Commercial vehicle thermal management detection system and detection method

Abstract

The application discloses a commercial vehicle thermal management detection system and a detection method, which are used for realizing detection of a target loop in a commercial vehicle thermal management system. An instrument controller is used for responding to a detection instruction and sending the detection instruction to a thermal management controller. The thermal management controller is used for controlling running states of the actuator and / or the sensor according to the received detection instruction, detecting whether feedback signals in the actuator and / or the sensor meet preset test requirements, and feeding back the feedback signals of the actuator and / or the sensor to the instrument controller, so as to visually display the running states of the actuator and / or the sensor. The application can intuitively display running states of various components in the thermal management system, quickly find faults, and improve intelligent detection efficiency on the basis of realizing automatic test of the whole vehicle thermal management system.

Description

Technical Field

[0001] This application relates to the field of automotive thermal management testing technology, specifically to a thermal management testing system and method for commercial vehicles. Background Technology

[0002] The main purpose of new energy vehicle thermal management system technology is to achieve internal matching of heat and cooling demands in each circuit, reduce overall vehicle energy consumption, and integrate the vehicle's cooling and heating functions. Testing the vehicle's thermal management system helps ensure the heat transfer process and guarantees the safe and efficient operation of key components and systems.

[0003] In related technologies, vehicle thermal management testing is usually conducted after the vehicle rolls off the production line, using diagnostic tools to test the working status and operation of each component individually. Existing thermal management system testing solutions mostly rely on real vehicle operating conditions or environmental chamber testing.

[0004] However, the functional testing of the thermal management system in off-line vehicles is highly dependent on actual vehicle operating conditions, resulting in high testing costs and the inability to promptly detect system malfunctions, thus severely impacting vehicle production efficiency. Furthermore, when thermal management system failures occur in after-sales vehicles, specialized engineers must bring testing equipment to troubleshoot, which cannot quickly pinpoint the cause of the problem. The lack of intelligent testing methods also prevents a clear visual display of the operational status of various vehicle components. Summary of the Invention

[0005] In view of the above problems, this application is made to provide a commercial vehicle thermal management testing system and testing method, so as to achieve the technical effect of intuitively displaying the operating status of each component in the system, quickly discovering the faults of the vehicle thermal management system, improving intelligent testing efficiency and production efficiency, and thus reducing testing and maintenance costs, based on realizing automatic testing of the whole vehicle thermal management system.

[0006] According to the first aspect of this application, a commercial vehicle thermal management detection system is provided for detecting a target loop in the commercial vehicle thermal management system.

[0007] The detection system includes: a thermal management controller, an instrument controller, actuators in the commercial vehicle thermal management system, and sensors in the commercial vehicle thermal management system. The instrument controller, the actuators, and the sensors are all communicatively connected to the thermal management controller.

[0008] The instrument controller responds to a detection command and sends the detection command to the thermal management controller;

[0009] The thermal management controller controls the operating state of the actuator and / or the sensor according to the received detection command, and detects whether the feedback signals in the actuator and / or the sensor meet the preset test requirements.

[0010] The thermal management controller is also used to feed back the feedback signals of the actuator and / or the sensor to the instrument controller, so as to visualize the detection results of the operating status of the actuator and / or the sensor.

[0011] Optionally, it also includes: a display screen for displaying an instrument engineering interface, the display screen being connected to the instrument controller.

[0012] Optionally, the actuators are connected to the thermal management controller via a Lin / CAN bus, and the thermal management controller and the instrument controller are connected via a CAN bus.

[0013] Optionally, the actuator includes one or more of the following: a control valve, a fan, a water pump, a compressor, a PTC heater, and a blower.

[0014] The control valve is used to control the flow rate or direction of coolant or refrigerant in the thermal management system. The control valve is controlled by the valve target opening signal or loop connection position signal of the thermal management controller, and can feed back the actual opening or loop connection position through the Lin / CAN bus.

[0015] The fan and the water pump are controlled by the PWM duty cycle signal of the thermal management controller and can provide feedback on their actual operating status through the Lin / CAN bus.

[0016] The compressor is controlled by the target speed signal of the thermal management controller and can provide feedback on its actual operating status through the Lin / CAN bus;

[0017] The PTC heater is controlled by the target temperature signal of the thermal management controller and can provide feedback on its actual operating status through the Lin / CAN bus;

[0018] The blower is controlled by the air volume level signal of the thermal management controller and can provide feedback on its actual operating status through the Lin / CAN bus;

[0019] The sensor is used to detect the temperature and / or pressure of the coolant or refrigerant at the target location and feed it back to the thermal management controller.

[0020] Optionally, the target loops of the thermal management system include: a cabin heating loop, a cabin cooling loop, a battery cooling loop, a battery heating loop, and an electric drive cooling loop;

[0021] The control valves include: a BEXV ball valve, a TXV thermostatic expansion valve, a first solenoid three-way valve, a second solenoid three-way valve, a third solenoid three-way valve, and a four-way valve.

