Thermal management system for electric vehicle

Abstract

The invention discloses a thermal management system for electric vehicles, which is characterized by comprising a thermal management object, a front-end module assembly, an HVAC assembly, an electric compressor and a heat pump assembly. The heat pump assembly is integrated with a plate heat exchanger, a water-cooled condenser, an electronic water pump, a gas-liquid separator and an expansion water tank. The heat pump assembly has interfaces for connecting with the thermal management object, the front-end module assembly, the HVAC assembly and the electric compressor respectively. The thermal management object, the front-end module assembly, the HVAC assembly and the electric compressor are connected with the heat pump assembly through corresponding interfaces respectively. The advantage is that the entire thermal management system is composed of five parts, namely, the thermal management object, the front-end module assembly, the HVAC assembly, the electric compressor and the heat pump assembly. The plate heat exchanger, the water-cooled condenser, the electronic water pump, the gas-liquid separator and the expansion water tank, which play a major role, are integrated in the heat pump assembly, so the loading efficiency is high and the maintenance is also relatively convenient.

Description

Technical Field

[0001] The invention relates to a thermal management system, in particular to a thermal management system for electric vehicles. Background Art

[0002] The various components of existing automotive thermal management systems are generally dispersedly arranged on the chassis of the vehicle. The components are connected by connecting pipes such as aluminum tubes, hoses, and water pipes. There are many installation and fixing points, which makes the production efficiency low during vehicle installation. When a vehicle breaks down, it is difficult to troubleshoot the fault. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a thermal management system for pure electric vehicles with a high degree of integration. By using the thermal management system, the loading efficiency can be effectively improved and fault troubleshooting can be facilitated.

[0004] The technical solution adopted by the present invention to solve the above technical problems is:

[0005] A thermal management system for an electric vehicle comprises a thermal management object, a front-end module assembly, an HVAC assembly, an electric compressor and a heat pump assembly. The heat pump assembly is integrated with a plate heat exchanger, a water-cooled condenser, an electronic water pump, a gas-liquid separator and an expansion water tank. The heat pump assembly has interfaces for connecting to the thermal management object, the front-end module assembly, the HVAC assembly and the electric compressor respectively. The thermal management object, the front-end module assembly, the HVAC assembly and the electric compressor are connected to the heat pump assembly through corresponding interfaces respectively.

[0006] The interfaces include a first refrigerant interface, a second refrigerant interface, a third refrigerant interface group, a first water side interface group and a second water side interface group. The suction port of the electric compressor is connected to the first refrigerant interface, the discharge port of the electric compressor is connected to the second refrigerant interface, the HVAC assembly is connected to the corresponding interface in the third refrigerant interface group, the thermal management object is connected to the corresponding interface in the first water side interface group, and the front end module assembly is connected to the corresponding interface in the second water side interface group.

[0007] The third refrigerant interface group includes a first refrigeration interface, a second refrigeration interface, a third refrigeration interface and a fourth refrigeration interface, the first water side interface group includes a first water interface, a second water interface, a third water interface and a fourth water interface, and the second water side interface group includes a fifth water interface and a sixth water interface;

[0008] The heat pump assembly also comprises a heater, a one-way valve, a two-way first solenoid valve, a second solenoid valve, a first electronic expansion valve, a second electronic expansion valve and a third electronic expansion valve, a four-way first water valve and a second water valve, and the electronic water pump comprises a first electronic water pump and a second electronic water pump;

[0009] The water-cooled condenser has a first condenser interface, a second condenser interface, a third condenser interface and a fourth condenser interface, and the plate heat exchanger has a first heat exchanger interface, a second heat exchanger interface, a third heat exchanger interface and a fourth heat exchanger interface;

