A thermal management system integrating heat pump air conditioning and battery cooling for pure electric commercial vehicles

Abstract

This invention discloses a thermal management system integrating heat pump air conditioning and battery cooling for pure electric commercial vehicles. The system includes an electric compressor, a dryer, a condenser, an evaporator, an expansion valve, and a four-way reversing valve. The condenser, dryer, and evaporator are connected to form a first circulation unit. The battery condenser and plate heat exchanger are connected to form a second circulation unit. A pressure switch, electric compressor, gas-liquid separator, and four-way reversing valve are connected to form a third circulation unit. The first and second circulation units are connected in parallel with the third circulation unit via the four-way reversing valve. By sharing a single compressor between two condensers, and using two separate condensers connected in parallel with the electric compressor for both air conditioning and battery cooling, this invention allows the air conditioning system to meet the cooling requirements of the battery in both cooling and heating conditions.

Description

Technical Field

[0001] This invention belongs to the field of new energy vehicle air conditioning technology, specifically relating to a thermal management system that integrates heat pump air conditioning and battery cooling for pure electric commercial vehicles. Background Technology

[0002] Currently, the cab cooling system of new energy commercial vehicles generally uses R134a electric compression evaporation, while heating is generally achieved using PTC air heating. PTC systems have high power consumption, impacting the vehicle's driving range. Battery cooling systems, on the other hand, are mostly liquid-cooled, employing independent battery cooling units. This means that all major components, such as the electric compressor, condenser, plate heat exchanger, and expansion valve, are installed in a separate unit. Only the water pipes and high / low voltage wiring harnesses connecting the battery cooling unit to the power battery pack are needed. The air conditioning system and battery cooling are independent systems.

[0003] A heat pump air conditioning system uses an electric compressor, condenser, evaporator, and four-way reversing valve to change the refrigerant flow. By utilizing the refrigerant's heat absorption and release characteristics, the functions of the external condenser and the internal evaporator are interchanged, thus achieving both cooling and heating. Traditional electric vehicles have a PTC heating efficiency of less than 1, while heat pump air conditioning systems can achieve a winter heating efficiency ratio of 2-4. Theoretically, using a heat pump air conditioning system for heating in winter can reduce energy consumption by 10%-60%. Currently, heat pump air conditioning systems are mainly used in relatively high-end new energy passenger vehicles in the domestic market. Summary of the Invention

[0004] The purpose of this invention is to provide a thermal management system that integrates heat pump air conditioning and battery cooling for pure electric commercial vehicles. Through integrated improvement, energy saving and consumption reduction can be achieved while further reducing the overall vehicle cost.

[0005] A thermal management system integrating heat pump air conditioning and battery cooling for pure electric commercial vehicles includes an electric compressor, a dryer, a condenser, an evaporator, an expansion valve, and a four-way reversing valve.

[0006] The condenser, dryer, and evaporator are connected to form the first circulation unit.

[0007] The battery condenser and the plate heat exchanger are connected to form a second circulation unit.

[0008] The pressure switch, electric compressor, gas-liquid separator, and four-way reversing valve are connected to form the third circulation unit.

[0009] The first and second circulation units are connected in parallel with the third circulation unit via a four-way reversing valve.

[0010] By sharing a single compressor with two condensers, and using two condensers connected in parallel with an electric compressor for both air conditioning and battery cooling, the air conditioning system can meet the cooling requirements of the battery in both cooling and heating conditions.

[0011] Furthermore, in the first circulation unit, the condenser and evaporator are respectively connected to the four-way reversing valve; in the second circulation unit, the plate heat exchanger is connected between the gas-liquid separator and the four-way reversing valve; and the battery condenser is connected between the four-way reversing valve and the pressure switch.

[0012] Furthermore, it also includes a second refrigerant sensor, which is connected in parallel with the first solenoid shut-off valve and the condenser, and a third solenoid shut-off valve is connected in series with the second refrigerant sensor.

[0013] Furthermore, it also includes a second electronic expansion valve. One end of the second electronic expansion valve is connected between the first electronic expansion valve and the evaporator, and the other end of the second electronic expansion valve is connected between the first electromagnetic shut-off valve and the condenser. By setting two electronic expansion valves, bidirectional flow of refrigerant can be achieved.

