Fuel cell bus intelligent comprehensive thermal management system and method

Abstract

This invention proposes an intelligent integrated thermal management system and method for fuel cell buses, comprising: a fuel cell thermal management circuit with a heat exchanger installed on it; a passenger compartment thermal management circuit connected to the heat exchanger, with a dual-core heat exchanger installed on it; a power battery thermal management circuit connected to the dual-core heat exchanger, with a four-way valve installed on it; a motor thermal management circuit connected to the four-way valve; and an air conditioning thermal management circuit connected in parallel to the dual-core heat exchanger.

Description

Technical Field

[0001] This invention belongs to the technical field of bus thermal management, and particularly relates to an intelligent integrated thermal management system and method for fuel cell buses. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] Fuel cell buses, as a new type of vehicle powered by advanced energy sources, have gained popularity among numerous companies and schools due to their advantages such as being clean and pollution-free, having a simple structure, stable power output, and high energy conversion efficiency. Hydrogen energy, as a sustainable energy source, is experiencing rapid and strong growth, with an increasing number of automakers joining the hydrogen energy industry.

[0004] In recent years, fuel cell systems have seen gradual improvements in functionality, simplification of structure, and increased integration, and their development has now reached a mature stage. However, fuel cell systems generate a significant amount of heat during operation, which, if not utilized, is directly released into the atmosphere, resulting in heat loss. Therefore, more research and development efforts are focused on the thermal management of fuel cells. From the perspective of fuel cell buses, this involves not only considering the thermal management of the fuel cell itself but also the integrated thermal management of the fuel cell with the passenger compartment, the power battery with the motor, and the air conditioning system. Summary of the Invention

[0005] To overcome the shortcomings of the prior art, the present invention provides an intelligent integrated thermal management system and method for fuel cell buses. By coupling the heat exchange regulation of individual independent systems through heat exchangers and three-way valves and four-way valves, the waste heat of fuel cells is recovered and utilized to form an interconnected whole system, avoiding energy waste, reducing hydrogen consumption, and improving the overall ride comfort of the vehicle.

[0006] To achieve the above objectives, one or more embodiments of the present invention provide the following technical solution: an intelligent integrated thermal management system for fuel cell buses, comprising:

[0007] A fuel cell thermal management circuit, wherein a heat exchanger is provided on the fuel cell thermal management circuit;

[0008] A passenger cabin thermal management circuit connected to the heat exchanger, and a dual-core heat exchanger disposed on the passenger cabin thermal management circuit;

[0009] A power battery thermal management circuit connected to the dual-core heat exchanger is provided with a four-way valve.

[0010] The motor thermal management circuit connected to the four-way valve;

[0011] And an air conditioning thermal management circuit connected in parallel to the dual-core heat exchanger.

[0012] A second aspect of the present invention provides an intelligent integrated thermal management method for a fuel cell bus, employing the aforementioned intelligent integrated thermal management system for a fuel cell bus, comprising:

[0013] The fuel cell thermal management loop exchanges heat with the passenger cabin thermal management loop through a heat exchanger;

[0014] The passenger cabin thermal management circuit exchanges heat with the power battery thermal management circuit through a dual-core heat exchanger.

[0015] The power battery thermal management circuit exchanges heat with the motor thermal management circuit through a four-way valve;

[0016] The air conditioning thermal management loop exchanges heat with the dual-core heat exchanger.

[0017] The above one or more technical solutions have the following beneficial effects:

[0018] In this invention, heat exchange regulation of individual independent systems is coupled through heat exchangers and three-way and four-way valves to recover and utilize waste heat from the fuel cell, forming an interconnected overall system. This system addresses the thermal management of the fuel cell under different operating conditions, as well as the integrated thermal management of the fuel cell, power battery, and motor. This avoids energy waste, reduces hydrogen consumption, and improves the overall vehicle ride comfort. Ensuring that all vehicle systems operate at suitable temperatures helps improve their reliability, efficiency, safety, and energy saving.

[0019] Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0020] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0021] Figure 1 This is a schematic diagram of an intelligent integrated thermal management system for a fuel cell bus according to Embodiment 1 of the present invention. Detailed Implementation

[0022] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0023] It should be noted that the terminology used herein is for the purpose of describing particular implementations only and is not intended to limit the exemplary implementations of the present invention.

