A thermal management integrator suitable for hybrid electric vehicles

Abstract

The present invention discloses a thermal management integrator suitable for a hybrid vehicle, including a thermal management integrated valve, a cooling fan, a bypass solenoid valve, a heat dissipation module, a vehicle thermal management controller, an electric air conditioner, a PTC heater and pipeline accessories; the present invention specifically proposes a new integrated design architecture for the thermal management system of a hybrid vehicle, integrates components, functions and controls of the traditional thermal management distributed arrangement of heat dissipation modules, heat exchange modules, heating and cooling modules, and realizes heat exchange and interconnection between the five systems of power battery, electronic power device, motor, internal combustion engine and cab cabin by controlling the opening and closing of the solenoid valve, shortening the thermal balance time of the whole vehicle and improving energy efficiency. The integrated innovative design concept of the present invention reduces the number of components of the thermal management system, simplifies the spatial layout of the thermal management of the whole vehicle, and provides a new design architecture for the design of the thermal management system of hybrid vehicles.

Description

Technical Field

[0001] The invention belongs to the field of new energy and energy-saving automobile thermal management design, and relates to a thermal management integrator suitable for a hybrid electric vehicle. Background Art

[0002] Power batteries, electronic power devices and drive motors are the core components of new energy and energy-saving vehicles. The thermal management design level of the above components directly affects the driving safety and service life of the vehicle. Traditional hybrid and pure electric vehicles are equipped with six thermal management systems: power batteries, electronic power devices, motors, PTC heaters, air conditioners and internal combustion engines. Each system is independent of each other, the vehicle pipeline layout is complex, and the thermal management cost is high.

[0003] At present, the utilization rate of waste heat in the electric drive system of hybrid and pure electric vehicles is relatively low. For hybrid vehicles, the internal combustion engine and the electric drive system are independent of each other, resulting in the winter power battery preheating mainly relying on PTC heaters or heat pump air conditioners. In winter, using PTC heaters or heat pump air conditioners to preheat the power battery takes a long time and consumes a lot of electricity. Using PTC to provide heat energy for the cab seriously shortens the vehicle's pure electric range. In summer, using air conditioning to cool the power battery alone is a low overall utilization rate. In extreme high temperatures and high torque conditions, the transient heat generated by motors and electronic power devices is large, and the design of a large-flow cooling system that meets extreme conditions increases the overall cost of the cooling system.

[0004] The motor coolant temperature is about 100°C, the internal combustion engine coolant temperature is about 80°C, the electronic power device operating temperature is about 50°C, and the power battery temperature is about 25°C. The temperature rise of the motor and the internal combustion engine is very fast, and the power battery temperature rises relatively slowly. Using the waste heat of the motor and the internal combustion engine to preheat the power battery in winter is an effective method to improve the energy utilization rate of the whole vehicle. The present invention integrates six independent systems of power batteries, electronic power devices, motors, PTC heaters, air conditioners and internal combustion engines, and designs an integrated thermal manager suitable for hybrid and pure electric vehicles to achieve coordinated management of the heat of the whole vehicle, which can effectively shorten the thermal balance time of the whole vehicle, greatly optimize the space layout of the thermal management system, reduce the energy consumption of the whole vehicle, and fill the gap in the field of integrated thermal management systems for new energy and energy-saving vehicles. Summary of the invention

[0005] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a thermal management integrator suitable for hybrid and pure electric vehicles, which solves the current problems of independent heat pipe systems of hybrid and pure electric vehicles, high energy consumption of thermal management of the whole vehicle, and complex assembly process, thereby achieving cost reduction, energy saving and space layout optimization of the whole vehicle.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A thermal management integrator suitable for a hybrid electric vehicle comprises a thermal management integrated valve, a cooling fan, a power battery water inlet bypass solenoid valve, an electronic power device water inlet bypass solenoid valve, a motor water inlet bypass solenoid valve, a power battery water outlet bypass solenoid valve, an electronic power device water outlet bypass solenoid valve, a motor water outlet bypass solenoid valve, a vehicle thermal management controller, a power battery cooling module, an electronic power device cooling module, a motor cooling module, an evaporator module, an electric air conditioner, a PTC heater and pipeline accessories.

[0008] The thermal management integrated valve is installed on the vehicle, and the cooling fan, evaporator module, and electric air conditioner are installed on the thermal management integrated valve; the electric air conditioner and the evaporator module are connected through pipeline accessories, and the grilles on both sides of the evaporator module and the thermal management integrated valve together form a closed heat exchange space, and the electric air conditioner provides cooling and heating for the evaporator module. The cooling fan is used to adjust the temperature of the power battery cooling module, the electronic power device cooling module, and the motor cooling module;

[0009] The water inlet and water outlet of the power battery water inlet bypass solenoid valve, the electronic power device water inlet bypass solenoid valve, the motor water inlet bypass solenoid valve, the power battery water outlet bypass solenoid valve, the electronic power device water outlet bypass solenoid valve and the motor water outlet bypass solenoid valve are respectively equipped with temperature sensors, and the vehicle thermal management controller controls the closing and opening of each solenoid valve through feedback information from the temperature sensor;

[0010] The vehicle thermal management controller controls the speed of the cooling fan, the cooling and heating amount of the electric air conditioner, the start or stop of the PTC heater, and the start and stop of the peripheral electric water pump, electric air pump and external solenoid valve according to the thermal management system control strategy.

