Cooling systems that reuse motor coolant and hybrid vehicles

Abstract

This invention relates to a cooling system for the secondary use of motor coolant and a hybrid vehicle. The cooling system includes a water tank. One outlet of the water tank is connected to the inlet of a three-way reversing valve via a low-temperature electronic water pump. Another outlet of the three-way reversing valve is connected in series with the cooling water circuits for the low-temperature and mid-temperature components, and then connected to one inlet of the three-way valve. The other outlet of the three-way reversing valve is connected to the other inlet of the three-way valve. The outlet of the three-way valve is connected to the cooling water circuit for the mid-temperature components, and then to the inlet of the water tank. The other outlet of the water tank is connected to the cooling water circuit for the high-temperature components via a high-temperature electronic water pump, and then to the inlet of the water tank. This invention uses a coupled design based on the coolant flow requirements of each temperature zone component. By reusing the motor coolant, it reduces the total coolant flow requirement of the hybrid vehicle while improving the efficiency of the hybrid vehicle's cooling system.

Description

Technical Field

[0001] This invention relates to the field of engine cooling system technology, and more specifically to a cooling system and hybrid vehicle that reuses motor coolant. Background Technology

[0002] The cooling system of a hybrid vehicle generally includes major components such as a fan, radiator, engine cooler and piping, hybrid electric motor cooler and piping, and transmission cooler. The coolant in the radiator is cooled by the fan before entering the hybrid vehicle's cooling system. The working principle is as follows... Figure 1 As shown, due to the different operating temperature ranges of components such as the engine, hybrid motor, and transmission, each component is equipped with its own cooler. The hybrid motor has also been upgraded from a low-speed motor to a high-speed motor plus a planetary gear system, as shown in the diagram. Figure 2 As shown.

[0003] The operating temperature requirements of components such as the engine, hybrid motor, and transmission vary considerably. The optimal operating temperature for the engine is ≥100℃, and the coolant inlet temperature is ≥115℃. The optimal operating temperature for components such as the motor controller PDU is ≤60℃, and the coolant inlet temperature needs to be <75℃. The optimal operating temperature for the motor planetary mechanism is 80℃~90℃, and the coolant inlet temperature is 75℃~95℃. The optimal operating temperature range for the transmission is between 80℃ and 90℃, and the coolant inlet temperature is 75℃~95℃.

[0004] In existing technical solutions, the inlet temperature of the transmission cooler is set at the same water intake point as the inlet temperature of the coolant cooling the engine block and cylinder head. If the coolant inlet temperature is >110℃, the coolant heats the transmission, and the transmission lubricating oil temperature exceeds the maximum allowable operating temperature, which will lead to premature transmission failure. If the coolant inlet temperature is <110℃, the engine cannot operate in the temperature range with the highest efficiency, which will reduce the engine efficiency.

[0005] In existing technical solutions, the vehicle cooling system arranges pipes and coolers according to components such as the engine, motor, and transmission. The outlet temperature of the motor coolant is ≤75℃. After the coolant cools the motor, it flows directly back to the water tank. The coolant entering the motor cooling system is not fully utilized, resulting in low efficiency of the motor cooling system.

[0006] Existing vehicle cooling systems require separate coolers and piping to accommodate the different operating temperatures of components such as the engine and transmission. The low-temperature and medium-temperature components of the electric motor also require separate cooling, necessitating two coolers for each. This results in at least four sets of coolers and piping for the entire vehicle cooling system. The piping occupies a large space, has numerous connection points, and suffers from unreliable sealing. Furthermore, the total coolant flow requirement for the entire vehicle cooling system is high, leading to high manufacturing costs for hybrid vehicle cooling systems. Summary of the Invention

[0007] To address the above problems, this invention provides a cooling system and hybrid vehicle that reuses motor coolant. By reusing the motor coolant, the total coolant flow requirement of the hybrid vehicle is reduced while improving the efficiency of the hybrid vehicle's cooling system.

[0008] The technical solution adopted in this invention is: a cooling system for secondary utilization of motor coolant, characterized in that: it includes a water tank; one outlet of the water tank is connected to the inlet of a three-way reversing valve via a low-temperature electronic water pump; one channel of the three-way reversing valve is connected in series with the cooling water circuits of the low-temperature zone components and the intermediate-low-temperature zone components, and then connected to one inlet of the three-way valve; the other channel of the three-way reversing valve is connected to the other inlet of the three-way valve; the outlet of the three-way valve is connected to the cooling water circuit of the intermediate-temperature zone components, and then connected to the inlet of the water tank;

[0009] The water tank outlet is connected to the cooling water circuit of the high-temperature zone components via a high-temperature electronic water pump, and then connected to the water tank inlet.