[0010] The second refrigerant interface is connected to the first refrigeration interface, the output port of the gas-liquid separator is connected to the first refrigerant interface, the fourth interface of the heat exchanger is connected to the third refrigeration interface to form a common port, which is connected to the first valve port of the first solenoid valve and connected to the input port of the gas-liquid separator, the first interface of the heat exchanger is connected to the first valve port of the first electronic expansion valve, the fourth refrigeration interface is connected to the first valve port of the third electronic expansion valve, the second valve port of the first electronic expansion valve is connected to the second valve port of the third electronic expansion valve to form a common port, which is connected to the second valve port of the second solenoid valve to form a common port, which is connected to the first valve port of the one-way valve, the second valve port of the first solenoid valve is connected to the second valve port of the one-way valve to form a common port, which is connected to the third interface of the condenser, the first valve port of the second solenoid valve is connected to the second refrigeration interface to form a common port, which is connected to the first valve port of the second electronic expansion valve, and the second valve port of the second electronic expansion valve is connected to the refrigeration The fourth interface of the condenser is connected, the first interface of the condenser is connected to the fourth water interface, the third interface of the heat exchanger is connected to the first interface of the heater, the second interface of the heater is connected to the first valve port of the first water valve, the second valve port of the first water valve is connected to the first valve port of the second water valve, the third valve port of the first water valve is connected to the first interface of the second electronic water pump, the second interface of the second electronic water pump is connected to the first water interface, the fourth valve port of the first water valve is connected to the second water interface, the common port formed by the third water interface and the sixth water interface is connected to the second valve port of the second water valve, the common port formed by the fifth water interface and the output port of the expansion water tank is connected to the fourth valve port of the second water valve, the common port formed by the second interface of the heat exchanger and the output port of the expansion water tank is connected to the common port formed by the third valve port of the second water valve, and the first interface of the first electronic water pump is connected to the second interface of the condenser.

[0011] The thermal management object includes a power battery, a motor and a motor controller. The first interface of the power battery is connected to the first water interface, the second interface of the power battery is connected to the second water interface, the first interface of the motor is connected to the third water interface, the second interface of the motor is connected to the first interface of the motor controller, and the second interface of the motor controller is connected to the fourth water interface.

[0012] The front-end module assembly includes a low-temperature radiator, a first interface of the low-temperature radiator is connected to the sixth water interface, and a second interface of the low-temperature radiator is connected to the fifth water interface.

[0013] The HVAC assembly includes an internal water-cooled condenser and an internal evaporator, the first interface of the internal water-cooled condenser is connected to the first refrigeration interface, the second interface of the internal water-cooled condenser is connected to the second refrigeration interface, the first interface of the internal evaporator is connected to the third refrigeration interface, and the second interface of the internal evaporator is connected to the fourth refrigeration interface.

[0014] The first refrigerant interface is equipped with a low-pressure PT sensor, and a high-pressure PT sensor is installed between the second refrigerant interface and the first refrigeration interface. The PT sensor is used to test the pressure and temperature of the refrigerant in the refrigeration system, and feedback is given to the controller, which controls the entire thermal management system to take corresponding actions; the refrigeration system is generally divided into a high-pressure side and a low-pressure side, the low-pressure PT sensor is arranged on the low-pressure side, and the high-pressure PT sensor is arranged on the high-pressure side.

[0015] A first temperature sensor is installed between the second interface of the second electronic water pump and the first water interface, a second temperature sensor is installed between the fourth valve port of the first water valve and the second water interface, and a third temperature sensor is installed between the second interface of the first electronic water pump and the second interface of the condenser. Each temperature sensor is used to measure the temperature of the fluid and feed it back to the controller, and the controller controls the entire thermal management system to take corresponding actions.

[0016] The heat pump assembly includes a water side valve plate and a refrigerant side valve plate. The electronic water pump and the expansion water tank are integrated on the water side valve plate to form a water side integrated module. The gas-liquid separator is integrated on the refrigerant side valve plate to form a refrigerant side integrated module. The water side integrated module is connected to the refrigerant side integrated module through the plate heat exchanger and the water-cooled condenser. The water side valve plate is used to integrate the main components constituting the water circuit, and the refrigerant side valve plate is used to integrate the main components constituting the refrigerant circuit, which is convenient for fault inspection and repair.

[0017] The control chips of the thermal management object, the front-end module assembly, the HVAC assembly, the electric compressor and the heat pump assembly are integrated in one controller. Each assembly is connected to the controller through a wiring harness, and all control chips are integrated in one controller, which can effectively reduce the cost of the entire thermal management system, thereby reducing the cost of the entire vehicle.