[0011] Furthermore, the thermal management integrated valve has the functions of a radiator, a heat exchanger and a multi-directional reversing valve. The thermal management integrated valve adopts a double-layer flow channel design, one layer is used as a heat dissipation channel to connect with the power battery heat dissipation module, the electronic power device heat dissipation module, and the motor heat dissipation module; the other layer is used as a heat exchange channel to connect with the internal combustion engine cooling circuit and the external cooling air water circuit, respectively realizing heat exchange in winter and cold exchange in summer;

[0012] Furthermore, the thermal management integrated valve includes an upper zone of a heat exchanger, a lower zone of a heat exchanger, a left connecting pipe, a right connecting pipe, a left connecting plate, a right connecting plate, a power battery heat dissipation outlet, an electronic power device heat dissipation outlet, and a motor heat dissipation outlet.

[0013] The heat dissipation channels inside the upper area of ​​the heat exchanger and the lower area of ​​the heat exchanger are connected through heat sinks installed at the heat dissipation outlets of the battery, the heat dissipation outlets of the electronic power device, and the heat dissipation outlets of the motor; the heat exchange channels inside the upper area of ​​the heat exchanger and the lower area of ​​the heat exchanger are connected through pipes arranged inside the left connecting pipe and the right connecting pipe; the left connecting plate and the right connecting plate serve as support plates or heat insulation plates.

[0014] The refrigerant medium circuits between the above-mentioned double-layer flow channels are independent of each other, and heat exchange is achieved by heat conduction; the bypass solenoid valve can achieve mutual flow and communication between the power battery, electronic power devices, motor and heating system coolant; the external solenoid valve is used to achieve the working state switching of the internal combustion engine cooling circuit and the external cooling air water circuit.

[0015] Furthermore, the upper zone and the lower zone of the heat exchanger are made of materials such as aluminum, copper, alloy or graphene.

[0016] Further, the upper area of ​​the thermal management integrated valve heat exchanger is a water inlet, including a power battery coolant outlet, an electronic power device outlet, a motor coolant outlet, a warm air system inlet, a cooling air water inlet, and an internal combustion engine coolant outlet; the lower area of ​​the heat exchanger is a water outlet, including a power battery coolant inlet, an electronic power device inlet, a motor coolant inlet, a warm air system water return port, a cooling air water outlet, and an internal combustion engine coolant return port;

[0017] The double-layer flow channel design can achieve at least six groups of flow channel combinations with a total of twelve channels, including power battery heat dissipation, electronic power device heat dissipation, motor heat dissipation, cab cabin heating system, internal combustion engine cooling system, and auxiliary cooling system.

[0018] Furthermore, the electric air conditioner includes two evaporators, one is arranged on the vehicle thermal management integrated valve, and the other is arranged in the cab cabin. The electric air conditioner can provide cooling and heating for the vehicle thermal management integrator alone, can provide cooling and heating for the cab cabin alone, and can also provide cooling and heating for the vehicle thermal management integrator and the cab cabin at the same time. The above working modes are switched by using an external solenoid valve.

[0019] Furthermore, the heat dissipation system, heat exchange system, electric air conditioner and PTC heater are integrated into a system, in which single cooling mode air conditioner, heat pump air conditioner and PTC heater are optional components, realizing various combinations of the heat dissipation system and heat exchange system.

[0020] The present invention has the following beneficial effects:

[0021] The biggest innovation of this invention is to propose an integrated vehicle thermal management design architecture to solve the problem of low working efficiency caused by the independence of multiple thermal management systems for new energy and energy-saving vehicles. The design method of this invention reduces the number of components in the thermal management system, optimizes the spatial layout of the vehicle, and can greatly improve energy efficiency. It has a simple structure, is easy to use, low cost, and high reliability.

