A cooling control method, system and storage medium of an electric vehicle controller

Abstract

The application relates to a cooling control method, system and storage medium of an electric vehicle controller, which comprises the following steps: collecting a working state signal and internal temperature information of the controller; performing flow control mode or over-temperature power reduction protection mode according to the collected information; emptying and cleaning a cooling water loop of a controller cooling system; collecting a cooling water inlet temperature and a real-time temperature of the controller, and obtaining corresponding requested cooling flow according to a calibrated cooling water inlet temperature flow MAP table and an internal device temperature-flow MAP table; and determining whether to start AC to actively control the cooling water inlet temperature; the application can adjust the cooling water inlet flow based on real-time information such as vehicle control information, controller water inlet temperature and controller internal power electronic device temperature, so that the controller is effectively cooled and the power consumption of the cooling system is reduced.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle control technology, and more specifically to a cooling control technology for an electric vehicle controller. Background Technology

[0002] With the rapid development of electric vehicles, and the continuous advancement of development needs and technology, integrated all-in-one controllers have emerged. However, integrated controllers generate a large amount of heat, requiring the development of corresponding cooling solutions to ensure the normal functioning and safe operation of the controller and eliminate safety risks; at the same time, it is also necessary to save energy to the greatest extent possible.

[0003] Patent document CN103029566B discloses a cooling control circuit for an electric vehicle motor controller, including: a temperature acquisition circuit, a processor unit, a water pump drive circuit, a fan drive circuit, and a water pump circuit and a fan circuit. The temperature acquisition circuit acquires the temperature signal of the motor controller. The processor unit controls the conduction of the water pump drive circuit or the fan drive circuit according to the temperature signal of the temperature acquisition circuit. By realizing the conduction of the water pump circuit or the fan circuit respectively, the energy loss of the cooling system is reduced. However, it does not acquire information such as the controller cooling water inlet temperature and the temperature of the internal power electronic devices of the controller to control the cooling water flow rate in real time, thereby achieving both effective cooling of the controller and reduction of water pump power consumption, resulting in optimal energy consumption. Summary of the Invention

[0004] The purpose of this invention is to provide a cooling control method, system, and storage medium for an electric vehicle controller. Based on real-time information such as vehicle control information, controller inlet water temperature, and the temperature of internal power electronic devices in the controller, the cooling water flow rate is adjusted to effectively cool the controller while reducing the power consumption of the cooling system.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] In a first aspect, the present invention provides a cooling control method for an electric vehicle controller, comprising the following steps:

[0007] S1. After the vehicle is powered on, data is collected, including the controller's operating status signal and internal temperature information.

[0008] S2. Based on the controller's working status signal and internal temperature information, if the controller is not working, no cooling flow is requested. If the controller is working and the temperature is normal, proceed to the next step. If the controller overheats, enter the over-temperature derating protection mode until the controller temperature is determined to be normal and then proceed to the next step.

[0009] S3. Enter flow control mode, collect cooling water temperature and controller real-time temperature, obtain the corresponding requested cooling flow rate according to the calibrated cooling water temperature-flow rate MAP table and internal device temperature-flow rate MAP table, and control the water pump opening according to the maximum requested cooling flow rate in the two types of MAP tables to adjust the cooling flow rate.

[0010] S4. Real-time monitoring of cooling water inlet temperature and flow rate; determines whether to activate AC to actively control cooling water inlet temperature based on cooling water inlet temperature and flow rate.

[0011] Furthermore, the controller is an integrated controller that integrates OBC, DCAC, and DCDC functions.

[0012] Furthermore, in step S2, if the controller overheats, it enters an over-temperature derating protection mode until the controller temperature is determined to be normal, at which point it proceeds to the next step.

[0013] The over-temperature derating protection mode includes cooling the controller using the maximum cooling flow rate;

[0014] The method for determining whether the controller temperature is normal is as follows:

[0015] If the internal temperature of the controller is still too high after N consecutive samplings, the controller will be shut down and a fault will be reported.

[0016] If the internal temperature of the controller drops to the normal temperature range within less than N sampling periods, counting begins. If the internal temperature of the controller exceeds the normal range, the count is reset to zero. If the counting time exceeds the set value, the controller temperature is considered normal.