[0010] Preferably, the low-temperature zone component includes a motor PDU and a motor controller, and the optimal operating temperature of the low-temperature zone component is 20℃~40℃.

[0011] Preferably, the medium-low temperature zone component includes a motor stator and a motor rotor, and the optimal operating temperature of the medium-low temperature zone component is 50℃~75℃.

[0012] Preferably, the medium-temperature zone component includes a motor planetary gear train and a gearbox, and the optimal operating temperature of the medium-temperature zone component is 80℃~100℃.

[0013] Preferably, the high-temperature zone components include the engine block, engine cylinder head, EGR, urea heater, fuel tank heater, and heater, and the optimal operating temperature of the high-temperature zone components is >100°C.

[0014] Preferably, temperature sensors are provided at the inlet and outlet of the cooling water circuits for the low-temperature zone, the medium-low-temperature zone, the medium-temperature zone, and the high-temperature zone.

[0015] Preferably, the temperature sensor is electrically connected to the control unit.

[0016] Preferably, a thermostat is provided between the water tank and the high-temperature electronic water pump.

[0017] Preferably, the inlet temperature of the cooling water circuit for the low-temperature component is ≤20℃, the outlet temperature of the three-way valve is ≤75℃, and the outlet temperature of the cooling water circuit for the medium-temperature component is ≤115℃; the inlet temperature of the cooling water circuit for the medium-temperature component is ≥95℃, and the inlet temperature is ≤115℃.

[0018] A hybrid vehicle according to the present invention has a cooling system as described above.

[0019] The beneficial effects achieved by this invention are as follows: This invention uses a coupling design based on the coolant flow requirements of components in each temperature zone, and connects the cooling water circuits of medium-temperature components such as the gearbox in series with the cooling water circuits of medium- and low-temperature components such as the motor. By reusing the motor coolant, the total coolant flow requirement of the hybrid vehicle is reduced while improving the efficiency of the hybrid vehicle cooling system. Attached Figure Description

[0020] Figure 1-2 This is a connection diagram of the existing cooling system;

[0021] Figure 3 This is a connection diagram of the cooling system of the present invention;

[0022] The components include: 1. Water tank; 2. Low-temperature electronic water pump; 3. High-temperature electronic water pump; 4. Three-way reversing valve; 5. Three-way valve; 6. Thermostat; 7. Control unit. Detailed Implementation

[0023] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0025] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0026] like Figure 3 As shown, the present invention provides a cooling system for secondary utilization of motor coolant, comprising a water tank 1. One outlet of the water tank 1 is connected to the inlet of a three-way reversing valve 4 via a low-temperature electronic water pump 2. One channel of the three-way reversing valve 4 is connected in series with the cooling water circuits for the low-temperature and medium-low-temperature components, and then connected to one inlet of a three-way valve 5. The other channel of the three-way reversing valve 4 is connected to the other inlet of the three-way valve 5. The outlet of the three-way valve 5 is connected to the cooling water circuit for the medium-temperature components, and then connected to the inlet of the water tank 1.

[0027] Another path from the outlet of water tank 1 is connected to the cooling water circuit of the high-temperature components via the high-temperature electronic water pump 3, and then connected to the inlet of water tank 1.

[0028] This invention connects a three-way reversing valve 4 to the rear end of the cryogenic electronic oil pump 2 to meet the cryogenic coolant flow requirements of the hybrid vehicle under two different operating conditions. When the motor and transmission are operating simultaneously, the three-way reversing valve 4 is open, and the coolant passes through the cryogenic electronic water pump 2 and sequentially enters the cooling water circuit for the low-temperature components of the motor, the cooling water circuit for the medium-low-temperature components of the motor, and then the cooling water circuit for the medium-temperature components of the motor, which is a coupled design between the medium-temperature components of the motor and the transmission lubrication unit, before finally entering the return channel. When the transmission is operating and the motor is not operating, the three-way reversing valve 4 is closed, and the coolant passes through the cryogenic electronic water pump 2 and directly enters the cooling water circuit for the medium-temperature components of the motor, which is a coupled design between the medium-temperature components of the motor and the transmission lubrication unit, before finally entering the return channel.