[0022] The core component of the present invention, the thermal management integrated valve, has the functions of heat dissipation, heat exchange, and multi-directional commutation. For the heat dissipation module, the fan and the electric air conditioner can cool the entire electric drive system at the same time to improve the energy efficiency. For the heat exchange module, the heat exchange between the internal combustion engine and the electric drive system is realized. In winter, the waste heat of the internal combustion engine can be used to provide heat for the power battery and the cab cabin, and the waste heat of the electric drive system can be used to reversely heat the engine to avoid cold start of the engine; in summer, the heat exchange module can be connected to high-pressure cooling air / water, and in extreme cases, the electric drive system can be assisted in cooling down, reducing the system design cost under the premise of meeting the needs. For the commutation module, the closing and disconnection of the bypass solenoid valve can realize the multi-directional commutation of the coolant between the four systems of power battery, electronic power device, motor and cab warm air. In low temperature conditions, the bypass solenoid valve can be opened to use the waste heat of the electronic power device and the motor to quickly exchange with the power battery coolant to achieve battery preheating; at high temperature, the lower temperature of the electronic power device can be used to exchange with the motor coolant to quickly reduce the working temperature of the motor. The water circuit of the heating system is connected in series with the PTC heater, and the cooling fluid exchange between the heating system and the electric drive system is realized by controlling the motor bypass solenoid valve. Through the integrated design of the above functions, the characteristics of the temperature field of thermal management of different components of the vehicle are fully utilized, and the dynamic adjustment and balanced distribution of the heat of the vehicle are realized through the vehicle controller, which reduces the overall design size of the system, optimizes the spatial layout of the vehicle, and improves the energy efficiency of the thermal management system of the vehicle. The system can reduce the number of components of the vehicle thermal management system by 30%, reduce the energy consumption of the vehicle by 5%, and reduce the thermal management system of the vehicle by more than 20%.

[0023] The modular design method adopted by the present invention can realize flexible selection of each module according to the needs of the whole vehicle. The specific configuration can adopt a thermal management integrated valve and a cooling fan combined with an economic configuration scheme, a thermal management integrated valve, a cooling fan and a single cooling mode electric air conditioner scheme, a thermal management integrated valve, a cooling fan and a heat pump air conditioner scheme, a thermal management integrated valve, a cooling fan, a single cooling mode electric air conditioner and a PTC heater scheme, a thermal management integrated valve, a cooling fan, a heat pump air conditioner and a PTC heater scheme, a thermal management integrated valve, a cooling fan and a PTC heater scheme, and a variety of combinations such as a thermal management integrated valve, a cooling fan and a PTC heater scheme can be used to achieve the maximum economy of the whole vehicle according to the vehicle use requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A three-dimensional schematic diagram of an embodiment of a hybrid vehicle thermal management integrator of the present invention

[0025] Figure 2 A three-dimensional schematic diagram of an embodiment of the thermal management integrated valve of the present invention

[0026] Figure 3A cross-sectional view of an embodiment of the thermal management integrated valve and PTC heater of the present invention

[0027] In the figure: 1. Thermal management integrated valve; 2. Cooling fan; 3. Power battery water inlet bypass solenoid valve; 4. Electronic power device water inlet bypass solenoid valve; 5. Motor water inlet bypass solenoid valve; 6. Power battery water outlet bypass solenoid valve; 7. Electronic power device water outlet bypass solenoid valve; 8. Motor water outlet bypass solenoid valve; 9. Vehicle thermal management controller; 10. Power battery cooling module; 11. Electronic power device cooling module; 12. Motor cooling module; 13 Evaporator module; 14. Electric air conditioner; 15. PTC heater; 16. Pipe accessories; 17. First assembly hole; 18. Second assembly hole; 19. Third assembly hole;

[0028] 1-1. Upper area of ​​heat exchanger; 1-2. Lower area of ​​heat exchanger; 1-3. Left connecting pipe; 1-4. Right connecting pipe; 1-5. Left connecting plate; 1-6. Right connecting plate; 1-7. Heat dissipation outlet of power battery; 1-8. Heat dissipation outlet of electronic power device; 1-9. Heat dissipation outlet of motor;

[0029] 2-1. Power battery coolant outlet; 2-2. Power battery coolant inlet; 2-3. Electronic power device coolant outlet; 2-4. Electronic power device coolant inlet; 2-5. Motor coolant outlet; 2-6. Motor coolant inlet; 2-7. Warm air system inlet; 2-8. Warm air system return port; 2-9. Cooling air / water inlet; 2-10. Cooling air / water outlet; 2-11. Internal combustion engine coolant outlet; 2-12. Internal combustion engine coolant return port; 2-13. Internal combustion engine coolant inlet flow channel; 2-14. Internal combustion engine coolant return flow channel; 2-15. Cooling air / water inlet flow channel; 2-16. Cooling air / water outlet flow channel; 2-17. Right connecting pipeline; 2-18. Left connecting pipeline; 2-19. Left connecting plate; 2-20 Right connecting plate; 2-21. PTC heater water inlet; 2-22. PTC heater water outlet. DETAILED DESCRIPTION

[0030] The specific contents of the present invention are further explained in detail below in conjunction with embodiments.

[0031] like Figure 1As shown, a thermal management integrator suitable for a hybrid electric vehicle of the present invention comprises a thermal management integrated valve 1, a cooling fan 2, a power battery water inlet bypass solenoid valve 3, an electronic power device water inlet bypass solenoid valve 4, a motor water inlet bypass solenoid valve 5, a power battery water outlet bypass solenoid valve 6, an electronic power device water outlet bypass solenoid valve 7, a motor water outlet bypass solenoid valve 8, a whole vehicle thermal management controller 9, a power battery heat dissipation module 10, an electronic power device heat dissipation module 11, a motor heat dissipation module 12, an evaporator module 13, an electric air conditioner 14, a PTC heater 15 and pipeline accessories 16. The whole vehicle thermal management integrator realizes component assembly by opening a first assembly hole 17, a second assembly hole 18 and a third assembly hole 19 at the corners.