[0022] The fan includes: a front-end electronic fan and a battery-powered electronic fan.

[0023] The water pumps include: heating pumps, battery pumps, and electric pumps.

[0024] The compressor includes: a cabin compressor and a battery compressor.

[0025] The PTC heater includes: a main WPTC heater and an auxiliary WPTC heater.

[0026] The sensors include: a first water temperature sensor, a second water temperature sensor, a third water temperature sensor, a fourth water temperature sensor, a fifth water temperature sensor, a sixth water temperature sensor, a first pressure sensor, a second pressure sensor, a third pressure sensor, a PT pressure-temperature sensor, and an ambient temperature sensor;

[0027] In the cabin heating circuit, the output of the main WPTC heater sequentially passes through the first position of the first electromagnetic three-way valve, the auxiliary WPTC heater, the plate heat exchanger, the second position of the four-way valve, the first liquid storage tank, and the heating pump before connecting to the input of the main WPTC heater; the second position of the first electromagnetic three-way valve is connected to the input of the heater core, and the output of the heater core is connected to the second position of the four-way valve; wherein the sixth water temperature sensor is located at the outlet of the main WPTC heater, and the fourth water temperature sensor is located at the outlet of the auxiliary WPTC heater.

[0028] In the cabin cooling circuit, the output end of the cabin compressor passes through the cabin condenser, TXV thermal expansion valve, and evaporator in sequence, and is then connected to the input end of the cabin compressor. The front-end electric fan is located near the cabin condenser, the blower is located near the evaporator, the first pressure sensor is located at the outlet of the cabin condenser, and the second pressure sensor is located at the outlet of the evaporator.

[0029] The battery cooling circuit includes a first battery cooling circuit and a second battery cooling circuit.

[0030] In the first battery cooling circuit, the output end of the power battery passes through the second liquid storage tank, the battery pump, the first position of the second electromagnetic three-way valve, and the battery Chiller integrated cooling and heating machine in sequence, and is then connected to the input end of the power battery; the second position of the second electromagnetic three-way valve passes through the plate heat exchanger and is then connected to the input end of the power battery, wherein the first water temperature sensor is set at the inlet of the power battery.

[0031] In the second battery cooling circuit, the output end of the battery compressor passes through the battery condenser, BEXV ball valve, and battery Chiller integrated cooling and heating unit in sequence, and is then connected to the input end of the battery compressor. The third pressure sensor is located at the outlet of the battery condenser, the PT pressure and temperature sensor is located at the inlet of the battery compressor, and the battery electronic fan is located near the battery condenser.

[0032] In the electric drive cooling circuit, the output end of the motor radiator sequentially passes through the first position of the four-way valve, the third liquid storage tank, the electric drive pump, the high-voltage accessory, the MCU controller, the TM gearbox, and the first position of the third electromagnetic three-way valve before connecting to the input end of the motor radiator; the second position of the third electromagnetic three-way valve is connected to the output end of the motor radiator, wherein the third water temperature sensor is located at the inlet of the four-way valve, the fifth water temperature sensor is located at the inlet of the high-voltage accessory, and the second water temperature sensor is located at the outlet of the TM gearbox.

[0033] Optionally, in the battery heating circuit, the first position of the first electromagnetic three-way valve and the second position of the second electromagnetic three-way valve are turned on, so that the coolant in the cabin heating circuit and the coolant in the first battery cooling circuit exchange heat in the plate heat exchanger to achieve heating of the power battery.

[0034] Optionally, it includes: an instrument button for receiving a detection command triggered by a testing personnel, the instrument button being connected to the instrument controller, wherein,

[0035] The instrument panel buttons include at least one or more of the following: cabin heating button, cabin cooling button, battery cooling button, battery heating button, and electric drive cooling button.

[0036] According to a second aspect of this application, a testing method for a commercial vehicle thermal management testing system is provided, applied to a commercial vehicle thermal management testing system as described in any of the first aspects above, the testing method comprising:

[0037] Step S1: Turn off the cabin heating and cabin cooling functions; control the actuators in the commercial vehicle thermal management system to either turn off or maintain their initial on position;

[0038] Step S2: The instrument controller in the commercial vehicle thermal management detection system responds to the detection command input by the instrument key and sends the detection command to the thermal management controller.

[0039] Step S3: The thermal management controller controls the operating state of the actuator and / or the sensor according to the received detection command, and detects whether the feedback signal in the actuator and / or the sensor meets the preset test requirements.

[0040] Step S4: The thermal management controller feeds back the feedback signals from the actuator and / or the sensor to the instrument controller to visualize the detection results of the operating status of the actuator and / or the sensor.