[0014] Furthermore, one end of the four-way reversing valve is connected between the fifth solenoid shut-off valve and the pressure switch via a fourth solenoid shut-off valve, and the other end of the four-way reversing valve is connected between the plate heat exchanger and the gas-liquid separator. The heat pump air conditioner and battery cooler use two condensers connected in parallel with the electric compressor. By sharing a single electric compressor, the air conditioning system can meet the cooling requirements of the battery in both cooling and heating conditions. The plate heat exchanger is used for heat exchange with the power battery.

[0015] Furthermore, port 1 of the four-way reversing valve is connected between the plate heat exchanger and the gas-liquid separator, port 2 of the four-way reversing valve is connected to the fourth electromagnetic shut-off valve, port 3 of the four-way reversing valve is connected to the first electromagnetic shut-off valve, and port 4 of the four-way reversing valve is connected to the first refrigerant sensor.

[0016] Furthermore, the condenser uses an external PTC for defrosting and heat replenishment. The condenser PTC is located externally, and the condenser is positioned at the front end of the motor radiator, utilizing the electric fan of the motor radiator. The electric compressor can be flexibly positioned in a suitable location within the vehicle. The condenser flat tubes are arranged vertically and have two inlets and two outlets. The heat pump air conditioner has a reserved mounting bracket for a built-in PTC. The condenser uses an external PTC for defrosting and heat replenishment.

[0017] This invention reduces the cost and weight of the vehicle by using a shared electric compressor, while ensuring the functionality and reliability of the battery cooling and air conditioning systems. By adopting a four-way reversing valve-type integrated heat pump air conditioning solution, it reduces the power consumption of the air conditioning system and simplifies the layout of the air conditioning pipes. By separating the control function of the heat pump valve body from the air conditioning controller, it achieves modular expansion of the air conditioning system and improves the versatility of various vehicle platforms. Attached Figure Description

[0018] Figure 1 Working principle of a thermal management system integrating heat pump air conditioning and battery cooling;

[0019] Figure 2 A schematic diagram of the layout of an integrated heat pump air conditioning system;

[0020] Figure 3 Schematic diagram of the working principle of heat pump air conditioner in standalone cooling mode;

[0021] Figure 4 The working principle of simultaneous cooling mode of heat pump air conditioner and battery cooling;

[0022] Figure 5 The working principle of the heat pump air conditioner's standalone heating mode;

[0023] Figure 6 The working principle of a heat pump air conditioner that simultaneously operates in heating and battery cooling modes;

[0024] Figure 7 The working principle of the separate cooling mode for battery cooling (the valve with a slash in the figure indicates that it is closed).

[0025] 1-Electric compressor; 2-Gas-liquid separator; 3-Battery cooler; 4-Four-way reversing valve; 5-Third electromagnetic shut-off valve; 6-First electromagnetic shut-off valve; 7-Second electronic expansion valve; 8-Heat pump controller; 9-Built-in PTC reserved mounting bracket; 10-Condenser; 11-Condenser PTC; 12-Second electromagnetic shut-off valve; 13-First electronic expansion valve; 14-Air conditioning controller; 15-Heat pump air conditioner; 16-Fan; 17-Fourth electromagnetic shut-off valve. Detailed Implementation

[0026] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be noted that while the description of these embodiments is intended to aid in understanding the invention, it does not constitute a limitation thereof. The functional details disclosed in this invention are only used to describe exemplary embodiments of the invention. However, the invention can be embodied in many alternative forms and should not be construed as being limited to the embodiments described herein.

[0027] It should be understood that the terminology used in this invention is only for describing specific embodiments and is not intended to limit the exemplary embodiments of the invention. When the terms "comprising," "including," "containing," and / or "comprises" are used in this invention, they specify the presence of the stated features, integers, steps, operations, units, and / or components, and do not exclude the presence or addition of one or more other features, quantities, steps, operations, units, components, and / or combinations thereof.

[0028] It should be understood that, and also noted, in some alternative embodiments, the functions / actions may appear in a different order than those shown in the figures. For example, depending on the functions / actions involved, they may actually be performed substantially concurrently, or sometimes the two figures shown consecutively may be performed in reverse order.