[0032] The evaporator module 13 is arranged at the upper and lower ends of the thermal management integrated valve 1 through the mounting holes, the cooling fan 2 is arranged at the rear end of the evaporator, the grilles at both ends of the evaporator and the thermal management integrated valve 1 form a closed heat exchange space, and the electric air conditioner 14 is arranged at the lower end of the thermal management integrated valve 1 through the mounting holes. The electric air conditioner 14 and the evaporator module 13 are connected through the pipeline accessories 16.

[0033] Temperature sensors are arranged at the water inlet and outlet of the power battery water inlet bypass solenoid valve 3, the electronic power device water inlet bypass solenoid valve 4, the motor water inlet bypass solenoid valve 5, the power battery water outlet bypass solenoid valve 6, the electronic power device water outlet bypass solenoid valve 7 and the motor water outlet bypass solenoid valve 8, respectively. The solenoid valves are opened and closed according to the temperatures on both sides, so as to realize the exchange of coolant of the four systems of power battery, electronic power device, motor and cab cabin.

[0034] At normal temperature, the electric air conditioner 14 does not work, and the cooling fan 2 cools the power battery cooling module 10, the electronic power device cooling module 11, and the motor cooling module 12. Under high temperature conditions, the electric air conditioner 14 provides refrigerant for the evaporator module 13, and can cool the thermal management integrated valve 1 by heat conduction, and cool the power battery cooling module 10, the electronic power device cooling module 11, and the motor cooling module 12 by air convection. Under low temperature conditions, the electric air conditioner 14 can provide heat for the evaporator module 13 and heat the battery cooling module 10 through the thermal management integrated valve 1. The PTC heater 15 is connected in series with the cab cabin heating system. When heating is required, the power is turned on to provide heat for the cab cabin heating system. At the same time, the electric drive system can be heated by opening and closing the bypass solenoid valve, and the heat can be transferred to the internal combustion engine by heat exchange to achieve heat engine.

[0035] The vehicle thermal management controller 9 coordinates the working status of each component of the vehicle thermal management. The vehicle thermal management controller can control the bypass solenoid valves 3, 4, 5, 6, 7, and 8 to open or close according to vehicle requirements, control the speed of the cooling fan 2, control the cooling and heating of the electric air conditioner 14 according to the set temperature of the cabin air conditioning system or the thermal management requirements of the electric drive system, and control the start or shut down of the PTC heater 15. The vehicle thermal controller can control peripheral electric water pumps, electric air pumps and other components, and can control the electric water valves on the internal combustion engine and the cooling air / water circulation loop to open or close. The control logic of the vehicle thermal management controller is based on the feedback temperature information of each system of the vehicle, and realizes the closed-loop control of the thermal management of the vehicle according to the built-in control strategy and algorithm. The vehicle thermal management controller can communicate with the vehicle controller, work according to the priority instructions issued by the vehicle controller, and can also transmit data to the cloud through the T-BOX system to realize remote monitoring and control of vehicle thermal management, and limit and protect the electric drive system of the vehicle in the event of thermal management out of control.

[0036] The power battery heat dissipation module 10, the electronic power device heat dissipation module 11 and the motor heat dissipation module 12 are three independent modules. At room temperature, the power battery water inlet bypass solenoid valve 3, the electronic power device water inlet bypass solenoid valve 4, the motor water inlet bypass solenoid valve 5, the power battery water outlet bypass solenoid valve 6, the electronic power device water outlet bypass solenoid valve 7 and the motor water outlet bypass solenoid valve 8 are in a normally off state, and the power battery heat dissipation module 10, the electronic power device heat dissipation module 11 and the motor heat dissipation module 12 work independently. If the coolant is the same, the three can form a series or parallel circuit according to the temperature field distribution requirements under high and low temperature conditions. In actual engineering, if the motor is oil-cooled, the position of the heat dissipation module can be adjusted.

[0037] The electric air conditioner 14 has two evaporators, one is arranged on the vehicle thermal management integrator, and the other is arranged in the cab cabin. The working mode is switched by using an external solenoid valve. It can provide cooling or heating for the hybrid vehicle thermal management integrator alone, or provide cooling and heating for the cab cabin alone, or provide cooling and heating for the hybrid vehicle thermal management integrator and the cab cabin at the same time.

[0038] like Figure 2 As shown, the thermal management integrated valve 1 comprises an upper heat exchange flow zone 1-1, a lower heat exchange flow zone 1-2, a left connecting pipe 1-3, a right connecting pipe 1-4, a left connecting plate 1-5, a right connecting plate 1-6, a battery heat dissipation outlet 1-7, an electronic power device heat dissipation outlet 1-8, and a motor heat dissipation outlet 1-9.