[0017] Furthermore, S3 also includes purging and cleaning the controller cooling system circuit before entering the flow control mode. The purging and cleaning method is as follows:

[0018] The cooling system circuit is internally flushed and cleaned by the maximum cooling flow rate for a set time to remove air bubbles present in the cooling system circulation components.

[0019] Furthermore, in S3, the calibration content of the cooling water inlet temperature-flow rate MAP table includes: minimum inlet water temperature and minimum inlet water flow rate, maximum inlet water temperature and maximum inlet water flow rate, flow rate interpolation starting temperature point, and interpolated inlet water flow rate.

[0020] Furthermore, the calibration method for the cooling water inlet temperature-flow rate MAP meter is as follows:

[0021] The minimum coolant temperature is set by taking the larger of the coolant freezing temperature and the minimum temperature of the controller's designed operating scenario.

[0022] The minimum inlet flow rate is set by taking the maximum value among the following three: the flow rate that the water pump can provide at its minimum speed, the critical flow rate that causes the coolant in the pipe to generate bubbles, and the minimum flow rate that the flow sensor can measure.

[0023] The maximum inlet water temperature is set according to the lowest derating point temperature among all power electronic devices in the controller, and the maximum inlet water flow rate is set according to the maximum flow rate that the water pump can provide.

[0024] Simulations or tests are conducted under the set operating conditions with the minimum flow rate. The inlet water temperature corresponding to the starting point of the electronic device in the controller where the slope of the temperature rise curve increases sharply is the earliest to be observed is used as the starting temperature point for flow interpolation.

[0025] Based on the temperature rise curve of the inlet water temperature after the starting temperature point of the flow interpolation, the inlet water flow rate corresponding to the inlet water temperature is linearly interpolated, and the interpolation range is between the minimum inlet water flow rate and the maximum inlet water flow rate.

[0026] Furthermore, in S3, the calibration content of the internal device temperature-flow rate MAP table includes: the minimum temperature point and minimum inlet flow rate of the electronic device, the maximum temperature point and maximum inlet flow rate of the electronic device, the derating temperature point of the electronic device and the corresponding derating temperature point flow rate, and the flow rate interpolation of the starting temperature point of the electronic device.

[0027] Furthermore, in S3, the calibration method for the internal device temperature-flow MAP table is as follows:

[0028] The minimum temperature point of the electronic device is the lowest temperature at which it can operate normally; the maximum temperature point of the electronic device and the maximum water inlet flow rate, the maximum temperature point of the electronic device is the maximum tolerable temperature that will not be damaged by overheating, i.e., the overheating point.

[0029] The derating temperature point of the electronic device is located between the minimum and maximum temperature points of the electronic device. It is the temperature point at which the power device reduces its power to operate when the temperature is too high. Derating is to ensure that the device has a certain power output without overheating and causing damage. The flow rate at the derating temperature point is determined by simulation or experiment. Based on the cooling requirements corresponding to the derating temperature point, the corresponding flow rate at the derating temperature point is set. The purpose of setting this point is to provide a cooling buffer before the electronic device reaches its temperature limit. During this buffer period, the electronic device can be cooled by reducing its output power and requesting a certain cooling flow rate. This achieves the goal of ensuring that the electronic device can continue to operate at a certain power while quickly restoring it to its normal operating temperature range with minimal cooling power consumption.

[0030] Simulations or tests are conducted under set operating conditions using the minimum flow rate. The time it takes for the electronic device temperature to reach the derating temperature point is used as a baseline. The electronic device temperature at the moment when the derating temperature point time is subtracted from the set value is used as the starting temperature point for flow rate interpolation. The purpose of subtracting the set value from the derating temperature point time is to ensure that the influent flow rate can reach the target cooling flow rate required to reach the derating temperature point from the minimum flow rate before flow rate interpolation within the set value time. This ensures that the electronic device is cooled in a timely manner when reaching the derating temperature point while minimizing the power consumption of the water pump. The purpose of reasonably setting the starting temperature point for flow rate interpolation of the electronic device is to always request a minimum cooling water flow rate before the starting temperature point of flow rate interpolation of the electronic device, thereby minimizing the power consumption of the water pump.