[0024] Where there is no conflict, the embodiments and features in the embodiments of the present invention can be combined with each other.

[0025] Example 1

[0026] like Figure 1 As shown, this embodiment discloses an intelligent integrated thermal management system for fuel cell buses, including:

[0027] A heat exchanger is installed in the fuel cell thermal management circuit.

[0028] Passenger cabin thermal management circuit connected to heat exchanger, and dual-core heat exchanger installed on passenger cabin thermal management circuit;

[0029] The power battery thermal management circuit connected to the dual-core heat exchanger is equipped with a four-way valve.

[0030] The motor thermal management circuit is connected to the four-way valve;

[0031] And an air conditioning thermal management circuit connected in parallel to the dual-core heat exchanger.

[0032] In this embodiment, the fuel cell thermal management loop includes the inlet of a first water pump connected to the first outlet of the heat exchanger via a pipeline, the outlet of the first water pump connected to the inlet of the fuel cell radiator via a pipeline, the outlet of the fuel cell radiator connected to the inlet of the fuel cell via a pipeline, and the outlet of the fuel cell connected to the first inlet of the heat exchanger via a pipeline.

[0033] In this embodiment, the passenger cabin thermal management loop includes a temperature sensor installed on the second outlet pipe of the heat exchanger to measure the temperature at the second outlet of the heat exchanger. The second outlet of the heat exchanger is connected to the inlet of the heater core via a pipe. The outlet of the heater core is connected to the first port of the first three-way valve and the first port of the second three-way valve. The second port of the first three-way valve is connected to the first inlet of the dual-core heat exchanger via a pipe. The first outlet of the dual-core heat exchanger is connected to the inlet of the heater core via a pipe. The third port of the first three-way valve is connected to the inlet of the PTC (positive temperature coefficient thermistor) heating element via a pipe. The outlet of the PTC heating element is connected to the inlet of the second water pump via a pipe. The outlet of the second water pump is connected to the pipe connecting the inlet of the heater core and the first outlet of the dual-core heat exchanger via a pipe. The second port of the second three-way valve is connected to the second inlet of the heat exchanger via a pipeline. The third port of the second three-way valve is connected to the pipeline connecting the temperature sensor and the inlet of the heater core via a first pipeline. The purpose of the first pipeline is that when the passenger cabin temperature reaches a suitable temperature, it is not necessary to use the waste heat of the fuel cell system to heat the passenger cabin, and therefore it is not necessary to exchange heat through the heat exchanger.

[0034] In this embodiment, the dual-core heat exchanger consists of a heating core and a cooling core. When the passenger compartment requires heating, the fuel cell heat exchanger participates in the heating cycle. At this time, the second three-way valve is closed, and cooling water circulates through the fuel cell heat exchanger, temperature sensor, heater core, first three-way valve, PTC, and second water pump to the heater core for heating. At this time, the first pipeline is closed. Whether the circulating water enters the dual-core heat exchanger through the first three-way valve depends on whether the power battery and motor need heating. If the power battery and motor need heating, the circulating water enters the dual-core heat exchanger through the second port of the first three-way valve. If the power battery and motor do not need heating, the second port of the first three-way valve is closed, and the circulating water will not enter the pipeline where the power battery and motor need heating. When the passenger compartment does not require heating, the cooling water circulates through the heater core and the third port of the second three-way valve to the heater core for heat dissipation.

[0035] It should be noted that heat is exchanged between the heating core and the cooling core.

[0036] The first inlet and the first outlet of the dual-core heat exchanger are the inlet and outlet of the cooling core of the dual-core heat exchanger, respectively.

[0037] In this embodiment, the power battery thermal management circuit includes: the second outlet of the dual-core heat exchanger is connected to the inlet of the battery water pump through a pipeline; the outlet of the battery water pump is connected to the first interface of the four-way valve through a pipeline; the second interface of the four-way valve is connected to the inlet of the battery pack assembly through a pipeline; and the outlet of the battery pack assembly is connected to the second inlet of the dual-core heat exchanger through a pipeline.