[0039] The upper zone 1-1 of the heat exchange flow and the lower zone 1-2 of the heat exchange flow each consist of two layers of pipes, one layer is used as a heat dissipation module and is connected to the heat dissipation outlet of the power battery, the heat dissipation outlet of the electronic power device, and the heat dissipation outlet of the motor. The other layer is used as a heat exchange module and is connected to the internal combustion engine cooling circuit and the cooling air / water circuit. The upper zone 1-1 of the heat exchanger and the lower zone 1-2 of the heat exchanger are interconnected through the internal flow channels of the left connecting pipe 1-3 and the right connecting pipe 1-4. The middle position of the upper zone 1-1 of the heat exchanger and the lower zone 1-2 of the heat exchanger are connected together by the left connecting plate 1-5 and the right connecting plate 1-6, and the connecting plates can be designed with heat insulation as needed.

[0040] like Figure 3 As shown, the thermal management integrated valve and PTC cross-sectional view include a power battery coolant outlet 2-1, a power battery coolant inlet 2-2, an electronic power device coolant outlet 2-3, an electronic power device coolant inlet 2-4, a motor coolant outlet 2-5, a motor coolant inlet 2-6, a warm air system inlet 2-7, a warm air system return 2-8, a cooling air / water inlet 2-9, a cooling air / water outlet 2-10, an internal combustion engine coolant outlet 2-11, an internal combustion engine coolant return 2-12, an internal combustion engine coolant inlet channel 2-13, an internal combustion engine coolant return channel 2-14, a cooling air / water inlet channel 2-15, a cooling air / water outlet channel 2-16, a right connecting pipe 2-17, a left connecting pipe 2-18, a left connecting plate 2-19, a right connecting plate 2-20, a PTC heater inlet 2-21, PTC heater water inlet and outlet 2-22.

[0041] The upper area of ​​the thermal management integrated valve is the water inlet, including the power battery coolant outlet 2-1, the electronic power device outlet 2-3, the motor coolant outlet 2-5, the warm air system inlet 2-7, the cooling air / water inlet 2-9, and the internal combustion engine coolant outlet 2-11. The lower area of ​​the thermal management integrated valve is the water outlet, including the power battery coolant inlet 2-2, the electronic power device coolant inlet 2-4, the motor coolant inlet 2-6, the warm air system return water inlet 2-8, the cooling air / water outlet 2-10, and the internal combustion engine coolant return water inlet 2-12. The power battery, electronic power device, motor, and warm air system together form the heat dissipation flow channel, and the internal combustion engine and cooling air / water form the heat exchange flow channel.

[0042] The water inlet 2-7 of the warm air system is connected in series with the water inlet 2-21 of the PTC heater, the water return port 2-8 of the warm air system is connected in series with the water inlet and outlet 2-22 of the PTC heater, and the water inlet and outlet 2-22 of the PTC heater and the water return port 2-8 of the warm air system are connected to the cab warm air system.

[0043] The upper area of ​​the thermal management integrated valve and the lower area of ​​the heat exchange are made of materials with good thermal conductivity such as aluminum, copper, alloy or graphene, and heat exchange can be achieved between the heat dissipation module and the heat exchange module through heat conduction.

[0044] When the cooling air / water inlet 2-9 and the cooling air / water outlet 2-10 are connected, the internal combustion engine coolant outlet 2-11 and the internal combustion engine coolant return port 2-12 are disconnected from the outside. When the internal combustion engine coolant outlet 2-11 and the internal combustion engine coolant return port 2-12 are connected, the cooling air / water inlet 2-9 and the cooling air / water outlet 2-10 are disconnected from the outside.

[0045] The internal combustion engine coolant water inlet flow channel 2-13, the internal combustion engine coolant water return flow channel 2-14 and the cooling air / water inlet flow channel 2-15 and the cooling air / water outlet flow channel 2-16 are interconnected through internal pipes.

[0046] For hybrid vehicles, the thermal management integrated valve introduces the internal combustion engine high-temperature coolant into the thermal management integrated valve through the internal combustion engine coolant outlet 2-11 and the internal combustion engine coolant return port 2-12 to achieve the heat exchange function between the internal combustion engine and the electric drive system. For pure electric vehicles, the above two interfaces can be sealed with plugs.

[0047] The water inlet 2-7 and the water return 2-8 of the heating system can transfer the heat generated by the PTC heater to the thermal management integrated valve, thereby realizing the power battery preheating function, and can also reversely provide the cold machine preheating function for the internal combustion engine. The heat exchanger can transfer the waste heat of the internal combustion engine to the thermal management integrated valve by heat conduction, thereby realizing the power battery preheating function; the water inlet 2-7 and the water return 2-8 of the heating system can transfer the waste heat of the internal combustion engine, the electric drive system and the heat of the PTC heater to the heating system to provide heat for the cab;

[0048] The external cooling air / water inlet 2-9 can assist in cooling the thermal management integrated valve, and the cooling air / water outlet 2-10 can be used as a discharge port to discharge the cooling air / water into the atmosphere or natural environment, thereby assisting in cooling the power battery, electronic power devices and motors.

