An air conditioner all-in-one controller, control method and electric vehicle air conditioner system

Abstract

The present disclosure relates to the field of automobile air conditioners, and particularly relates to an air conditioner all-in-one controller, a control method and an electric vehicle air conditioning system. The air conditioner all-in-one controller comprises: a high-voltage side control unit, comprising a high-voltage side controller for controlling the operation of a water heater and a compressor to achieve temperature regulation; a low-voltage side control unit, comprising a low-voltage side controller for receiving an external input instruction for controlling the water heater and the compressor, the low-voltage side controller being further configured to transmit the external input instruction to the high-voltage side controller through a communication circuit via a digital isolation unit; a digital isolation unit arranged between the high-voltage side control unit and the low-voltage side control unit; and a circuit board, on which the high-voltage side control unit, the low-voltage side control unit and the digital isolation unit are arranged. The present disclosure can solve the problems of the electric vehicle air conditioning thermal management system due to the relative independence of each subcomponent.

Description

Technical Field

[0001] This disclosure relates to the field of automotive air conditioning, specifically to an all-in-one air conditioning controller, control method, and electric vehicle air conditioning system. Background Technology

[0002] Whether it's a traditional gasoline-powered car, a hybrid vehicle, or a pure electric vehicle, the principle of in-vehicle air conditioning is similar, only the power source differs. Traditional gasoline-powered cars use the engine for their air conditioning, while hybrid and pure electric vehicles typically use a battery to drive an electric air conditioning compressor. However, the heating principle differs significantly between traditional gasoline-powered cars and electric vehicles. Traditional gasoline-powered cars primarily generate heat from the waste heat produced during engine operation, which is then delivered into the vehicle via a blower. Pure electric vehicles, lacking an engine, rely on auxiliary heating methods, such as PTC heating or other similar methods.

[0003] The entire automotive thermal management system requires multiple functional circuits or controllers and structural components. A typical complete thermal management system typically consists of the following electrical and structural components: a top-level thermal management controller, a PTC controller, an air conditioning compressor controller, water heater channels, and water heater resistor units. In existing electric vehicle air conditioning thermal management systems, these sub-components are relatively independent, and communication and control between them are generally achieved through external wiring harnesses.

[0004] The pain points when each sub-component is implemented relatively independently include the following:

[0005] 1) The various sub-components are often developed and designed by different suppliers or technicians, resulting in mismatched structures and a lack of aesthetic appeal;

[0006] 2) The entire thermal management system is bulky, reducing the space for passengers and drivers and decreasing their comfort.

[0007] 3) Each sub-component is a self-contained system, resulting in a relatively heavy total weight and reducing the driving range of electric vehicles;

[0008] 4) The various sub-components are connected by external wiring harnesses. The wiring harnesses are easily damaged or the connector ports have poor contact, which reduces the reliability of the product and poses a threat to the smooth operation of the vehicle and the safety of the drivers and passengers.

[0009] 5) The housings and filter components of each sub-component cannot be shared, resulting in a waste of resources. External connectors and wiring harnesses are expensive, leading to increased manufacturing costs. Summary of the Invention

[0010] This disclosure provides an all-in-one air conditioner controller, a control method, and an electric vehicle air conditioning system, which can solve at least one of the problems mentioned in the background art. To solve the above-mentioned technical problems, this disclosure provides the following technical solutions:

[0011] As one aspect of this disclosure, an all-in-one air conditioner controller is provided, comprising:

[0012] The high-pressure side control unit includes a high-pressure side controller for controlling the operation of the water heater and compressor to achieve temperature regulation;

[0013] The low-pressure side control unit includes a low-pressure side controller for receiving external input commands to control the water heater and the compressor, and the low-pressure side controller is also used to transmit the external input commands to the high-pressure side controller via a communication circuit and a digital isolation unit.

[0014] A digital isolation unit is disposed between the high-voltage side control unit and the low-voltage side control unit to achieve isolated communication between the high-voltage side control unit and the low-voltage side control unit;

[0015] The circuit board on which the high-voltage side control unit, the low-voltage side control unit, and the digital isolation unit are mounted.