[0041] Step S5: When the detection command is switched, control the actuator in the commercial vehicle thermal management system to close or maintain the initial on position, and repeat steps S2 to S4 according to another detection command;

[0042] Alternatively, upon completion of the detection, the actuators in the commercial vehicle thermal management system may be shut down or kept in their initial on position.

[0043] Optionally, step S1 includes:

[0044] The actuator controls the BEXV ball valve and TXV thermal expansion valve to close, and controls the first solenoid three-way valve, the second battery solenoid three-way valve, the third solenoid three-way valve, and the four-way valve in the actuator to remain in their initial closed positions. At the same time, the actuator controls the fan, water pump, compressor, PTC heater, and blower to stop operating.

[0045] Optionally, in step S2 or step S5,

[0046] The detection commands include: cabin heating circuit detection, cabin cooling circuit detection, battery cooling circuit detection, battery heating circuit detection, and electric drive cooling circuit detection;

[0047] Step S3 also includes:

[0048] During cabin heating circuit testing, the feedback signals of the heating pump, main WPTC heater, blower, second position of the first electromagnetic three-way valve, first position of the four-way valve, and sixth water temperature sensor in the cabin heating circuit are tested to see if they meet the preset test requirements.

[0049] During cabin cooling circuit testing, the feedback signals of the cabin compressor, front-end electric fan, blower, TXV thermal expansion valve, first pressure sensor, and second pressure sensor in the cabin cooling circuit are tested to see if they meet the preset test requirements.

[0050] When testing the battery cooling circuit, the feedback signals of the battery compressor, battery electric fan, battery pump, BEXV ball valve, first position of the second battery three-way valve, PT pressure and temperature sensor, first water temperature sensor, and third pressure sensor in the battery cooling circuit are tested to see if they meet the preset test requirements.

[0051] When testing the battery heating circuit, the feedback signals of the heating pump, auxiliary WPTC heater, battery pump, first position of the first electromagnetic three-way valve, second position of the second battery three-way valve, first position of the four-way valve, fourth water temperature sensor, and first water temperature sensor in the battery heating circuit are tested to see if they meet the preset test requirements.

[0052] During the testing of the electric drive cooling circuit, the feedback signals of the electric drive pump, the front-end electric fan, the first position of the third electromagnetic three-way valve, the first position of the four-way valve, the third water temperature sensor, the ambient temperature sensor, the second water temperature sensor, and the fifth water temperature sensor in the electric drive cooling circuit are tested to see if they meet the preset test requirements.

[0053] As can be seen from the above, at least one technical solution adopted in the embodiments of this application can achieve the following beneficial effects:

[0054] A testing system and method for thermal management systems in commercial vehicles are proposed. This system detects target loops within the thermal management system of commercial vehicles. An instrument cluster controller responds to testing commands and sends these commands to the thermal management controller. The thermal management controller, based on the received testing commands, controls the operating status of actuators and / or sensors, and detects whether the feedback signals from the actuators and / or sensors meet preset test requirements. The thermal management controller then feeds back the feedback signals from the actuators and / or sensors to the instrument cluster controller, providing a visual display of the detection results regarding the operating status of the actuators and / or sensors. This application enables automated testing of the entire vehicle's thermal management system, providing a clear view of the operating status of each component. During vehicle off-line testing or fault repair, it allows for rapid detection of faults in the thermal management system. Furthermore, the instrument cluster interface is simpler to use, improving intelligent testing efficiency and production efficiency, thereby reducing testing and repair costs.

[0055] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0056] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0057] Figure 1 This is a schematic diagram of the structure of a commercial vehicle thermal management detection system according to one embodiment of this application;

[0058] Figure 2 This is a schematic diagram of the structure of a commercial vehicle thermal management system in one embodiment of this application;

[0059] Figure 3 This is a flowchart illustrating the detection method of a commercial vehicle thermal management detection system according to one embodiment of this application;

[0060] Figure 4 This is one of the schematic diagrams of an instrumentation engineering interface (cabin heating) in one embodiment of this application;

[0061] Figure 5 This is a second schematic diagram of the instrumentation engineering interface (cabin cooling) in one embodiment of this application;

[0062] Figure 6 This is a third schematic diagram of an instrumentation engineering interface (battery cooling) in one embodiment of this application;

[0063] Figure 7 This is a fourth schematic diagram of an instrumentation engineering interface (battery heating) in one embodiment of this application;

[0064] Figure 8 This is the fifth schematic diagram of an instrumentation engineering interface (electrically driven cooling) in one embodiment of this application;

[0065] In the diagram: 101, Thermal Management Controller; 102, Instrument Controller; 103, Actuator; 104, Sensor; 105, Display Screen; 106, Instrument Buttons;