[0029] It should be understood that specific details are provided in the following description to facilitate a complete understanding of the exemplary embodiments. However, those skilled in the art will understand that the exemplary embodiments can be implemented without these specific details. For example, the system may be shown in block diagrams to avoid obscuring the example with unnecessary details. In other instances, well-known processes, structures, and techniques may be shown without unnecessary details to avoid obscuring the exemplary embodiments.

[0030] Example 1:

[0031] like Figure 1 As shown, a thermal management system integrating a heat pump air conditioner 15 and battery cooling for a pure electric commercial vehicle includes an electric compressor 1, a dryer tank, a condenser 10, an evaporator, an expansion valve, and a four-way reversing valve 4.

[0032] The condenser 10, the drying tank and the evaporator are connected to form the first circulation unit.

[0033] The battery condenser 10 and the plate heat exchanger are connected to form a second circulation unit.

[0034] The pressure switch, electric compressor 1, gas-liquid separator 2, and four-way reversing valve 4 are connected to form the third circulation unit.

[0035] The first and second circulation units are connected in parallel with the third circulation unit via a four-way reversing valve 4.

[0036] Example 2:

[0037] Based on Example 1, such as Figure 2 As shown, in the first circulation unit, the condenser 10 and the evaporator are respectively connected to the four-way reversing valve 4.

[0038] In the second circulation unit, the plate heat exchanger is connected between the gas-liquid separator 2 and the four-way reversing valve 4, and the battery condenser 10 is connected between the four-way reversing valve 4 and the pressure switch.

[0039] It also includes a second refrigerant sensor, which is connected in parallel with the first solenoid shut-off valve 6 and the condenser 10, and the second refrigerant sensor is connected in series with a third solenoid shut-off valve 5.

[0040] It also includes a second electronic expansion valve 7, one end of which is connected between the first electronic expansion valve 13 and the evaporator, and the other end of which is connected between the first electromagnetic shut-off valve 6 and the condenser 10.

[0041] By setting two electronic expansion valves, bidirectional flow of refrigerant is achieved.

[0042] One end of the four-way reversing valve 4 is connected between the fifth electromagnetic shut-off valve and the pressure switch through the fourth electromagnetic shut-off valve 17, and the other end of the four-way reversing valve 4 is connected between the plate heat exchanger and the gas-liquid separator 2. The fourth electromagnetic shut-off valve is used to control the connection between the first circulation unit and the third circulation unit.

[0043] The heat pump air conditioner 15 and the battery cooler 3 are connected in parallel with two condensers 10 and an electric compressor 1. By sharing one electric compressor 1, the air conditioning system can meet the cooling requirements of the battery in both cooling and heating conditions.

[0044] The plate heat exchanger is used for heat exchange with the power battery.

[0045] Port 1 of the four-way reversing valve 4 is connected between the plate heat exchanger and the gas-liquid separator 2, port 2 of the four-way reversing valve 4 is connected to the fourth electromagnetic shut-off valve 17, port 3 of the four-way reversing valve 4 is connected to the first electromagnetic shut-off valve 6, and port 4 of the four-way reversing valve 4 is connected to the first refrigerant sensor.

[0046] Port 2 of the four-way directional valve 4 is the inlet, port 1 of the four-way directional valve 4 is the outlet, and ports 3 and 4 of the four-way directional valve 4 can be used as both inlets and outlets.

[0047] The condenser 10 uses an external PTC for defrosting and replenishing heat, with the condenser PTC 11 located externally.

[0048] The condenser 10 is located at the front end of the motor radiator and can utilize the electric fan 16 of the motor radiator.

[0049] The electric compressor 1 can be flexibly arranged in a suitable position in the vehicle.

[0050] The condenser 10 has flat tubes arranged vertically and has two inlets and two outlets.

[0051] The heat pump air conditioner 15 is equipped with a built-in PTC reserved mounting base 9.