[0049] In other embodiments, the size of the thermal management integrated valve and the positions of the battery, controller, motor cooling module, and each inlet and outlet can be redefined as needed.

[0050] In another embodiment, the thermal management integrator of the hybrid electric vehicle can be equipped with a PTC heating module, an electric air conditioner or a heat pump air conditioner as needed.

[0051] This technical solution is achieved as follows:

[0052] The thermal management integrated valve is the main structure of the thermal management integrator of the hybrid vehicle. The cooling fan is installed on the thermal management integrated valve. The vehicle can be equipped with a PTC heater, a single cooling mode air conditioner, and a heat pump air conditioner. The vehicle thermal management controller can communicate with the peripheral electric water pump, electric air pump, internal combustion engine cooling pipeline and cooling air / water electric water valve, vehicle controller, power supply module, etc., and coordinately control the vehicle thermal management system according to the information transmitted by the temperature sensors of various vehicle components.

[0053] The present invention provides a whole vehicle thermal management controller suitable for hybrid electric vehicles, which can control the speed of the cooling fan, the start and stop of the PTC heater, the cooling capacity of the electric air conditioner, and the working states of the peripheral electric water pump, the electric air pump, etc. according to the environment and the vehicle working temperature requirements; the whole vehicle thermal management controller can communicate with the whole vehicle controller and match a variety of thermal management working modes according to the vehicle working conditions; the whole vehicle thermal management controller can control the opening and closing of the solenoid valve according to the built-in temperature sensor of the solenoid valve, so as to realize multi-directional commutation between the power battery and the electronic power device, the motor, and the cab heating system; the whole vehicle thermal management controller can start or shut down the internal combustion engine cooling circuit and the cooling air / water circuit according to the needs, and realize heat exchange between the electric drive and the internal combustion engine, the electric air conditioner, and the PTC heater in a heat conduction manner.

[0054] The positive effect of the present invention is that the hybrid vehicle thermal management integrated device has the functions of radiator, heat exchanger, pipeline commutation, cooling and heating at the same time, and can realize the interconnection of the vehicle electric drive system, internal combustion engine system and cab cockpit, and has the characteristics of intelligent control, low cost and high reliability, which can greatly reduce the number of parts and improve assembly efficiency. The structure of the device is original and effectively solves the problems of low efficiency, redundant thermal management design and high use cost caused by the independence of each set of thermal management systems of hybrid vehicles.

[0055] Vehicle working modes at different temperature conditions:

[0056] When the vehicle is working at a low temperature, the power battery water inlet bypass solenoid valve 3 and the power battery water outlet bypass solenoid valve 6 are closed at the same time, and the power battery heat dissipation module 10 and the electronic power device heat dissipation module 11 form an interconnected loop. Since the temperature rise of the electronic power device is very fast and the temperature rise of the power battery is relatively slow, the heat of the electronic power device can be used to quickly heat the battery. After the battery reaches a predetermined temperature, the battery water inlet bypass solenoid valve 3 and the battery water outlet bypass solenoid valve 6 are disconnected at the same time. Figure 1 shown.

[0057] When the vehicle is in an extremely cold working state, the power battery water inlet bypass solenoid valve 3, the electronic power device water inlet bypass solenoid valve 4, the power battery water outlet bypass solenoid valve 6, and the electronic power device water outlet bypass valve 7 are closed at the same time, and the power battery heat dissipation module 10, the electronic power device heat dissipation module 11, and the motor heat dissipation module 12 form an interconnected loop. Since the temperature rise of the motor and the electronic power device is very fast, and the battery temperature rise is slow, the residual heat of the motor and the electronic power device can be used to quickly heat the battery. After the battery reaches a predetermined temperature, the power battery water inlet bypass solenoid valve 3, the electronic power device water inlet bypass solenoid valve 4, the power battery water outlet bypass solenoid valve 6, and the electronic power device water outlet bypass valve 7 are disconnected at the same time. Figure 1 shown.

[0058] When the vehicle is in the internal combustion engine single working mode, the heating system water inlet 2-7 and the heating system water return port 2-8 can obtain the residual heat of the internal combustion engine through heat exchange to provide heat energy for the power battery and the cab heating system. Figure 3 shown.

[0059] When the vehicle is in pure electric working mode, the electronic power device water inlet bypass solenoid valve 4, the electronic power device water outlet bypass solenoid valve 7, the motor water inlet bypass solenoid valve 5, and the motor water outlet bypass solenoid valve 8 are opened. Figure 1 The heating system water inlet 2-7 and the heating system water return port 2-8 can use the electronic power device and the motor waste heat to provide heat energy for the cab heating system in winter. Figure 3 shown.