[0031] Furthermore, the internal device temperature-flow MAP table includes the LLC primary-side tube temperature-flow MAP table, LLC secondary-side tube temperature-flow MAP table, MOSFET temperature-flow MAP table, transformer temperature-flow MAP table, low-voltage aluminum substrate temperature-flow MAP table, AC aluminum substrate temperature-flow MAP table, high-voltage aluminum substrate temperature-flow MAP table, and PFC tube temperature-flow MAP table.

[0032] Furthermore, in step S4, the determination of whether to activate AC to actively control the cooling water inlet temperature is based on the cooling water inlet temperature and the inlet water flow rate. The determination method is as follows:

[0033] When the cooling water inlet temperature is greater than the set temperature and the inlet water flow rate is greater than the set flow rate, request to start the AC. When the cooling water inlet temperature is actively cooled down to below the set temperature by the AC, request to shut down the AC.

[0034] Secondly, the present invention also provides a system for executing the cooling control method of the electric vehicle controller described above, comprising a data acquisition unit, a judgment unit, a control unit, and an execution unit;

[0035] The acquisition unit is used to acquire the controller's operating status signals, internal temperature information, inlet water temperature, and inlet water flow rate;

[0036] The judgment unit determines whether the controller and inlet water temperature are over-temperature based on the information collected by the acquisition unit;

[0037] The control unit is used to generate corresponding control commands based on the judgment result of the judgment unit, the internal temperature information of the controller, the inlet water temperature, the inlet water flow rate, the cooling inlet water temperature-flow rate MAP table, and the internal device temperature-flow rate MAP table.

[0038] The execution unit is used to execute the opening degree of the water pump and the opening and closing of AC according to the control command, thereby adjusting the inlet water flow rate and inlet water temperature.

[0039] Thirdly, the present invention also provides a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of the cooling control method for the electric vehicle controller described above.

[0040] The beneficial effects of this invention are:

[0041] 1. This invention acquires information such as the controller's cooling water inlet temperature and the temperature of the internal power electronic components in real time, and controls the cooling water flow rate in real time according to the calibrated cooling water temperature-flow rate MAP table and the internal component temperature-flow rate MAP table, thereby achieving both effective cooling of the controller and reduction of water pump power consumption, resulting in optimal energy consumption.

[0042] 2. This invention addresses the issue of overheating of individual control modules within an integrated controller by utilizing flow calibration data of the overall cooling water temperature and the temperatures of individual internal components, and selecting the maximum cooling flow rate as the requested cooling flow rate.

[0043] 3. This invention removes air bubbles present in the cooling system circulation components during each initial run of the cooling system, thus preventing system malfunctions and a decrease in cooling performance. Attached Figure Description

[0044] Figure 1 This is a flowchart illustrating the cooling control method;

[0045] Figure 2 This is a system block diagram of the cooling control system;

[0046] Figure 3 This is a schematic diagram of the cooling system circulation.

[0047] Technical features and markings in the diagram:

[0048] 1. Integrated controller; 2. Heat exchanger; 3. Water pump; 4. Water temperature sensor; 5. AC;

[0049] 10. Acquisition unit; 20. Judgment unit; 30. Control unit; 40. Execution unit. Detailed Implementation

[0050] The embodiments of the present invention will be described below with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be understood that the preferred embodiments are only for illustrating the present invention and not for limiting the scope of protection of the present invention.

[0051] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. The illustrations only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0052] This embodiment proposes a cooling control method for an electric vehicle controller, such as... Figure 1 As shown, it includes the following steps:

[0053] S1. After the vehicle is powered on, data is collected, including the controller's operating status signal and internal temperature information.

[0054] S2. Based on the controller's working status signal and internal temperature information, if the controller is not working, no cooling flow is requested. If the controller is working and the temperature is normal, proceed to the next step. If the controller overheats, enter the over-temperature derating protection mode until the controller temperature is determined to be normal and then proceed to the next step.

[0055] S3. Enter flow control mode, collect cooling water temperature and controller real-time temperature, obtain the corresponding requested cooling flow rate according to the calibrated cooling water temperature-flow rate MAP table and internal device temperature-flow rate MAP table, and control the opening of water pump 3 according to the maximum requested cooling flow rate in the two types of MAP tables to adjust the cooling flow rate.