[0018] Compared with the prior art, the advantages of the present invention are that the entire thermal management system consists of five parts: a thermal management object, a front-end module assembly, an HVAC assembly, an electric compressor and a heat pump assembly. The plate heat exchanger, water-cooled condenser, electronic water pump, gas-liquid separator and expansion water tank that play a major role are integrated into the heat pump assembly. When loading the vehicle, it is only necessary to install the above five parts to the corresponding positions on the vehicle, and then connect the parts through connecting pipes. The loading efficiency is high, and once a fault occurs, it is also more convenient to repair. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a principle architecture diagram of the present invention;

[0020] Figure 2 The schematic diagram of different front-end module assemblies selected for the present invention;

[0021] Figure 3 It is a schematic diagram of the specific structure of the present invention;

[0022] Figure 4 It is a schematic diagram of the mechanical three-dimensional structure of the heat pump assembly in the present invention;

[0023] Figure 5 It is a first mechanical front view structural diagram of the heat pump assembly in the present invention;

[0024] Figure 6 It is a second mechanical front view structural diagram of the heat pump assembly in the present invention. DETAILED DESCRIPTION

[0025] The present invention is further described in detail below with reference to the accompanying drawings.

[0026] As shown in the figure, a thermal management system for electric vehicles includes a thermal management object 5, a front-end module assembly 1, an HVAC assembly 2, an electric compressor 3 and a heat pump assembly 4. The heat pump assembly 4 is integrated with a plate heat exchanger 6, a water-cooled condenser 7, an electronic water pump, a gas-liquid separator 8 and an expansion water tank 9. The heat pump assembly 4 has interfaces for connecting to the thermal management object 5, the front-end module assembly 1, the HVAC assembly 2 and the electric compressor 3 respectively. The thermal management object 5, the front-end module assembly 1, the HVAC assembly 2 and the electric compressor 3 are respectively connected to the heat pump assembly 4 through corresponding interfaces.

[0027] In this specific embodiment, the interface includes a first refrigerant interface A, a second refrigerant interface B, a third refrigerant interface group, a first water side interface group and a second water side interface group, the suction port 3-1 of the electric compressor 3 is connected to the first refrigerant interface A, the discharge port 3-2 of the electric compressor 3 is connected to the second refrigerant interface B, the HVAC assembly 2 is connected to the corresponding interface in the third refrigerant interface group, the thermal management object 5 is connected to the corresponding interface in the first water side interface group, and the front end module assembly 1 is connected to the corresponding interface in the second water side interface group.

[0028] In this specific embodiment, the third refrigerant interface group C includes a first refrigeration interface C1, a second refrigeration interface C2, a third refrigeration interface C3 and a fourth refrigeration interface C4, the first water side interface group includes a first water interface G1, a second water interface G2, a third water interface I1 and a fourth water interface I2, and the second water side interface group includes a fifth water interface H1 and a sixth water interface H2;

[0029] The heat pump assembly 4 also has a heater 41, a one-way valve 42, a two-way first solenoid valve D1, a second solenoid valve D2, a first electronic expansion valve D4, a second electronic expansion valve D5 and a third electronic expansion valve D6, a four-way first water valve P and a second water valve Q, and the electronic water pump includes a first electronic water pump 10 and a second electronic water pump 11;

[0030] The water-cooled condenser 7 has a first condenser interface 71, a second condenser interface 72, a third condenser interface 73 and a fourth condenser interface 74, and the plate heat exchanger 6 has a first heat exchanger interface 61, a second heat exchanger interface 62, a third heat exchanger interface 63 and a fourth heat exchanger interface 64;