[0038] The second inlet and the second outlet of the dual-core heat exchanger are the inlet and outlet of the heating core of the dual-core heat exchanger, respectively.

[0039] When the power battery temperature is low, the passenger compartment is heated and circulated through the heating core of the dual-core heat exchanger, the battery water pump, the four-way valve, and the battery pack assembly. When the power battery temperature is high, the air conditioning thermal management circuit is cooled through the compressor, condenser assembly, cooling core of the dual-core heat exchanger, the battery water pump, the four-way valve, and the battery pack assembly. At this time, the throttle valve is closed.

[0040] The heating circuit of the power battery thermal management system heats the power battery with waste heat from the fuel cell through the heating core and the heating section of the dual-core heat exchanger; the cooling circuit of the power battery thermal management system cools the power battery with the air conditioning system through the cooling section of the dual-core heat exchanger.

[0041] In this embodiment, the motor thermal management circuit includes a third three-way valve, a motor radiator assembly and a four-way valve third interface connected in sequence to the second interface of the third three-way valve via a pipeline; the third interface of the third three-way valve is connected to the fourth interface of the four-way valve via a second pipeline; the third interface of the four-way valve is connected to the inlet of the motor water pump via a pipeline; the outlet of the motor water pump is connected to the inlet of the motor controller assembly via a pipeline; and the outlet of the motor controller assembly is connected to the first interface of the third three-way valve via a pipeline.

[0042] When the motor temperature is low, the waste heat from the power battery passes sequentially through the heater core, the dual-core heat exchanger heating core, the battery water pump, the four-way valve, the motor water pump, the motor controller assembly, and the third three-way valve before entering the motor water pump again through the second pipeline for circulating heating. At this time, the second port of the third three-way valve is closed. When the motor temperature is high, the coolant circulates for heat dissipation through the four-way valve, the motor water pump, the motor controller assembly, the three-way valve, and the motor radiator assembly.

[0043] It should be noted that the battery pack assembly includes the power battery, and the battery pack assembly is the process of assembling individual battery cells to form a power battery pack.

[0044] The air conditioning thermal management circuit is as follows: the compressor outlet is connected to the condenser assembly inlet via a pipe; the condenser assembly outlet is connected to the first port of the expansion valve via a pipe; the second port of the expansion valve is connected to the inlet of the vehicle's evaporator assembly via a pipe; and the evaporator assembly outlet is connected to the compressor inlet via a pipe. The compressor inlet is connected to the first outlet of the dual-core heat exchanger via a pipe, and the first port of the expansion valve is connected to the first inlet of the dual-core heat exchanger via a pipe.

[0045] In this embodiment, the waste heat from the fuel cell is used to heat the passenger cabin, power battery, and motor, and the air conditioner is used to cool the passenger cabin, power battery, and motor, thereby enhancing the coupling and interconnectivity of the power system.

[0046] Example 2

[0047] This embodiment provides an intelligent integrated thermal management method for fuel cell buses, employing an intelligent integrated thermal management system for fuel cell buses as described in Embodiment 1, including:

[0048] Based on the minimum suitable temperature of the passenger compartment and the minimum operating temperature of the power battery and motor, determine whether the waste heat of the fuel cell needs to be exchanged to the passenger compartment, power battery, and motor.

[0049] Based on the minimum suitable temperature in the passenger cabin and the maximum operating temperature of the fuel cell, power battery, and motor, determine whether the air conditioning system needs to exchange heat to the passenger cabin, fuel cell, power battery, and motor.

[0050] Based on the above determination of whether the system is in heating or cooling mode, the first three-way valve, the second three-way valve, the third three-way valve, and the four-way valve of the heating and cooling circuits are opened or closed.

[0051] In heating mode, the integrated thermal management of the fuel cell, passenger compartment, power battery, and motor relies on the PCT, heater core, and heat exchanger.

[0052] Specifically, when the vehicle's driving mode switches from pure electric mode to fuel cell electric mode, the fuel cell system starts up in a short time and generates less heat, which is insufficient to provide excess heat to other systems, so there is no need to transfer heat to other systems.