[0056] S4. Monitor the cooling water inlet temperature and flow rate in real time, and determine whether to activate AC5 to actively control the cooling water inlet temperature based on the cooling water inlet temperature and flow rate.

[0057] The controller is an integrated controller 1, which integrates OBC, DCAC5 and DCDC functions.

[0058] In this embodiment, in step S2, if the controller overheats, it enters the over-temperature derating protection mode until the controller temperature is determined to be normal, and then proceeds to the next step.

[0059] The over-temperature derating protection mode includes cooling the controller using the maximum cooling flow rate;

[0060] The method for determining whether the controller temperature is normal is as follows:

[0061] If the internal temperature of the controller is still too high after N consecutive samplings, the controller will be shut down and a fault will be reported.

[0062] If the internal temperature of the controller drops to the normal temperature range within less than N sampling periods, counting begins. If the internal temperature of the controller exceeds the normal range, the count is reset to zero. If the counting time exceeds the set value, the controller temperature is considered normal.

[0063] In this embodiment, step S3 further includes purging and cleaning the controller cooling system circuit before entering the flow control mode. The purging and cleaning method is as follows:

[0064] The cooling system circuit is internally flushed and cleaned by maximizing the cooling flow rate for a set period of time to remove air bubbles present in the cooling system circulation components. The purpose of this logic is to remove air bubbles from the cooling system circulation components during each initial power-on run, preventing system malfunctions and degradation of cooling performance.

[0065] In this embodiment, step S3, as shown in Table 1, includes the calibration content and method of the cooling water inlet temperature-flow rate MAP table:

[0066] The minimum inlet water temperature and minimum inlet water flow rate are determined by taking the larger value of the coolant freezing temperature and the minimum temperature of the controller's design application scenario. The minimum coolant temperature of this MAP is determined by taking the larger value of the flow rate that the water pump 3 can provide at its minimum speed, the critical flow rate that causes the coolant to generate bubbles in the pipe, and the minimum flow rate that the flow sensor can measure.

[0067] The maximum inlet water temperature and the maximum inlet water flow rate are set according to the lowest derating point temperature among all power electronic devices in the controller. The maximum inlet water temperature is set according to the maximum flow rate that water pump 3 can provide.

[0068] The flow interpolation starting temperature point is determined by conducting simulations or experiments under the set operating conditions at the minimum flow rate. The inlet water temperature corresponding to the starting point of the electronic component in the controller where the slope of the temperature rise curve first increases sharply is taken as the flow interpolation starting temperature point for this MAP. An example of determining this flow interpolation starting temperature point is as follows: Under the set operating conditions, an experiment is conducted at the minimum flow rate of 2 L / Min. The temperature curves of all temperature detection points in the controller are measured over time. Simultaneously, the cooling water inlet temperature rises continuously with circulation. Assuming that the experimental data shows that the slope of the PFC tube temperature curve increases sharply at 50s, and the cooling water inlet temperature rises to 30℃ at this time, then the water temperature of 30℃ corresponding to the PFC tube temperature curve at 60s is taken as the flow interpolation starting temperature point. The purpose of setting this point is to always request a minimum cooling water flow rate when the cooling water temperature is lower than the flow interpolation starting temperature point, thereby minimizing the power consumption of pump 3.

[0069] The inlet flow rate is interpolated by linearly interpolating the inlet flow rate corresponding to the inlet temperature based on the temperature rise curve of the inlet temperature after the inlet temperature starting point of the flow rate interpolation. The interpolation range is between the minimum inlet flow rate and the maximum inlet flow rate.

[0070]

[0071] Table 1

[0072] In this embodiment, step S3, as shown in Table 2, includes the calibration content and method of the internal device temperature-flow rate MAP table:

[0073] The minimum temperature point and minimum inlet water flow rate of the electronic device, wherein the minimum temperature point of the electronic device is the lowest temperature at which it is allowed to operate normally; the maximum temperature point and maximum inlet water flow rate of the electronic device, wherein the maximum temperature point of the electronic device is the maximum tolerable temperature that will not be damaged by overheating, i.e., the over-temperature point; the minimum inlet water flow rate and the maximum inlet water flow rate are consistent with the calibration method of the cooling water temperature-flow rate MAP table.