[0029] This invention, based on the operating temperature requirements of various components in hybrid vehicles, divides the vehicle components into high-temperature, medium-temperature, medium-low-temperature, low-temperature, and ultra-low-temperature zones. In existing solutions, the transmission cooling system is decoupled from the engine cooling system, and the medium-temperature motor components are decoupled from the low-temperature and medium-low-temperature motor component cooling systems. The medium-temperature components, including the transmission and motor planetary gear system, are connected in series after the low-temperature and medium-low-temperature motor components. The cooling system for the medium-low-temperature components is redesigned with a new coupling mechanism, and the coolant entering the low-temperature motor zone is reused. The entire vehicle cooling system is divided into a high-temperature water circuit and a low-temperature water circuit. The high-temperature water circuit has an inlet coolant temperature in the range of 110℃ to 115℃, while the low-temperature water circuit has an inlet coolant temperature in the range of 20℃ to 40℃.

[0030] Example 1: A cooling system for secondary utilization of motor coolant includes a water tank 1. One outlet of the water tank 1 is connected to the inlet of a three-way reversing valve 4 via a low-temperature electronic water pump 2. One channel of the three-way reversing valve 4 is connected in series with the cooling water circuits for the low-temperature and medium-low-temperature components, and then connected to one inlet of a three-way valve 5. The other channel of the three-way reversing valve 4 is connected to the other inlet of the three-way valve 5. The outlet of the three-way valve 5 is connected to the cooling water circuit for the medium-temperature components, and then connected to the inlet of the water tank 1.

[0031] Another path from the outlet of water tank 1 is connected to the cooling water circuit of the high-temperature components via the high-temperature electronic water pump 3, and then connected to the inlet of water tank 1.

[0032] In this embodiment, the low-temperature zone components include the motor PDU and motor controller, with an optimal operating temperature of 20°C to 40°C. The medium-low temperature zone components include the motor stator and motor rotor, with an optimal operating temperature of 50°C to 75°C. The medium-temperature zone components include the motor planetary gear system and gearbox, with an optimal operating temperature of 80°C to 100°C. The high-temperature zone components include the engine block, engine cylinder head, EGR, urea heater, fuel tank heater, and heater, with an optimal operating temperature >100°C.

[0033] The operating temperature requirements for various components of a hybrid vehicle are as follows:

[0034]

[0035] Example 2: A cooling system for secondary utilization of motor coolant includes a water tank 1. One outlet of the water tank 1 is connected to the inlet of a three-way reversing valve 4 via a low-temperature electronic water pump 2. One channel of the three-way reversing valve 4 is connected in series with the cooling water circuits for the low-temperature and medium-low-temperature components, and then connected to one inlet of a three-way valve 5. The other channel of the three-way reversing valve 4 is connected to the other inlet of the three-way valve 5. The outlet of the three-way valve 5 is connected to the cooling water circuit for the medium-temperature components, and then connected to the inlet of the water tank 1.

[0036] Another path from the outlet of water tank 1 is connected to the cooling water circuit of the high-temperature components via the high-temperature electronic water pump 3, and then connected to the inlet of water tank 1.

[0037] In this embodiment, the low-temperature zone components include the motor PDU and motor controller, with an optimal operating temperature of 20°C to 40°C. The medium-low temperature zone components include the motor stator and motor rotor, with an optimal operating temperature of 50°C to 75°C. The medium-temperature zone components include the motor planetary gear system and gearbox, with an optimal operating temperature of 80°C to 100°C. The high-temperature zone components include the engine block, engine cylinder head, EGR, urea heater, fuel tank heater, and heater, with an optimal operating temperature >100°C.

[0038] The operating temperature requirements for various components of a hybrid vehicle are as follows:

[0039]

[0040] In this embodiment, temperature sensors are installed at the inlet and outlet of the cooling water circuits for the low-temperature, medium-low-temperature, medium-temperature, and high-temperature components. A thermostat 6 is installed between the water tank 1 and the high-temperature electronic water pump 3. The thermostat 6, temperature sensors, low-temperature electronic water pump 2, and high-temperature electronic water pump 3 are all electrically connected to the control unit 7.

[0041] Example 2: A cooling system for secondary utilization of motor coolant includes a water tank 1. One outlet of the water tank 1 is connected to the inlet of a three-way reversing valve 4 via a low-temperature electronic water pump 2. One channel of the three-way reversing valve 4 is connected in series with the cooling water circuits for the low-temperature and medium-low-temperature components, and then connected to one inlet of a three-way valve 5. The other channel of the three-way reversing valve 4 is connected to the other inlet of the three-way valve 5. The outlet of the three-way valve 5 is connected to the cooling water circuit for the medium-temperature components, and then connected to the inlet of the water tank 1.

[0042] Another path from the outlet of water tank 1 is connected to the cooling water circuit of the high-temperature components via the high-temperature electronic water pump 3, and then connected to the inlet of water tank 1.

