) is connected to the first interface (201), and the inflow portion of the electronic device circuit (40) is connected to the second interface (202). Downstream of the second interface (202), a first electronic device circuit node (248) is arranged. The first electronic device circuit node divides the electronic device circuit (40) into a first electronic device circuit segment (141) and a second electronic device circuit segment (142). Downstream of the first electronic device circuit node (248), a first electronic device circuit water pump (247) is arranged in the first electronic device circuit segment (141). Downstream of the first electronic device circuit water pump (247), a first heating element (240) is arranged. Downstream of the thermal component (240) is a third mixing valve (244) with three ports, which is fluidly connected to the first port (201). A second electronic device loop node (250) is arranged in the second electronic device loop section (142). Downstream of the second electronic device loop node (250) is a second electronic device loop pump (245). Downstream of the second electronic device loop pump (245) is an indirect condenser (241). Downstream of the indirect condenser (241) is a third electronic device loop node (249), which is fluidly connected to the third mixing valve (244). A third electronic device loop section (143) is formed between the third electronic device loop node (249) and the second electronic device loop node (250). The third electronic device loop section (143) has a second compartment heat exchanger (243).

2. The cooling system (1) according to claim 1, characterized in that, The first mixing valve (213), the second mixing valve (232), and the third mixing valve (244) are all three-way valves, which can be switched to isolate two-way or mix three-way.

3. The cooling system (1) according to any one of the preceding claims, characterized in that, The refrigerator (230) and the indirect condenser (241) are connected in the refrigeration circuit (50).

4. The cooling system (1) according to claim 3, characterized in that, The refrigeration circuit (50) can operate in hot gas circulation mode and / or steam injection mode.

5. The cooling system (1) according to any one of the preceding claims, characterized in that, The first switching valve (200) - In the first switching position S1, the first interface (201) is connected to the seventh interface (207), the eighth interface (208) is connected to the second interface (202), the sixth interface (206) is connected to the third interface (203), and the fourth interface (204) is connected to the fifth interface (205). - In the second switching position S2, the first interface (201) is connected to the seventh interface (207), the fourth interface (204) is connected to the third interface (203), the eighth interface (208) is connected to the fifth interface (205), and the sixth interface (206) is connected to the second interface (202). - In the third switching position S3, the first interface (201) is connected to the fifth interface (205), the sixth interface (206) is connected to the second interface (202), the eighth interface (208) is connected to the third interface (203), and the fourth interface (204) is connected to the seventh interface (207). - In the fourth switching position S4, the first interface (201) is connected to the second interface (202), the fourth interface (204) is connected to the fifth interface (205), the sixth interface (206) is connected to the third interface (203), and the eighth interface (208) is connected to the seventh interface (207). - In the fifth switching position S5, the first interface (201) is connected to the third interface (203), the fourth interface (204) is connected to the second interface (202), the sixth interface (206) is connected to the fifth interface (205), and the eighth interface (208) is connected to the seventh interface (207).

6. The cooling system (1) according to any one of the preceding claims, characterized in that, A first temperature sensor (401) is arranged at the output end of the refrigeration unit (230), and / or a second temperature sensor (402) is arranged between the indirect condenser (241) and the second compartment heat exchanger (243), and / or a third temperature sensor (403) is arranged after the first electronic device loop water pump (247) and in front of the first heating element (240), and / or a fourth temperature sensor (404) is arranged after the second interface (202) and in front of the first electronic device loop node (248), and / or a fifth temperature sensor (405) is arranged between the fifth interface (205) and the first check valve (234).

7. The cooling system (1) according to any one of the preceding claims, characterized in that, A control device (400) is provided, which adjusts valves (200, 213, 244, 232), refrigeration circuit (50), and water pumps (233, 247, 235, 245) based on the values ​​of temperature sensors (401, 402, 403, 405) and the heating or cooling requirements of the cockpit.

8. A thermal management module (3), wherein the thermal management module has a cooling system according to claims 1 to 7, characterized in that, At least the first switching valve (200), refrigeration circuit (50), first refrigeration circuit water pump (233), second refrigeration circuit water pump (235), refrigeration unit (230), indirect condenser (241), first mixing valve (213), second mixing valve (232), and third mixing valve (244) form a thermal management module (3) in the form of structural units.

9. A motor vehicle (2) having a thermal management module (3) according to claim 8 or a cooling system (1) according to any one of claims 1 to 7.

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