[0052] Example 3:

[0053] Based on Example 2, such as Figure 3 As shown, the heat pump air conditioner 15 operates in a standalone cooling mode. When the air conditioner controller 14 detects only the AC on signal and the set temperature - interior temperature ≤ 0℃ signals, the system determines that it has entered the standalone cooling mode for the heat pump air conditioner 15. Upon entering this mode, the heat pump controller 8 closes the third solenoid shut-off valve 5, the fifth solenoid shut-off valve, and the second electronic expansion valve 7. The four-way reversing valve 4 remains in its initial state, and the refrigerant... Figure 3 The flow direction is shown, and the speed of electric compressor 1 is automatically adjusted according to the set temperature. (The valve marked with a diagonal line in the diagram indicates that it is closed.)

[0054] Example 4:

[0055] Based on Example 2, such as Figure 4 As shown, the heat pump air conditioner 15 and the battery cooler 3 cool simultaneously. When the air conditioner controller 14 detects three signals—the air conditioner AC on signal, the battery cooling demand signal, and the set temperature - vehicle interior temperature ≤ 0℃—it determines that the system enters the simultaneous cooling mode of the heat pump air conditioner 15 and the battery cooler 3. After entering this mode, the electric compressor 1 starts, the heat pump controller 8 closes the third solenoid shut-off valve 5 and the second electronic expansion valve 7, the four-way reversing valve 4 maintains its initial state, and the refrigerant flows according to… Figure 4 The flow direction is indicated, and the speed of electric compressor 1 is automatically adjusted according to the set temperature.

[0056] Example 5:

[0057] Based on Example 2, such as Figure 5 As shown, the heat pump air conditioner 15 operates in independent heating mode. When the air conditioner controller 14 detects only the AC on signal and the set temperature - interior temperature > 0℃ signals, it determines that the system has entered the independent heating mode of the heat pump air conditioner 15. Upon entering this mode, the electric compressor 1 starts, the heat pump controller 8 closes the first solenoid shut-off valve 6, the second solenoid shut-off valve 12, the fifth solenoid shut-off valve, and the first electronic expansion valve 13, and the four-way reversing valve 4 rotates 90° from its initial state, allowing the refrigerant to flow according to... Figure 5 The flow direction is indicated, and the speed of electric compressor 1 is automatically adjusted according to the set temperature.

[0058] Example 6:

[0059] Based on Example 2, such as Figure 6As shown, the heat pump air conditioner 15 operates simultaneously for heating and the battery cooler 3 for cooling. When the air conditioner controller 14 detects three signals—the air conditioner AC on signal, the battery cooling demand signal, and the set temperature - interior temperature > 0°C—it determines that the system has entered the simultaneous operation mode of the heat pump air conditioner 15 for heating and the battery cooler for cooling. After entering this mode, the electric compressor 1 starts, the heat pump controller 8 closes the first solenoid shut-off valve 6, the second solenoid shut-off valve 12, and the first electronic expansion valve 13, and the four-way reversing valve 4 remains in its initial state. The refrigerant... Figure 6 The flow direction is indicated, and the speed of electric compressor 1 is automatically adjusted according to the set temperature.

[0060] Example 7:

[0061] Based on Example 2, such as Figure 7 As shown, the battery cooler operates independently. When the air conditioning controller 14 does not detect an AC on signal but only a battery cooling demand signal, it determines that the system enters the battery cooler 3 independent cooling mode. Upon entering this mode, the electric compressor 1 starts, the heat pump controller 8 closes the fourth solenoid shut-off valve 17, and the refrigerant... Figure 7 The flow direction is indicated, and the speed of the electric compressor 1 is automatically adjusted according to the needs of the battery cooler 3.

[0062] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. These modifications or substitutions do not cause the essence of the corresponding technical solutions to depart from the spirit and scope of the technical solutions of the embodiments of the present invention.

[0063] This invention is not limited to the optional embodiments described above, and anyone can derive other various forms of products based on the inspiration of this invention. The specific embodiments described above should not be construed as limiting the scope of protection of this invention; the scope of protection of this invention should be determined by the claims, and the specification can be used to interpret the claims.