[0043] In this embodiment, the low-temperature zone components include the motor PDU and motor controller, with an optimal operating temperature of 20°C to 40°C. The medium-low temperature zone components include the motor stator and motor rotor, with an optimal operating temperature of 50°C to 75°C. The medium-temperature zone components include the motor planetary gear system and gearbox, with an optimal operating temperature of 80°C to 100°C. The high-temperature zone components include the engine block, engine cylinder head, EGR, urea heater, fuel tank heater, and heater, with an optimal operating temperature >100°C.

[0044] The operating temperature requirements for various components of a hybrid vehicle are as follows:

[0045]

[0046] In this embodiment, temperature sensors are installed at the inlet and outlet of the cooling water circuits for the low-temperature, medium-low-temperature, medium-temperature, and high-temperature components. A thermostat 6 is installed between the water tank 1 and the high-temperature electronic water pump 3. The thermostat 6, temperature sensors, low-temperature electronic water pump 2, and high-temperature electronic water pump 3 are all electrically connected to the control unit 7.

[0047] In this embodiment, the inlet temperature of the cooling water circuit for the low-temperature component is ≤20℃, the outlet temperature of the three-way valve is ≤75℃, and the outlet temperature of the cooling water circuit for the medium-temperature component is ≤115℃; the inlet temperature of the cooling water circuit for the medium-temperature component is ≥95℃, and the inlet temperature is ≤115℃.

[0048] A hybrid vehicle according to the present invention has a cooling system as described above.

[0049] This invention, based on the parameters of each component in the vehicle's cooling system, heat dissipation requirements, and the optimal operating temperature range of each temperature zone component, uses simulation calculations to estimate the inlet and outlet temperatures and flow rates of the coolant for each temperature zone component under different operating conditions. The cooling water circuits for medium-temperature zone components such as the transmission are connected in series with the cooling water circuits for medium- and low-temperature zone components such as the motor, and the resulting cooling system is recoupled based on temperature zoning and coolant flow rate calculations.

[0050] Because the battery requires low cooling water flow and extremely low water temperature (≤20℃), a separate cooling system was installed to cool the ultra-low temperature water circuit containing the battery. The battery's independent cooling system was not included in... Figure 3 It is displayed in the middle.

[0051] This invention decouples the gearbox cooling system from the engine cooling system in the existing solution, decouples the cooling systems of the motor's medium-temperature zone components from the motor's low-temperature zone and medium-low-temperature zone components, connects the medium-temperature zone components where the gearbox and motor planetary gear system are located in series after the motor's low-temperature zone and medium-low-temperature zone components, redesigns the coupling of the medium-low-temperature zone component cooling system, and reuses the cooling water entering the motor's low-temperature zone.

[0052] This invention connects a three-way reversing valve 4 to the rear end of the cryogenic electronic water pump 2 to meet the cryogenic coolant flow requirements of the hybrid vehicle under two different operating conditions. When the motor and transmission are working simultaneously, the three-way reversing valve opens, and the coolant passes through the electronic oil pump to sequentially enter the cooling water circuit of the motor's cryogenic components, the cooling water circuit of the motor's low-to-medium cryogenic components, and then enters the medium-temperature cooling system water circuit, which is a coupling design between the motor's medium-temperature components and the transmission lubrication unit, before finally entering the return channel. When the transmission is working and the motor is not working, the three-way reversing valve closes, and the coolant passes through the electronic oil pump directly into the medium-temperature cooling system water circuit, which is a coupling design between the motor's medium-temperature components and the transmission lubrication unit, before finally entering the return channel.

[0053] This invention divides the vehicle cooling system into a high-temperature water circuit and a low-temperature water circuit. The inlet temperature of the coolant in the high-temperature water circuit is in the range of 110℃-115℃, and the inlet temperature of the coolant in the low-temperature water circuit is in the range of 20℃-40℃. The control unit adjusts the inlet flow rate of the high-temperature water circuit's electronic water pump based on the outlet water temperature of the high-temperature water circuit where components such as the engine are located, controlling the inlet water temperature of the high-temperature water circuit within the range of 110℃-115℃. The coolant flow rate requirement for the high-temperature water circuit is: Qh1+Qh2+Qh3+Qh4+Qh5. The control unit adjusts the inlet flow rate of the low-temperature water circuit's electronic water pump based on the inlet water temperature of the medium-temperature water circuit where components such as the transmission and motor planetary gear system are located, controlling the inlet water temperature of the low-temperature water circuit within the range of 20℃-40℃. The coolant flow rate requirement for the high-temperature water circuit is: max{Ql1+Ql2,Qz1,Qm1+Qm2}. The total coolant flow rate requirement of the hybrid vehicle's cooling system is reduced in the new coupled solution compared to the existing solution.