[0016] Optionally, the high-voltage side control unit also includes an EMC filter circuit, which is used to connect to the power battery to achieve stable power supply from the power battery;

[0017] And / or, the high-voltage side control unit further includes a phase current sampling circuit, which is used to monitor the three-phase current of the compressor;

[0018] And / or, the high-voltage side control unit also includes a bus voltage sampling circuit for voltage detection of the power battery;

[0019] And / or, the high-voltage side control unit also includes a bus current sampling circuit, which is used for sampling the input current of the air conditioning all-in-one controller.

[0020] Optionally, the high-pressure side control unit further includes a compressor U, V, W three-phase output module, which is used to control the start-up, shutdown, and operating power of the compressor.

[0021] Optionally, the high-voltage side control unit further includes a water heater and a water heater power circuit for controlling the start-up, shutdown, and power of the water heater.

[0022] Optionally, the high-voltage side control unit further includes a heating resistor current sampling circuit for collecting the operating current of the water heater.

[0023] Optionally, the high-voltage side control unit further includes a shell temperature sampling module for collecting the shell temperature of the water heater and a board temperature sampling module for collecting the temperature of the circuit board.

[0024] Optionally, the low-voltage side control unit includes:

[0025] A water temperature sampling module for detecting the water temperature of the water heater, wherein the water temperature sampling module is electrically connected to the low-pressure side controller;

[0026] And / or, a low-voltage EMC filter circuit connected to a low-voltage power supply battery that powers the modules contained in the low-voltage side control unit, for stabilizing the power supply to the low-voltage side control unit;

[0027] And / or, a solenoid valve control module for controlling fans and / or water pumps to enable start / stop or power control of fans and / or water pumps.

[0028] As another aspect of this disclosure, an air conditioning thermal management control method is provided, comprising the following steps:

[0029] The low-pressure side controller acquires external input commands from the control panel. The external input commands include one or more of the following: power on / off information, temperature setting information, or airflow level.

[0030] The low-voltage side controller transmits the external input commands to the high-voltage side controller via a communication circuit and a digital isolation unit; wherein, the digital isolation unit is located between the high-voltage side control unit and the low-voltage side control unit to achieve isolated communication between the high-voltage side control unit and the low-voltage side control unit.

[0031] The high-pressure side controller controls the operation of the water heater and compressor to achieve temperature regulation.

[0032] Optionally, the low-pressure side is also used to obtain: the water temperature of the water heater;

[0033] And / or, the operating current of the water heater;

[0034] And / or, the temperature of the water heater housing and the temperature of the circuit board.

[0035] As another aspect of this disclosure, an electric vehicle air conditioning system is provided, including the above-described air conditioning all-in-one controller; or, implementing the above-described air conditioning thermal management control method.

[0036] Compared to existing technologies, this disclosure solves the problems caused by the relatively independent nature of the sub-components in electric vehicle air conditioning thermal management systems. By placing the high-pressure side control unit and the low-pressure side control unit on the same circuit board, a multi-functional controller is formed, which has the following beneficial effects:

[0037] 1) All-in-one controllers can be developed and designed by the same engineering team, with a perfect structural match and a clean appearance;

[0038] 2) The all-in-one controller reduces overall consumables and lowers costs;

[0039] 3) The power density of the all-in-one controller is improved, reducing the system size;

[0040] 4) The all-in-one controller reduces overall weight and increases battery life;

[0041] 5) The all-in-one controller eliminates the need for external wiring harness connections, reducing potential points of failure and enhancing reliability. Attached Figure Description

[0042] Figure 1 This is a structural block diagram of the air conditioner all-in-one controller in the embodiments of this disclosure;

[0043] Figure 2 This is an exploded view of the structure of the air conditioning all-in-one controller in the embodiments of this disclosure;

[0044] Figure 3 This is a schematic diagram of the power main topology of the air conditioner all-in-one controller in the embodiments of this disclosure;

[0045] Figure 4 This is a flowchart of the air conditioning thermal management control method in the embodiments of this disclosure;

[0046] Figure 5 This is a schematic diagram illustrating the implementation of temperature regulation in an embodiment of this disclosure. Detailed Implementation

[0047] Various exemplary embodiments, features, and aspects of this disclosure will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0048] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0049] In this document, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Furthermore, the term "at least one" in this document means any combination of at least two of any one or more elements. For example, including at least one of A, B, and C can mean including any one or more elements selected from the set consisting of A, B, and C.