[0031] The second refrigerant interface B is connected to the first refrigeration interface C1, the output port 81 of the gas-liquid separator 8 is connected to the first refrigerant interface A, the common port formed by the fourth interface 64 of the heat exchanger and the third refrigeration interface C3 is connected to the first valve port D1-1 of the first solenoid valve D1 to form a common port connected to the input port 82 of the gas-liquid separator 8, the first interface 61 of the heat exchanger is connected to the first valve port D4-1 of the first electronic expansion valve D4, the fourth refrigeration interface C4 is connected to the first valve port D6-1 of the third electronic expansion valve D6, and the second valve port D4-1 of the first electronic expansion valve D6 is connected to the first valve port D The common port formed by connecting the second valve port D6-2 of the third electronic expansion valve D6 and the second valve port D2-2 of the second solenoid valve D2 to form a common port connected to the first valve port 42-1 of the one-way valve 42, the common port formed by connecting the second valve port D1-2 of the first solenoid valve D1 and the second valve port 42-2 of the one-way valve 42 to form a common port connected to the third interface 73 of the condenser, the common port formed by connecting the first valve port D2-1 of the second solenoid valve D2 and the second refrigeration interface C2 to form a common port connected to the first valve port D5-1 of the second electronic expansion valve D5, and the second electronic expansion valve D5 The second valve port D5-2 is connected to the fourth interface 74 of the condenser, the first interface 71 of the condenser is connected to the fourth water interface I2, the third interface 63 of the heat exchanger is connected to the first interface of the heater 41, the second interface of the heater 41 is connected to the first valve port P1 of the first water valve P, the second valve port P2 of the first water valve P is connected to the first valve port Q1 of the second water valve Q, the third valve port P3 of the first water valve P is connected to the first interface 11-1 of the second electronic water pump 11, the second interface 11-2 of the second electronic water pump 11 is connected to the first water interface G1, and the fourth valve port P4 of the first water valve P is connected to The second water interface G2 is connected, the third water interface I1 and the sixth water interface H2 are connected to form a common port which is connected to the second valve port Q2 of the second water valve Q, the fifth water interface H1 and the output port of the expansion water tank 9 are connected to form a common port which is connected to the fourth valve port Q4 of the second water valve Q, the second interface 62 of the heat exchanger is connected to form a common port which is connected to the output port of the expansion water tank 9 and the third valve port Q3 of the second water valve Q are connected to form a common port which is connected to the first interface 10-1 of the first electronic water pump 10, and the second interface 10-2 of the first electronic water pump 10 is connected to the second interface 72 of the condenser.

[0032] In this specific embodiment, the thermal management object 5 includes a power battery 51, a motor 52 and a motor controller 53. The first interface of the power battery 51 is connected to the first water interface G1, the second interface of the power battery 51 is connected to the second water interface G2, the first interface of the motor 52 is connected to the third water interface I1, the second interface of the motor 52 is connected to the first interface of the motor controller 53, and the second interface of the motor controller 53 is connected to the fourth water interface I2.

[0033] In this specific embodiment, the front-end module assembly 1 includes a low-temperature radiator 101, a first interface of the low-temperature radiator 101 is connected to the sixth water interface H2, and a second interface of the low-temperature radiator 101 is connected to the fifth water interface H1. The front-end module assembly 1 can be selected according to specific usage requirements. Some front-end module assemblies 1 have an external water-cooled condenser 102 in addition to the low-temperature radiator 101. According to the specific selection, a corresponding refrigerant interface is added to the heat pump assembly 4, such as Figure 2 As shown, interfaces E1 and E2 are added for connecting to two ports of an external water-cooled condenser 102 .

[0034] In this specific embodiment, the HVAC assembly 2 includes an internal water-cooled condenser 21 and an internal evaporator 22. The first interface of the internal water-cooled condenser 21 is connected to the first refrigeration interface C1, the second interface of the internal water-cooled condenser 21 is connected to the second refrigeration interface C2, the first interface of the internal evaporator 22 is connected to the third refrigeration interface C3, and the second interface of the internal evaporator 22 is connected to the fourth refrigeration interface C4. The HVAC assembly 2 can also be selected according to specific usage requirements. According to the specific selection, the corresponding refrigerant interface can be added to the heat pump assembly 4.

[0035] In this specific embodiment, a low-pressure PT sensor PT1 is installed at the first refrigerant interface A, and a high-pressure PT sensor PT2 is installed between the second refrigerant interface B and the first refrigeration interface C1. The PT sensor is used to test the pressure and temperature of the refrigerant in the refrigeration system, and feedback is given to the controller 12, which controls the entire thermal management system to take corresponding actions; the refrigeration system is generally divided into a high-pressure side and a low-pressure side, the low-pressure PT sensor PT1 is arranged on the low-pressure side, and the high-pressure PT sensor PT2 is arranged on the high-pressure side.