[0053] The thermal management of the fuel cell thermal management loop and the passenger cabin thermal management loop is as follows: When the fuel cell system starts working and the passenger cabin temperature is lower than the preset temperature (in this embodiment, the preset temperature is 23°C), the heater core and PCT are opened sequentially, along with the first three-way valve, for heating. The heat energy generated by the fuel cell passes through the heat exchanger, then sequentially through the temperature sensor, heater core, first three-way valve, PTC heater, and second water pump, returning to the heater core to form a thermal circulation loop of heater core, PTC, and second water pump. When the passenger cabin does not require fuel cell heat exchange, the first three-way valve is closed and the second three-way valve is opened, allowing the heat to return to the heater core for heat dissipation circulation through the heater core, the second three-way valve, and the first pipeline.

[0054] In this embodiment, the temperature of the passenger cabin is maintained at a comfortable temperature for the human body by adjusting the opening and closing of the first three-way valve and the second three-way valve.

[0055] The temperature sensor is used to detect the temperature at the second outlet of the heat exchanger in real time to determine whether the coolant needs continuous heating.

[0056] The thermal management of the fuel cell thermal management loop and the power battery thermal management loop is as follows: When the fuel cell system is working normally and the temperature of the power battery is lower than the minimum normal operating temperature, the heat of the fuel cell is transferred sequentially through the heat exchanger, temperature sensor, heater core, first three-way valve, dual-core heat exchanger, battery water pump, four-way valve and battery pack assembly.

[0057] The waste heat from the fuel cell is heated by a PTC heater and then used to heat the power battery through the heating core of a dual-core heat exchanger.

[0058] The thermal management of the fuel cell thermal management loop and the motor thermal management loop is as follows: When the fuel cell system is working normally, and its motor temperature is lower than the minimum normal operating temperature, the heat from the fuel cell thermal management loop passes through the heat exchanger, temperature sensor, heater core, first three-way valve, dual-core heat exchanger, battery water pump, motor water pump, motor control assembly, and third three-way valve, and then returns to the motor water pump through the second pipeline to achieve heat circulation.

[0059] It should be noted that the heater core, the first three-way valve, the PTC and the second water pump return to the heater core to form a heat circulation pipeline. After being heated by the PTC heating element, the circulating water enters the dual-core heat exchanger through the first three-way valve, and then circulates heat for the power battery thermal management circuit and the motor thermal management circuit.

[0060] In this embodiment, the fuel cell heats the motor through the heating core of the dual-core heat exchanger.

[0061] In the cooling mode of this embodiment, the integrated thermal management of the fuel cell, passenger cabin, power battery, and motor relies on the air conditioning thermal management loop and heat exchanger.

[0062] Specifically, the thermal management of the fuel cell thermal management loop and the passenger cabin thermal management loop is as follows: when the fuel cell temperature reaches the maximum operating temperature and the passenger cabin temperature exceeds the suitable temperature, heat exchange occurs through the cooling core of the dual-core heat exchanger. The heat from the fuel cell and the passenger cabin are sequentially circulated through the heating core, the first three-way valve, the heating core of the dual-core heat exchanger, the cooling core of the dual-core heat exchanger, the compressor, and the condenser assembly to the cooling core of the dual-core heat exchanger for cooling.

[0063] Thermal management of fuel cell thermal management circuit and power battery thermal management circuit: When the power battery temperature reaches the maximum operating temperature, the compressor starts to work. The cold air from the compressor passes through the condenser assembly, the cooling core of the dual-core heat exchanger, the battery water pump, and the battery pack assembly in sequence, and returns to the compressor through the dual-core heat exchanger to dissipate heat from the power battery.

[0064] Thermal management of the fuel cell thermal management loop and the motor thermal management loop: When the motor temperature reaches the maximum operating temperature, the compressor starts to work. The cold air from the compressor passes sequentially through the condenser assembly, the cooling core of the dual-core heat exchanger, the battery water pump, the four-way valve, the motor water pump, the motor controller assembly, the motor radiator assembly, the four-way valve, the battery pack assembly, and the dual-core heat exchanger back to the compressor to cool the motor.