[0050] Furthermore, to better illustrate this disclosure, numerous specific details are set forth in the following detailed description. Those skilled in the art will understand that this disclosure can be practiced without certain specific details. In some instances, methods, means, components, and circuits well known to those skilled in the art have not been described in detail in order to highlight the main points of this disclosure.

[0051] It is understood that the various method embodiments mentioned above in this disclosure can be combined with each other to form combined embodiments without violating the principle and logic. Due to space limitations, this disclosure will not elaborate further.

[0052] As one aspect of this disclosure, an all-in-one air conditioner controller is provided, such as... Figure 1-2 As shown, it includes:

[0053] The high-pressure side control unit 10 includes a high-pressure side controller 101 for controlling the operation of the water heater 60 and the compressor to achieve temperature regulation;

[0054] The low-pressure side control unit 20 includes a low-pressure side controller 201 for receiving external input commands to control the water heater 60 and the compressor. The low-pressure side controller 201 is also used to transmit the external input commands to the high-pressure side controller via a communication circuit and a digital isolation unit 30.

[0055] A digital isolation unit 30 is disposed between the high-voltage side control unit 10 and the low-voltage side control unit 20 to realize isolated communication between the high-voltage side control unit 10 and the low-voltage side control unit 20.

[0056] The high-voltage side control unit 10, the low-voltage side control unit 20, and the digital isolation unit 30 are disposed on the circuit board 40.

[0057] Among them, the air conditioning all-in-one controller can be used to control battery-powered heating in electric vehicles or hybrid vehicles, and can also be used in other fields to control equipment that requires electric heating to obtain heat.

[0058] The high-voltage side controller 101 or the low-voltage side controller 201 can be a processor or microcontroller capable of control and data processing, such as an 8-bit or 32-bit MCU.

[0059] The water heater 60 can be a resistance water heater, such as a PTC resistor or a film resistor, used to achieve temperature rise in spaces such as vehicles.

[0060] External input commands can be generated through the control panel or received wireless signal commands, such as power on / off commands, heating or cooling commands, temperature adjustment commands, or heating / cooling modes.

[0061] The digital isolation unit 30 can be implemented using a digital isolation chip, such as an optocoupler.

[0062] The communication circuit can be a commonly used vehicle communication method, such as CAN communication, LIN communication, or a combination of both.

[0063] The circuit board 40 can be a PCBA board, which can realize the functions of multiple controllers using a single PCBA board. External connections, such as the connection between the high-voltage side control unit and the compressor, can be achieved through high-voltage DC connectors. Signal transmission in the low-voltage side control unit can be achieved using low-voltage signal connectors, thus saving costs associated with connectors, wiring harnesses, housings, filter components, and multiple chips such as the MCU. Additionally, the external physical interface includes a water channel interface for the water heater 60, supplying water to the water heater 60. The high-voltage DC connector port connects to the high-voltage DC wiring harness and the power battery PDU; the low-voltage signal connector port connects to the low-voltage wiring harness and is mainly used to receive / send low-voltage battery power supply signals, air conditioning panel communication signals, fan control signals, water pump control signals, solenoid valve signals, etc.; the water channel interface for the water heater 60 connects to the vehicle's circulating water system. Connections to the three-phase terminals of the air conditioning compressor and the power terminals of the water heater 60 can be made via flexible plug-in, crimping, or screw fastening.

[0064] Among them, the high-voltage side control unit 10 and the low-voltage side control unit 20 realize separate control of high-voltage equipment and low-voltage equipment, and realize bidirectional communication through isolated communication. This can enhance the reliability of the electric vehicle air conditioning thermal management system and reduce the manufacturing and R&D costs of the electric vehicle air conditioning thermal management system.

[0065] As an optional implementation, the high-voltage side control unit 10 further includes an EMC filter circuit 102, which is connected to the power battery to achieve stable power supply from the power battery. The power battery may be a lithium battery pack or other batteries capable of providing power. And / or, the high-voltage side control unit 10 further includes a phase current sampling circuit, which is used to monitor the three-phase current of the compressor;

[0066] And / or, the high-voltage side control unit 10 also includes a bus voltage sampling circuit for detecting the voltage of the power battery;

[0067] And / or, the high-voltage side control unit 10 further includes a bus current sampling circuit, which is used for sampling the input current of the air conditioning all-in-one controller.