[0074] The derating temperature point and corresponding derating temperature point flow rate of electronic devices are defined. The derating temperature point is located between the minimum and maximum temperature points of the electronic device. It is the temperature point at which the power device reduces its power to operate when the temperature is too high. Derating is intended to ensure that the device has a certain power output without overheating and causing damage. The derating temperature point flow rate is determined through simulation or experimentation. Based on the cooling requirements corresponding to the derating temperature point, the corresponding derating temperature point flow rate is set. The purpose of setting this point is to provide a cooling buffer before the electronic device reaches its temperature limit. During this buffer period, the electronic device can be cooled by reducing its output power and requesting a certain cooling flow rate. This achieves the goal of ensuring that the electronic device can continue to operate at a certain power while quickly restoring it to its normal operating temperature range with minimal cooling power consumption.

[0075] The flow interpolation starts at the electronic device's initial temperature point. Simulations or tests are conducted under set operating conditions using the minimum flow rate, and the time it takes for the electronic device's temperature to reach the derating temperature point is used as a benchmark. The electronic device's temperature at the moment when the derating temperature point time is subtracted from the set value is taken as the flow interpolation starting temperature point. The purpose of subtracting the set value from the derating temperature point time is to ensure that the influent flow rate can reach the target cooling flow rate required for the derating temperature point from the minimum flow rate before flow interpolation within the set value time. This ensures that the electronic device is cooled promptly when it reaches the derating temperature point while minimizing the power consumption of water pump 3. The purpose of reasonably setting the flow interpolation starting temperature point for the electronic device is to always request a minimum cooling water flow rate before the flow interpolation starting temperature point, thereby minimizing the power consumption of water pump 3.

[0076]

[0077] Table 2

[0078] In this embodiment, the internal device temperature-flow MAP table includes the LLC primary-side tube temperature-flow MAP table, the LLC secondary-side tube temperature-flow MAP table, the MOS tube temperature-flow MAP table, the transformer temperature-flow MAP table, the low-voltage aluminum substrate temperature-flow MAP table, the AC5 aluminum substrate temperature-flow MAP table, the high-voltage aluminum substrate temperature-flow MAP table, and the PFC tube temperature-flow MAP table.

[0079] In this embodiment, in step S4, the determination of whether to activate AC5 to actively control the cooling water inlet temperature is based on the cooling water inlet temperature and the inlet water flow rate. The determination method is as follows:

[0080] When the cooling water inlet temperature is higher than the set temperature T1℃ and the inlet water flow rate is higher than the set flow rate Q1L / Min, AC5 is activated. When the cooling water inlet temperature is actively cooled by AC5 to below the set temperature T2℃, AC5 is deactivated. AC5 refers to the air conditioner. Activating or deactivating AC5 indicates whether the compressor in the vehicle cooling system participates in cooling the cooling water. In this embodiment, the set temperature T1℃ is set at the coolant temperature at which the temperature of the electronic components in the controller just rises to the derating operating temperature point when the controller operates at maximum power and the cooling cycle operates at maximum flow rate. The temperature of the electronic components that rise to the derating temperature point fastest is used as the reference setting. The set flow rate Q1L / Min is set as the maximum flow rate that the water pump can provide. When the cooling water inlet temperature is higher than the set temperature T1℃ and the inlet water flow rate is higher than the set flow rate Q1L / Min, it indicates that flow control alone cannot meet the cooling requirements of the controller, and active control of the inlet water temperature is required.

[0081] This embodiment also proposes a system for implementing the cooling control method of the electric vehicle controller described above, such as... Figure 2 As shown, it includes a data acquisition unit 10, a judgment unit 20, a control unit 30, and an execution unit 40;

[0082] The acquisition unit 10 is used to acquire the controller's working status signal and internal temperature information, inlet water temperature and inlet water flow. In this embodiment, the acquisition unit 10 for acquiring the inlet water temperature is a water temperature sensor 4 installed on the outlet of the water pump 3.