[0036] In this specific embodiment, a first temperature sensor T1 is installed between the second interface 11-2 of the second electronic water pump 11 and the first water interface G1, a second temperature sensor T2 is installed between the fourth valve port P4 of the first water valve P and the second water interface G2, and a third temperature sensor T3 is installed between the second interface 10-2 of the first electronic water pump 10 and the second interface 72 of the condenser. Each temperature sensor is used to measure the temperature of the fluid and feed it back to the controller 12, and the controller 12 controls the entire thermal management system to take corresponding actions.

[0037] In this specific embodiment, the heat pump assembly 4 includes a water-side valve plate 401 and a refrigerant-side valve plate 402. The electronic water pump and the expansion water tank 9 are integrated on the water-side valve plate 401 to form a water-side integrated module. The gas-liquid separator 8 is integrated on the refrigerant-side valve plate 402 to form a refrigerant-side integrated module. The water-side integrated module and the refrigerant-side integrated module are connected via a plate heat exchanger 6 and a water-cooled condenser 7. The water-side valve plate 401 is used to integrate the main components constituting the water circuit, and the refrigerant-side valve plate 402 is used to integrate the main components constituting the refrigerant circuit, which is convenient for fault inspection and repair. The connection of the various components can be achieved by directly processing the connection channel inside the valve plate, which makes the installation of the various components more convenient, reduces the use of connecting pipes, and makes the installation more convenient and quick; the valve plate not only plays the role of carrying the various components, but also realizes the connection between the interfaces of the various components.

[0038] In this specific embodiment, the control chips of the thermal management object 5, the front-end module assembly 1, the HVAC assembly 2, the electric compressor 3 and the heat pump assembly 4 are integrated in a controller 12. Each assembly is connected to the controller through a wiring harness, and all the control chips are integrated in a controller 12, which can effectively reduce the cost of the entire thermal management system, thereby reducing the cost of the entire vehicle.

Claims

1. A thermal management system for electric vehicles, characterized in that It includes a thermal management object, a front-end module assembly, an HVAC assembly, an electric compressor and a heat pump assembly. The heat pump assembly is integrated with a plate heat exchanger, a water-cooled condenser, an electronic water pump, a gas-liquid separator and an expansion water tank. The heat pump assembly has interfaces for connecting with the thermal management object, the front-end module assembly, the HVAC assembly and the electric compressor respectively. The thermal management object, the front-end module assembly, the HVAC assembly and the electric compressor are connected with the heat pump assembly through corresponding interfaces respectively. The interface includes a first refrigerant interface, a second refrigerant interface, a third refrigerant interface group, a first water side interface group and a second water side interface group, the suction port of the electric compressor is connected to the first refrigerant interface, the discharge port of the electric compressor is connected to the second refrigerant interface, the HVAC assembly is connected to a corresponding interface in the third refrigerant interface group, the thermal management object is connected to a corresponding interface in the first water side interface group, and the front end module assembly is connected to a corresponding interface in the second water side interface group; The third refrigerant interface group includes a first refrigeration interface, a second refrigeration interface, a third refrigeration interface and a fourth refrigeration interface, the first water side interface group includes a first water interface, a second water interface, a third water interface and a fourth water interface, and the second water side interface group includes a fifth water interface and a sixth water interface; The heat pump assembly also comprises a heater, a one-way valve, a two-way first solenoid valve, a second solenoid valve, a first electronic expansion valve, a second electronic expansion valve and a third electronic expansion valve, a four-way first water valve and a second water valve, and the electronic water pump comprises a first electronic water pump and a second electronic water pump; The water-cooled condenser has a first condenser interface, a second condenser interface, a third condenser interface and a fourth condenser interface, and the plate heat exchanger has a first heat exchanger interface, a second heat exchanger interface, a third heat exchanger interface and a fourth heat exchanger interface; The second refrigerant interface is connected to the first refrigeration interface, the output port of the gas-liquid separator is connected to the first refrigerant interface, the fourth interface of the heat exchanger is connected to the third refrigeration interface to form a common port, which is connected to the first valve port of the first solenoid valve and connected to the input port of the gas-liquid separator, the first interface of the heat exchanger is connected to the first valve port of the first electronic expansion valve, the fourth refrigeration interface is connected to the first valve port of the third electronic expansion valve, the second valve port of the first electronic expansion valve is connected to the second valve port of the third electronic expansion valve to form a common port, which is connected to the second valve port of the second solenoid valve to form a common port, which is connected to the first valve port of the one-way valve, the second valve port of the first solenoid valve is connected to the second valve port of the one-way valve to form a common port, which is connected to the third interface of the condenser, the first valve port of the second solenoid valve is connected to the second refrigeration interface to form a common port, which is connected to the first valve port of the second electronic expansion valve, and the second valve port of the second electronic expansion valve is connected to the refrigeration The fourth interface of the condenser is connected, the first interface of the condenser is connected to the fourth water interface, the third interface of the heat exchanger is connected to the first interface of the heater, the second interface of the heater is connected to the first valve port of the first water valve, the second valve port of the first water valve is connected to the first valve port of the second water valve, the third valve port of the first water valve is connected to the first interface of the second electronic water pump, the second interface of the second electronic water pump is connected to the first water interface, the fourth valve port of the first water valve is connected to the second water interface, the common port formed by the third water interface and the sixth water interface is connected to the second valve port of the second water valve, the common port formed by the fifth water interface and the output port of the expansion water tank is connected to the fourth valve port of the second water valve, the common port formed by the second interface of the heat exchanger and the output port of the expansion water tank is connected to the common port formed by the third valve port of the second water valve, and the first interface of the first electronic water pump is connected to the second interface of the condenser.