[0060] When the vehicle is in hybrid operation mode, the thermal management integrated valve 1 obtains the waste heat of the internal combustion engine through heat exchange, and the electronic power device water inlet bypass solenoid valve 4, the motor water inlet bypass solenoid valve 5, the electronic power device water outlet bypass solenoid valve 7, and the motor water outlet bypass solenoid valve 8 are opened to form a series circuit with the heating system. Figure 1 The water inlet 2-7 and the water return 2-8 of the heating system can simultaneously utilize the waste heat of the internal combustion engine, the electronic power device, and the motor to provide heat energy for the cab heating system. Figure 3 shown.

[0061] In parking mode, when the vehicle is not started or in driving state, the PTC heating device works, and the PTC heater water inlet 2-21 and the PTC heater water inlet and outlet 2-22 form a series circuit with the warm air system water inlet 2-7 and the warm air system return water inlet 2-8, which can distribute heat energy to the electric drive system and the cab cabin. Figure 3 as shown in .

[0062] In parking mode, when the vehicle is not started or in driving state, the PTC heating device works, the PTC heater water inlet 2-21 and the PTC heater water inlet and outlet 2-22 form a series loop with the warm air system water inlet 2-7 and the warm air system return port 2-8, and the thermal management integrated valve can provide the internal combustion engine with winter heating function through the internal combustion engine coolant outlet 2-11 and the internal combustion engine coolant return port 2-12, such as Figure 3 shown.

[0063] In parking mode, when the vehicle is not started or in driving state, the electric air conditioner 14 starts the heating function, and the power battery can be preheated through the thermal management integrated generator 1 and the evaporator module 13, such as Figure 1 shown.

[0064] In parking mode, when the vehicle is not started or in driving state, the low-temperature electric air conditioner 14 starts the heating function, and the thermal management integrated generator 1 and the evaporator module 13 can reversely provide the internal combustion engine with a cold machine preheating function in a heat conduction manner, such as Figure 1 shown.

[0065] The cooling fan 2 works in parking mode, charging state, when the vehicle is not started or in driving state, and can cool the power battery cooling module 10, the electronic power device module 11 and the motor cooling module 12 at the same time. The vehicle thermal management controller 9 controls the speed of the cooling fan 2 according to the temperature of the coolant on both sides of the power battery water inlet bypass solenoid valve 3, the electronic power device water inlet bypass solenoid valve 4, the motor water inlet bypass solenoid valve 5, the power battery water outlet bypass solenoid valve 6, the electronic power device water outlet bypass solenoid valve 7 and the motor water outlet bypass solenoid valve 8. Figure 1 shown.

[0066] In a relatively high temperature state, the cooling air / water inlet 2-9 is connected to an external high-pressure cooling air or an external water tank, and the cooling air / water outlet 2-10 is opened, and the high-pressure cooling air / water outlet 2-10 is discharged to the vehicle external system through the cooling air / water inlet flow channel 2-15, the cooling air / water outlet flow channel 2-16, and the high-pressure cooling air / water outlet 2-10, taking away the excess heat of the vehicle and assisting in cooling the thermal management system, such as Figure 3 shown.

[0067] When the motor temperature is high, the electronic power device water inlet bypass solenoid valve 4 and the electronic power device water outlet bypass solenoid valve 7 are connected, and the electronic power device heat dissipation module 11 and the motor heat dissipation module 12 form an interconnecting pipeline, and the lower temperature field of the electronic power device module can be used to assist in cooling the motor. Figure 1 shown.

[0068] In an extremely high temperature state, the electric air conditioner 14 starts the cooling function, and can cool the power battery cooling module 10, the electronic power device cooling module 11 and the motor cooling module 12 through the thermal management integrated generator 1, the cooling fan 2, and the evaporator module 13 in the parking mode, the charging mode, the vehicle is not started or the driving state. The vehicle thermal management controller 9 adjusts the cooling capacity of the electric air conditioner 14 according to the temperature of the coolant on both sides of the power battery water inlet bypass solenoid valve 3, the electronic power device water inlet bypass solenoid valve 4, the motor water inlet bypass solenoid valve 5, the power battery water outlet bypass solenoid valve 6, the electronic power device water outlet bypass solenoid valve 7 and the motor water outlet bypass solenoid valve 8. Figure 1 shown.

[0069] The electric air conditioner 14 is provided with another evaporator in the cab cabin, and the cab can be heated and cooled by an external solenoid valve.