[0083] The judgment unit 20 determines whether the controller and the inlet water temperature are over-temperature based on the information collected by the acquisition unit 10.

[0084] The control unit is used to generate corresponding control commands based on the judgment result of the judgment unit 20, the controller's internal temperature information, inlet water temperature, inlet water flow rate, temperature-flow rate MAP table, and internal device temperature-flow rate MAP table, etc.

[0085] The execution unit 40 is used to execute the opening degree of water pump 3 and the opening and closing of AC5 according to control commands, thereby adjusting the inlet water flow rate and inlet water temperature. The cooling water temperature is dissipated through heat exchanger 2 and then enters the inlet of water pump 3 to start circulation. AC5 is installed on heat exchanger 2 to participate in cooling the cooling water.

[0086] This embodiment also proposes a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements the steps of the cooling control method for the electric vehicle controller described above.

[0087] As can be seen from the detailed description of the above embodiments, the present invention obtains information such as the controller cooling water inlet temperature and the temperature of the internal power electronic devices of the controller in real time, and controls the cooling water flow rate in real time according to the calibrated cooling water temperature-flow rate MAP table and the internal device temperature-flow rate MAP table, thereby achieving both effective cooling of the controller and reduction of water pump 3 power consumption, resulting in optimal energy consumption.

[0088] In addition, this invention, for integrated controllers, utilizes flow calibration data of the overall cooling inlet water temperature and the individual internal component temperatures, and selects the largest cooling flow rate as the requested cooling flow rate, which can prevent individual control modules in the integrated controller from overheating.

[0089] Secondly, by expelling air bubbles present in the cooling system circulation components during each initial run of the cooling system, the present invention can prevent system malfunctions and a decline in cooling performance.

[0090] The above embodiments are merely preferred embodiments provided to fully illustrate the present invention, and the scope of protection of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the art based on the present invention are all within the scope of protection of the present invention.

Claims

1. A cooling control method for an electric vehicle controller, characterized in that, Includes the following steps: S1. After the vehicle is powered on, data is collected, including the controller's operating status signal and internal temperature information. S2. Based on the controller's working status signal and internal temperature information, if the controller is not working, no cooling flow is requested. If the controller is working and the temperature is normal, proceed to the next step. If the controller overheats, enter the over-temperature derating protection mode until the controller temperature is determined to be normal and then proceed to the next step. S3. Enter flow control mode, collect cooling water temperature and controller real-time temperature, obtain the corresponding requested cooling flow rate according to the calibrated cooling water temperature-flow rate MAP table and internal device temperature-flow rate MAP table, and control the water pump opening according to the maximum requested cooling flow rate in the two types of MAP tables to adjust the cooling flow rate. S4. Real-time monitoring of cooling water inlet temperature and flow rate, and determination of whether to turn on AC to actively control cooling water inlet temperature based on cooling water inlet temperature and flow rate. The calibration method for the cooling water inlet temperature-flow rate MAP table is as follows: The minimum coolant temperature is set by taking the larger of the coolant freezing temperature and the minimum temperature of the controller's designed operating scenario. The minimum inlet flow rate is set by taking the maximum value among the following three: the flow rate that the water pump can provide at its minimum speed, the critical flow rate that causes the coolant in the pipe to generate bubbles, and the minimum flow rate that the flow sensor can measure. The maximum inlet water temperature is set according to the lowest derating point temperature among all power electronic devices in the controller, and the maximum inlet water flow rate is set according to the maximum flow rate that the water pump can provide. Simulation or experimental testing under the set operating conditions with minimum flow rate is performed, and the inlet water temperature corresponding to the starting point of the electronic device in the controller where the slope of the temperature rise curve increases sharply is the first to appear is taken as the starting temperature point for flow interpolation. Based on the temperature rise curve of the inlet water temperature after the starting temperature point of the flow interpolation, the inlet water flow rate corresponding to the inlet water temperature is linearly interpolated, and the interpolation range is between the minimum inlet water flow rate and the maximum inlet water flow rate.

2. The cooling control method for an electric vehicle controller according to claim 1, characterized in that, The controller is an integrated controller that integrates OBC, DCAC, and DCDC functions.