Claims

1. A thermal management system integrating heat pump air conditioning and battery cooling for pure electric commercial vehicles, characterized in that: Includes an electric compressor (1), a dryer, a condenser (10), an evaporator, an expansion valve, and a four-way reversing valve (4). The condenser (10), the drying tank and the evaporator are connected to form the first circulation unit; The battery condenser and the plate heat exchanger are connected to form a second circulation unit, and the plate heat exchanger is used to exchange heat with the power battery. The pressure switch, electric compressor (1), gas-liquid separator (2) and four-way reversing valve (4) are connected to form the third circulation unit; The first circulation unit and the second circulation unit are connected in parallel with the third circulation unit through a four-way reversing valve (4). In the first circulation unit, the condenser (10) and the evaporator are respectively connected to the four-way reversing valve (4). In the second circulation unit, the plate heat exchanger is connected between the gas-liquid separator (2) and the four-way reversing valve (4). The battery condenser is connected between the four-way reversing valve (4) and the pressure switch. A first electromagnetic shut-off valve (6) is connected between the condenser (10) and the four-way reversing valve (4), a second electromagnetic shut-off valve (12) is connected between the condenser (10) and the drying tank, a first electronic expansion valve (13) is connected between the drying tank and the evaporator, a first refrigerant sensor is connected between the evaporator and the four-way reversing valve (4), a fifth electromagnetic shut-off valve is connected between the pressure switch and the battery condenser, and a thermal expansion valve is connected between the battery condenser and the plate heat exchanger. The first port of the four-way reversing valve (4) is connected between the plate heat exchanger and the gas-liquid separator (2), the second port of the four-way reversing valve (4) is connected to the fourth electromagnetic shut-off valve (17), the third port of the four-way reversing valve (4) is connected to the first electromagnetic shut-off valve (6), the fourth port of the four-way reversing valve (4) is connected to the first refrigerant sensor, the first electromagnetic shut-off valve (6) is connected between the condenser (10) and the four-way reversing valve (4), one end of the four-way reversing valve (4) is connected between the fifth electromagnetic shut-off valve and the pressure switch through the fourth electromagnetic shut-off valve (17), the other end of the four-way reversing valve (4) is connected between the plate heat exchanger and the gas-liquid separator (2), the fourth electromagnetic shut-off valve is used to control the connection between the first circulation unit and the third circulation unit, the heat pump air conditioner (15) and the battery cooler (3) adopt two condensers connected in parallel with the electric compressor (1); It also includes a second electronic expansion valve (7), one end of which is connected between the first electronic expansion valve (13) and the evaporator, and the other end of which is connected between the first electromagnetic shut-off valve (6) and the condenser (10); It also includes a second refrigerant sensor, which is connected in parallel with the first electromagnetic shut-off valve (6) and the condenser (10), and the second refrigerant sensor is connected in series with a third electromagnetic shut-off valve (5). After entering the heat pump air conditioner (15) standalone cooling mode, the heat pump controller (8) closes the third electromagnetic shut-off valve (5), the fifth electromagnetic shut-off valve, and the second electronic expansion valve (7), while the four-way reversing valve (4) remains in its initial state. After entering the simultaneous cooling mode of heat pump air conditioner (15) and battery cooler (3), electric compressor (1) is turned on, heat pump controller (8) closes the third electromagnetic shut-off valve (5) and the second electronic expansion valve (7), and four-way reversing valve (4) remains in its initial state. After entering the heat pump air conditioner's stand-alone heating mode, the electric compressor (1) is turned on, and the heat pump controller (8) closes the first electromagnetic shut-off valve (6), the second electromagnetic shut-off valve (12), the fifth electromagnetic shut-off valve, and the first electronic expansion valve (13), and the four-way reversing valve (4) rotates 90° from its initial state. After entering the simultaneous heating and cooling mode of the heat pump air conditioner (15) and the battery cooler (3), the electric compressor (1) is turned on, the heat pump controller (8) closes the first electromagnetic shut-off valve (6), the second electromagnetic shut-off valve (12) and the first electronic expansion valve (13), and the four-way reversing valve (4) remains in its initial state. After the battery cooler (3) enters the independent cooling working mode, the electric compressor (1) is turned on, and the heat pump controller (8) closes the fourth electromagnetic shut-off valve (17).

2. The thermal management system integrating heat pump air conditioning and battery cooling for pure electric commercial vehicles according to claim 1, characterized in that: The condenser (10) is located at the front end of the motor radiator.

3. The thermal management system integrating heat pump air conditioning and battery cooling for pure electric commercial vehicles according to claim 1, characterized in that: The condenser (10) uses an external PTC for defrosting and replenishing heat.

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