Claims

1. A thermal management integrator suitable for hybrid electric vehicles, characterized by: It comprises a thermal management integrated valve (1), a cooling fan (2), a power battery water inlet bypass solenoid valve (3), an electronic power device water inlet bypass solenoid valve (4), a motor water inlet bypass solenoid valve (5), a power battery water outlet bypass solenoid valve (6), an electronic power device water outlet bypass solenoid valve (7), a motor water outlet bypass solenoid valve (8), a vehicle thermal management controller (9), a power battery cooling module (10), an electronic power device cooling module (11), a motor cooling module (12), an evaporator module (13), an electric air conditioner (14), a PTC heater (15) and pipeline accessories (16); The thermal management integrated valve (1) is installed on a vehicle, and a cooling fan (2), an evaporator module (13), and an electric air conditioner (14) are installed on the thermal management integrated valve 1; the electric air conditioner (14) and the evaporator module (13) are connected via a pipeline accessory (16); grilles on both sides of the evaporator module (13) and the thermal management integrated valve (1) together form a closed heat exchange space; the electric air conditioner (14) provides cooling and heating for the evaporator module (13); the cooling fan (2) is used to adjust the temperature of the power battery cooling module (10), the electronic power device cooling module (11), and the motor cooling module (12); The water inlet and water outlet of the power battery water inlet bypass solenoid valve (3), the electronic power device water inlet bypass solenoid valve (4), the motor water inlet bypass solenoid valve (5), the power battery water outlet bypass solenoid valve (6), the electronic power device water outlet bypass solenoid valve (7) and the motor water outlet bypass solenoid valve (8) are respectively equipped with temperature sensors, and the vehicle thermal management controller (9) controls the closing and opening of each solenoid valve through feedback information from the temperature sensors; The vehicle thermal management controller (9) controls the speed of the cooling fan (2), the cooling and heating amount of the electric air conditioner (14), the start or stop of the PTC heater (15), and the start and stop of the peripheral electric water pump, electric air pump and external solenoid valve according to the thermal management system control strategy; The thermal management integrated valve (1) has the functions of a radiator, a heat exchanger and a multi-directional reversing valve; the thermal management integrated valve (1) adopts a double-layer flow channel design, one layer is used as a heat dissipation flow channel and is connected to the power battery heat dissipation module, the electronic power device heat dissipation module, and the motor heat dissipation module; the other layer is used as a heat exchange flow channel and is connected to the internal combustion engine cooling circuit and the external cooling air / water circuit, respectively realizing heat exchange in winter and cold exchange in summer; The refrigerant medium circuits between the above-mentioned double-layer flow channels are independent of each other, and heat exchange is achieved by heat conduction; the bypass solenoid valve can realize the mutual flow and communication between the power battery, electronic power devices, motors and the heating system coolant; the external solenoid valve is used to realize the working state switching between the internal combustion engine cooling circuit and the external cooling air / water circuit; The thermal management integrated valve (1) comprises a heat exchanger upper area (1-1), a heat exchanger lower area (1-2), a left connecting pipe (1-3), a right connecting pipe (1-4), a left connecting plate (1-5), a right connecting plate (1-6), a power battery heat dissipation outlet (1-7), an electronic power device heat dissipation outlet (1-8), and a motor heat dissipation outlet (1-9); The heat dissipation channels inside the upper zone (1-1) of the heat exchanger and the lower zone (1-2) of the heat exchanger are connected through heat sinks installed at the heat dissipation outlets (1-7) of the battery, the heat dissipation outlets (1-8) of the electronic power device, and the heat dissipation outlets (1-9) of the motor; the heat exchange channels inside the upper zone (1-1) of the heat exchanger and the lower zone (1-2) of the heat exchanger are connected through pipes arranged inside the left connecting pipe (1-3) and the right connecting pipe (1-4); the left connecting plate (1-5) and the right connecting plate (1-6) serve as support plates or heat insulation plates; The upper area of ​​the heat exchanger of the thermal management integrated valve is a water inlet, including a power battery coolant outlet (2-1), an electronic power device outlet (2-3), a motor coolant outlet (2-5), a warm air system inlet (2-7), a cooling air / water inlet (2-9), and an internal combustion engine coolant outlet (2-11); the lower area of ​​the heat exchanger is a water outlet, including a power battery coolant inlet (2-2), an electronic power device inlet (2-4), a motor coolant inlet (2-6), a warm air system return water inlet (2-8), a cooling air / water outlet (2-10), and an internal combustion engine coolant return water inlet (2-12); The double-layer flow channel design can achieve at least six groups of flow channel combinations with a total of twelve channels, including power battery heat dissipation, electronic power device heat dissipation, motor heat dissipation, cab cabin heating system, internal combustion engine cooling system, and auxiliary cooling system.

2. The thermal management integrated device for hybrid electric vehicles according to claim 1, characterized in that: The upper zone and the lower zone of the heat exchanger are made of aluminum, copper, alloy or graphene material.

3. The thermal management integrated device for hybrid electric vehicles according to claim 1, characterized in that: The electric air conditioner (14) comprises two evaporators, one of which is arranged on the vehicle thermal management integrated valve, and the other is arranged in the driver's cab. The electric air conditioner can provide cooling and heating for the vehicle thermal management integrated valve alone, can provide cooling and heating for the driver's cab alone, and can also provide cooling and heating for the vehicle thermal management integrated valve and the driver's cab at the same time. The above working modes are switched by using an external solenoid valve.

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