[0065] This implementation monitors the temperature of the passenger cabin, fuel cell, power battery, and motor. It monitors whether the temperature exceeds the upper limit or falls below the lower limit. If the threshold is exceeded, the temperature of the corresponding system is regulated.

[0066] If a system temperature is detected to be below the lower limit, the waste heat from the fuel cell is used to heat its circuit; if a system temperature is detected to be above the upper limit, the air conditioning system is used to cool its circuit.

[0067] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A fuel cell bus intelligent integrated thermal management system, characterized in that, include: A fuel cell thermal management circuit, wherein a heat exchanger is provided on the fuel cell thermal management circuit; A passenger cabin thermal management circuit connected to the heat exchanger, and a dual-core heat exchanger disposed on the passenger cabin thermal management circuit; A power battery thermal management circuit connected to the dual-core heat exchanger is provided with a four-way valve. The motor thermal management circuit connected to the four-way valve; And an air conditioning thermal management circuit connected in parallel to the dual-core heat exchanger; The passenger cabin thermal management loop includes a heater core, a first port of a first three-way valve, a PTC, and an inlet of a second water pump, all connected in sequence to the second outlet of a heat exchanger via pipelines. The outlet of the second water pump is connected to the inlet of the heater core via a pipeline. The second port of the first three-way valve is connected to the first inlet of a dual-core heat exchanger via a pipeline. The first outlet of the dual-core heat exchanger is connected to the outlet of the second water pump via a pipeline. The outlet of the heating core is also connected to the first interface of the second three-way valve through a pipeline. The second interface of the second three-way valve is connected to the second inlet of the heat exchanger through a pipeline. The third interface of the second three-way valve is connected to the pipeline connecting the second outlet of the heat exchanger and the inlet of the heating core through a pipeline. The power battery thermal management circuit includes a battery water pump, a four-way valve, and a water inlet of the battery pack assembly, which are sequentially connected to the second outlet of the dual-core heat exchanger. The outlet water of the battery pack assembly is connected to the second inlet of the dual-core heat exchanger.

2. The intelligent integrated thermal management system for fuel cell buses as described in claim 1, characterized in that, The fuel cell thermal management circuit includes a first water pump, a fuel cell radiator, and a fuel cell inlet, which are sequentially connected to the first outlet of the heat exchanger via pipelines. The outlet of the fuel cell is connected to the first inlet of the heat exchanger via pipeline.

3. The intelligent integrated thermal management system for fuel cell buses as described in claim 1, characterized in that, The motor thermal management circuit includes a third three-way valve, a motor radiator assembly and a four-way valve third interface connected in sequence to the second interface of the third three-way valve; The third port of the third three-way valve is connected to the fourth port of the four-way valve via a pipeline; the fourth port of the four-way valve is sequentially connected to the motor pump, the motor controller assembly, and the first port of the third three-way valve via a pipeline.

4. The intelligent integrated thermal management system for fuel cell buses as described in claim 1, characterized in that, The air conditioning thermal management circuit includes an in-vehicle evaporator assembly, a compressor, a condenser assembly, and a throttle valve connected in sequence by circulating pipes; Alternatively, the dual-core heat exchanger includes a heating core and a cooling core, and the air conditioning thermal management circuit is connected to the cooling core piping of the dual-core heat exchanger.

5. A method for intelligent integrated thermal management of a fuel cell bus, employing the intelligent integrated thermal management system for a fuel cell bus as described in any one of claims 1-4, characterized in that, include: The fuel cell thermal management loop exchanges heat with the passenger cabin thermal management loop through a heat exchanger; The passenger cabin thermal management circuit exchanges heat with the power battery thermal management circuit through a dual-core heat exchanger. The power battery thermal management circuit exchanges heat with the motor thermal management circuit through a four-way valve; The air conditioning thermal management loop exchanges heat with the dual-core heat exchanger.

6. The intelligent integrated thermal management method for a fuel cell bus as described in claim 5, characterized in that, In cooling mode, the air conditioning thermal management circuit is connected to the cooling core of the dual-core heat exchanger, and dissipates heat for the passenger cabin thermal management circuit, the power battery thermal management circuit, and the motor thermal management circuit through the air conditioning thermal management circuit.

Images