2. A thermal management system for electric vehicles as claimed in claim 1, characterized in that The thermal management object includes a power battery, a motor and a motor controller. The first interface of the power battery is connected to the first water interface, the second interface of the power battery is connected to the second water interface, the first interface of the motor is connected to the third water interface, the second interface of the motor is connected to the first interface of the motor controller, and the second interface of the motor controller is connected to the fourth water interface.

3. A thermal management system for electric vehicles as claimed in claim 1, characterized in that The front-end module assembly includes a low-temperature radiator, a first interface of the low-temperature radiator is connected to the sixth water interface, and a second interface of the low-temperature radiator is connected to the fifth water interface.

4. A thermal management system for electric vehicles as claimed in claim 1, characterized in that The HVAC assembly includes an internal water-cooled condenser and an internal evaporator, the first interface of the internal water-cooled condenser is connected to the first refrigeration interface, the second interface of the internal water-cooled condenser is connected to the second refrigeration interface, the first interface of the internal evaporator is connected to the third refrigeration interface, and the second interface of the internal evaporator is connected to the fourth refrigeration interface.

5. A thermal management system for electric vehicles as claimed in claim 1, characterized in that A low-pressure PT sensor is installed between the output port of the gas-liquid separator and the first refrigerant interface, and a high-pressure PT sensor is installed between the second refrigerant interface and the first refrigeration interface.

6. A thermal management system for electric vehicles as claimed in claim 1 or 5, characterized in that A first temperature sensor is installed between the second interface of the second electronic water pump and the first water interface, a second temperature sensor is installed between the fourth valve port of the first water valve and the second water interface, and a third temperature sensor is installed between the second interface of the first electronic water pump and the second interface of the condenser.

7. A thermal management system for electric vehicles as claimed in claim 1, characterized in that The heat pump assembly includes a water side valve plate and a reagent side valve plate. The electronic water pump and the expansion water tank are integrated on the water side valve plate to form a water side integrated module. The gas-liquid separator is integrated on the reagent side valve plate to form a reagent side integrated module. The water side integrated module is connected to the reagent side integrated module via the plate heat exchanger and the water-cooled condenser.

8. A thermal management system for electric vehicles as claimed in claim 1, characterized in that The thermal management object, the front-end module assembly, the HVAC assembly, the electric compressor and the control chip of the heat pump are integrated in a controller.

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