[0054] The foregoing has shown and described the basic principles and main structural features of the present invention. The present invention is not limited to the above examples; various changes and modifications can be made without departing from the spirit and scope of the invention, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection of the present invention is defined by the appended claims and their equivalents.

[0055] It should be noted that the above description of the technical solutions is exemplary, and this specification may be embodied in different forms and should not be construed as limiting it to the technical solutions set forth herein. Rather, providing these descriptions will ensure that the disclosure of this invention is thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Furthermore, the technical solutions of this invention are defined only by the scope of the claims.

[0056] Finally, it should be noted that the above embodiments are merely representative examples of the present invention. Obviously, the present invention is not limited to the above embodiments and many variations are possible. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention should be considered within the protection scope of the present invention.

Claims

1. A cooling system for the secondary utilization of motor coolant, characterized in that: The system includes a water tank. One outlet of the water tank is connected to the inlet of a three-way reversing valve via a low-temperature electronic water pump. One path of the three-way reversing valve is connected in series with the cooling water circuits for the low-temperature and medium-low-temperature components, and then connected to one inlet of the three-way valve. The other path of the three-way reversing valve is connected to the other inlet of the three-way valve. The outlet of the three-way valve is connected to the cooling water circuit for the medium-temperature components, and then connected to the inlet of the water tank. The water tank outlet is connected to the cooling water circuit of the high-temperature component via a high-temperature electronic water pump, and then connected to the water tank inlet. Based on the operating temperature requirements of various components in hybrid vehicles, the vehicle components are divided into high-temperature zone, medium-temperature zone, medium-low-temperature zone, low-temperature zone, and ultra-low-temperature zone. The low-temperature zone components include the motor PDU and motor controller; the medium-low-temperature zone components include the motor stator and motor rotor; the medium-temperature zone components include the motor planetary gear system and transmission; and the high-temperature zone components include the engine block, engine cylinder head, EGR, urea heater, fuel tank heater, and heater. When the motor and gearbox are working simultaneously, the three-way reversing valve opens, and the coolant passes through the cryogenic electric water pump to enter the cooling water circuit of the motor's cryogenic components, the cooling water circuit of the motor's intermediate-crystal components, and then the cooling water circuit of the intermediate-temperature components, which is a coupled design between the motor's intermediate-temperature components and the gearbox lubrication unit, before finally entering the return channel. When the gearbox is working but the motor is not working, the three-way reversing valve closes, and the coolant passes through the cryogenic electric water pump directly into the cooling water circuit of the intermediate-temperature components, which is a coupled design between the motor's intermediate-temperature components and the gearbox lubrication unit, before finally entering the return channel.

2. The cooling system for secondary utilization of motor coolant according to claim 1, characterized in that: The optimal operating temperature for the low-temperature component is 20℃~40℃.

3. The cooling system for secondary utilization of motor coolant according to claim 1, characterized in that: The optimal operating temperature for the medium-low temperature zone component is 50℃~75℃.

4. The cooling system for secondary utilization of motor coolant according to claim 1, characterized in that: The optimal operating temperature for the medium-temperature component is 80℃~100℃.

5. The cooling system for secondary utilization of motor coolant according to claim 1, characterized in that: The optimal operating temperature of the high-temperature component is >100℃.

6. The cooling system for secondary utilization of motor coolant according to claim 1, characterized in that: Temperature sensors are installed at the inlet and outlet of the cooling water circuits for the low-temperature zone, the medium-low-temperature zone, the medium-temperature zone, and the high-temperature zone.

7. The cooling system for secondary utilization of motor coolant according to claim 6, characterized in that: The temperature sensor is electrically connected to the control unit.

8. The cooling system for secondary utilization of motor coolant according to claim 1, characterized in that: A temperature regulator is installed between the water tank and the high-temperature electronic water pump.

9. The cooling system for secondary utilization of motor coolant according to claim 1, characterized in that: The inlet temperature of the cooling water circuit for the low-temperature component is ≤20℃, the outlet temperature of the three-way valve is ≤75℃, and the outlet temperature of the cooling water circuit for the medium-temperature component is ≤115℃; the inlet temperature of the cooling water circuit for the medium-temperature component is ≥95℃, and the inlet temperature is ≤115℃.

10. A hybrid vehicle, characterized in that: It has a cooling system as described in any one of claims 1 to 9.

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