[0068] As an optional implementation, the high-pressure side control unit 10 further includes a compressor U, V, W three-phase output module 50, which is used to control the start-up, shutdown and operating power of the compressor.

[0069] As an optional implementation, the high-voltage side control unit 10 further includes a water heater and a water heater power circuit 104 for controlling the start-up, shutdown, and power of the water heater.

[0070] As an optional implementation, the high-voltage side control unit 10 further includes a water heater current sampling module 105 for collecting the operating current of the water heater.

[0071] As an optional implementation, the high-voltage side control unit 10 further includes a shell temperature sampling module 106 for collecting the shell temperature of the water heater and a board temperature sampling module 107 for collecting the temperature of the circuit board 40.

[0072] As an optional implementation, the low-voltage side control unit 20 includes:

[0073] A water temperature sampling module 202 is used to detect the water temperature of the water heater, and the water temperature sampling module is electrically connected to the low-pressure side controller 201;

[0074] As an optional implementation, a low-voltage EMC filter circuit 203 connected to the low-voltage power supply battery that powers the modules included in the low-voltage side control unit 20 is used to stabilize the power supply to the low-voltage side control unit 20.

[0075] As an optional implementation, a solenoid valve control module 204 controls the fan and / or water pump to achieve start / stop or power control of the fan and / or water pump. As an optional implementation, start / stop or power control can be implemented using power switching devices, such as SiC or IGBTs, using either a single transistor or a power module. Figure 3 The diagram shows the main power topology of an all-in-one air conditioner controller. It includes: ① EMC filter circuit, ② compressor three-phase output module (U, V, W), ③ phase current sampling circuit, ④ bus voltage sampling circuit, ⑤ bus current sampling circuit, ⑥ water heater, ⑦ power semiconductor devices driving the water heater, and ⑧ water heater current sampling circuit. G1-G6 are power switching devices controlling the normal operation of the compressor, G7-G8 are power switching devices controlling the heating of the PTC resistor or film resistor, M is the compressor, and R1-R6 are current sampling resistors. The sampled current signal is used for loop control. The power devices are not limited to IGBTs and MOSFETs.

[0076] As another aspect of this disclosure, an air conditioning thermal management control method is provided, employing the air conditioning multi-function controller described in the above embodiments, such as... Figure 4 As shown, it includes the following steps:

[0077] S10. The low-pressure side controller 201 acquires external input commands from the control panel. The external input commands include one or more of the following: power on / off information, temperature setting information, or airflow level.

[0078] S20. The low-voltage side controller 201 transmits the external input command to the high-voltage side controller through the communication circuit and the digital isolation unit 30. The digital isolation unit 30 is located between the high-voltage side control unit 10 and the low-voltage side control unit 20 to realize isolated communication between the high-voltage side control unit 10 and the low-voltage side control unit 20.

[0079] The high-pressure side controller 101 controls the operation of the water heater and compressor to achieve temperature regulation.

[0080] As an optional implementation, the low-pressure side controller 201 is also used to acquire: the water temperature of the water heater;

[0081] And / or, the operating current of the water heater;

[0082] And / or, the temperature of the water heater housing and the temperature of the circuit board 40.

[0083] As one example, such as Figure 5 The diagram illustrates the temperature regulation method used in this embodiment. Passengers input control signals via the air conditioning panel. The low-pressure side MCU receives signal information (including power on / off information, temperature setting information, and airflow information from the vents) through CAN / LIN communication. The low-pressure side MCU then transmits this information to the high-pressure side MCU (Compressor & Heater main control MCU) via CAN / LIN communication. The low-pressure side MCU also controls the operation of actuators such as the fan, water pump, and solenoid valve. The high-pressure side MCU sends PWM waves to control the switching on and off of the EAC / Heater power devices, controlling the operation of the air conditioning compressor / Heater, thereby regulating the cabin temperature and achieving temperature control. The Heater is a PTC-heated water heater.

[0084] As another aspect of this disclosure, an electric vehicle air conditioning system is provided, including the above-described air conditioning all-in-one controller; or, implementing the above-described air conditioning thermal management control method.