3. The cooling control method for an electric vehicle controller according to claim 1, characterized in that, In step S2, if the controller overheats, it enters the over-temperature derating protection mode until the controller temperature is determined to be normal, then proceeds to the next step. The over-temperature derating protection mode includes cooling the controller using the maximum cooling flow rate; The method for determining whether the controller temperature is normal is as follows: If the internal temperature of the controller is still too high after N consecutive samplings, the controller will be shut down and a fault will be reported. If the internal temperature of the controller drops to the normal temperature range within less than N sampling periods, counting begins. If the internal temperature of the controller exceeds the normal range, the count is reset to zero. If the counting time exceeds the set value, the controller temperature is considered normal.

4. The cooling control method for an electric vehicle controller according to claim 1, characterized in that, S3 further includes purging and cleaning the controller cooling system circuit before entering the flow control mode. The purging and cleaning method is as follows: The cooling system circuit is internally flushed and cleaned by the maximum cooling flow rate for a set time to remove air bubbles present in the cooling system circulation components.

5. The cooling control method for an electric vehicle controller according to claim 2, characterized in that, In S3, the calibration content of the internal device temperature-flow rate MAP table includes: minimum temperature point and minimum inlet flow rate of electronic device, maximum temperature point and maximum inlet flow rate of electronic device, derating temperature point of electronic device and corresponding derating temperature point flow rate, and flow rate interpolation of the starting temperature point of electronic device.

6. The cooling control method for an electric vehicle controller according to claim 5, characterized in that, In S3, the calibration method for the internal device temperature-flow MAP table is as follows: The minimum temperature point of an electronic device is the lowest temperature at which it is allowed to operate normally. The maximum temperature point of the electronic device is the maximum temperature it can withstand without being damaged by overheating, i.e., the overheating point. The derating temperature point of the electronic device is located between the minimum and maximum temperature points of the electronic device, and is the temperature point at which the power device dries out due to excessively high temperature. The temperature point at which low power is used for derating is to ensure that the device has a certain power output without overheating and causing damage. The flow rate at the derating temperature point is determined by simulation or experiment. The flow rate at the derating temperature point is set based on the cooling requirements corresponding to the derating temperature point. Simulations or tests are performed under set operating conditions using the minimum flow rate, and the time it takes for the electronic device temperature to reach the derating temperature point is used as the reference. The electronic device temperature at the moment when the derating temperature point time is minus the set value is used as the starting temperature point for flow rate interpolation.

7. The cooling control method for an electric vehicle controller according to claim 5, characterized in that, The internal device temperature-flow MAP tables include those for LLC primary-side transistors, LLC secondary-side transistors, MOSFETs, transformers, low-voltage aluminum substrates, AC aluminum substrates, high-voltage aluminum substrates, and PFC transistors.

8. The cooling control method for an electric vehicle controller according to claim 1, characterized in that, In step S4, the determination of whether to activate AC to actively control the cooling water inlet temperature is based on the cooling water inlet temperature and the inlet water flow rate. The determination method is as follows: When the cooling water inlet temperature is greater than the set temperature and the inlet water flow rate is greater than the set flow rate, request to start the AC. When the cooling water inlet temperature is actively cooled down to below the set temperature by the AC, request to shut down the AC.

9. A system for performing a cooling control method for an electric vehicle controller according to any one of claims 1-8, characterized in that, It includes a data acquisition unit, a judgment unit, a control unit, and an execution unit; The acquisition unit is used to acquire the controller's operating status signals, internal temperature information, inlet water temperature, and inlet water flow rate; The judgment unit determines whether the controller and inlet water temperature are over-temperature based on the information collected by the acquisition unit; The control unit is used to generate corresponding control commands based on the judgment result of the judgment unit, the internal temperature information of the controller, the inlet water temperature, the inlet water flow rate, the cooling inlet water temperature-flow rate MAP table, and the internal device temperature-flow rate MAP table information. The execution unit is used to execute the opening degree of the water pump and the opening and closing of AC according to the control command, thereby adjusting the inlet water flow rate and inlet water temperature.

10. A computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of the cooling control method of the electric vehicle controller according to any one of claims 1 to 8.

Images