[0085] Compared to existing technologies, this disclosure solves the problems caused by the relatively independent nature of the sub-components in electric vehicle air conditioning thermal management systems. The high-pressure side control unit 10 and the low-pressure side control unit 20 are mounted on the same circuit board 40, thus forming a multi-functional controller, which has the following advantages:

[0086] 1) All-in-one controllers can be developed and designed by the same engineering team, with a perfect structural match and a clean appearance;

[0087] 2) The all-in-one controller reduces overall consumables and lowers costs;

[0088] 3) The power density of the all-in-one controller is improved, reducing the system size;

[0089] 4) The all-in-one controller reduces overall weight and increases battery life;

[0090] 5) The all-in-one controller eliminates the need for external wiring harness connections, reducing potential points of failure and enhancing reliability.

[0091] Although embodiments of the present disclosure have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present disclosure, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An all-in-one air conditioner controller, characterized in that, include: The high-voltage side control unit includes a high-voltage side controller for controlling the operation of the water heater and compressor to achieve temperature regulation; the high-voltage side control unit also includes a phase current sampling circuit for monitoring the three-phase current of the compressor; the high-voltage side control unit also includes a bus voltage sampling circuit for detecting the voltage of the power battery; the high-voltage side control unit also includes a bus current sampling circuit for sampling the input current of the air conditioning multi-function controller. The low-pressure side control unit includes a low-pressure side controller for receiving external input commands to control the water heater and the compressor, the low-pressure side controller also being used to transmit the external input commands to the high-pressure side controller via a communication circuit and a digital isolation unit; it also includes a water temperature sampling module for detecting the water temperature of the water heater, the water temperature sampling module being electrically connected to the low-pressure side controller; A digital isolation unit is disposed between the high-voltage side control unit and the low-voltage side control unit to achieve isolated communication between the high-voltage side control unit and the low-voltage side control unit; The circuit board on which the high-voltage side control unit, the low-voltage side control unit, and the digital isolation unit are mounted.

2. The air conditioner all-in-one controller as described in claim 1, characterized in that, The high-voltage side control unit also includes an EMC filter circuit, which is used to connect to the power battery to achieve stable power supply from the power battery.

3. The air conditioner all-in-one controller as described in claim 1, characterized in that, The high-pressure side control unit also includes a compressor U, V, W three-phase output module, which is used to control the start-up, shutdown and operating power of the compressor.

4. The air conditioner all-in-one controller as described in claim 1, characterized in that, The high-voltage side control unit also includes a water heater and a water heater power circuit that controls the start-up, shutdown, and power of the water heater.

5. The air conditioner all-in-one controller as described in claim 4, characterized in that, The high-voltage side control unit also includes a heating resistor current sampling circuit for collecting the operating current of the water heater.

6. The air conditioning all-in-one controller as described in any one of claims 1-2 and 4, characterized in that, The high-voltage side control unit also includes a shell temperature sampling module for collecting the temperature of the water heater shell and a board temperature sampling module for collecting the temperature of the circuit board.

7. The air conditioning all-in-one controller as described in any one of claims 1-2 and 4, characterized in that, The low-voltage side control unit includes: A low-voltage EMC filter circuit connected to the low-voltage power supply battery that powers the modules contained in the low-voltage side control unit is used to stabilize the power supply to the low-voltage side control unit. And / or, a solenoid valve control module for controlling fans and / or water pumps to enable start / stop or power control of fans and / or water pumps.

8. An air conditioning thermal management control method, employing an air conditioning all-in-one controller as described in any one of claims 1-7, characterized in that, Includes the following steps: The low-pressure side controller acquires external input commands from the control panel. The external input commands include one or more of the following: power on / off information, temperature setting information, or airflow level. The low-pressure side controller transmits the external input commands to the high-pressure side controller via a communication circuit and a digital isolation unit. The digital isolation unit is located between the high-pressure side control unit and the low-pressure side control unit to achieve isolated communication between them. The low-pressure side controller is also used to acquire the water temperature of the water heater. The high-pressure side controller controls the operation of the water heater and compressor to achieve temperature regulation.

9. The air conditioning thermal management control method as described in claim 8, characterized in that, The low-pressure side is also used to obtain: the operating current of the water heater; And / or, the temperature of the water heater housing and the temperature of the circuit board.

10. An electric vehicle air conditioning system, characterized in that, Includes the air conditioning all-in-one controller as described in any one of claims 1-7; or implements the air conditioning thermal management control method as described in any one of claims 8-9.

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