[0066] 201. BEXV ball valve; 202. TXV thermal expansion valve; 203. First solenoid three-way valve (heating solenoid three-way valve); 204. Second solenoid three-way valve (battery solenoid three-way valve); 205. Third solenoid three-way valve (radiator front solenoid three-way valve); 206. Four-way valve; 207. Front-end electric fan; 208. Battery electric fan; 209. Heating pump; 210. Battery pump; 211. Electric drive pump; 212. Cabin compressor; 213. Battery compressor; 214. Main WPTC heater; 215. Auxiliary WPTC heater; 216. First water temperature sensor (battery inlet water temperature); 217. Second water temperature sensor (electric drive outlet water temperature); 218. Third water temperature sensor (electric drive circuit four-way valve inlet water temperature); 219. Fourth water temperature sensor (auxiliary WPTC heater outlet water temperature); 220. Fifth water temperature sensor 221. High-pressure accessory inlet water temperature; 222. Sixth water temperature sensor (main WPTC heater outlet water temperature); 223. First pressure sensor (cabin condenser outlet pressure); 224. Second pressure sensor (evaporator outlet pressure); 225. Third pressure sensor (battery condenser outlet pressure); 226. PT pressure and temperature sensor (compressor inlet temperature and pressure); 227. Ambient temperature sensor; 228. Blower; 229. Heater core; 230. Plate heat exchanger; 231. Cabin condenser; 232. Motor radiator; 233. Evaporator; 234. Power battery; 235. Battery Chiller integrated cooling and heating cycle unit; 236. Battery condenser; 237. First liquid storage tank (heating liquid storage tank); 238. Second liquid storage tank (battery liquid storage tank); 239. Third liquid storage tank (electric drive liquid storage tank);

[0067] HVAS stands for High Voltage Accessory; FTM stands for Front Gearbox; RTM stands for Rear Gearbox; FMCU stands for Front Motor Controller; RMCU stands for Rear Motor Controller. Detailed Implementation

[0068] Exemplary embodiments of the present application will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present application are shown in the drawings, it should be understood that the present application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this application will be thorough and complete, and will fully convey the scope of the present application to those skilled in the art.

[0069] The technical concept of this application is to make full use of the communication functions between the instrument controller, the thermal management controller, and the actuators and sensors related to vehicle thermal management in the commercial vehicle thermal management testing system, so as to realize the detection of the operating status of the target loop of the whole vehicle thermal management system, and then feed back the operating status information of each component to the instrument controller and achieve the purpose of visualization processing through the instrument engineering test interface.

[0070] In one embodiment of this application, such as Figure 1 As shown, a commercial vehicle thermal management detection system is proposed for detecting target loops in the commercial vehicle thermal management system. The detection system includes: a thermal management controller 101, an instrument controller 102, an actuator 103 in the commercial vehicle thermal management system, and a sensor 104 in the commercial vehicle thermal management system. The instrument controller 102, the actuator 103, and the sensor 104 are all communicatively connected to the thermal management controller 101.

[0071] The instrument controller 102 responds to a detection command and sends the detection command to the thermal management controller 101;

[0072] The thermal management controller 101 controls the operating state of the actuator 103 and / or the sensor 104 according to the received detection command, and detects whether the feedback signals in the actuator 103 and / or the sensor 104 meet the preset test requirements.

[0073] The thermal management controller 101 is also used to feed back the feedback signals of the actuator 103 and / or the sensor 104 to the instrument controller 102, so as to visualize the detection results of the operating status of the actuator 103 and / or the sensor 104.

[0074] In this embodiment, the thermal management controller can control the operating status of actuators and sensors in the thermal management system, and can detect whether the feedback signals of actuators and sensors meet the requirements. The instrument controller can receive the detection instructions triggered by the testing personnel and process the status signals fed back from the thermal management controller, thereby achieving closed-loop control of the entire testing system.

[0075] Furthermore, the commercial vehicle thermal management detection system also includes a display screen 105 for displaying the instrument engineering interface, the display screen 105 being connected to the instrument controller 102.

[0076] Specifically, in this embodiment, the instrument controller can determine the operating status of each component in the target circuit, and display the normal or fault status of the components on the display screen using different text and background colors. Please refer to the instrument engineering interface on the display screen. Figures 4 to 8 As shown, the instrumentation engineering test interface enables visualization of test results, and its control operation is simpler, which helps testers quickly troubleshoot faults.

[0077] Therefore, this application can intuitively display the operating status of each component in the vehicle thermal management system based on the realization of automatic testing of the vehicle thermal management system, quickly discover faults in the vehicle thermal management system, and has the advantages of simple operation and high efficiency of intelligent self-testing when vehicle off-line inspection or after-sales problem troubleshooting. In this way, it can achieve the technical effect of reducing the testing and maintenance costs of the vehicle thermal management system.

[0078] Furthermore, such as Figure 1 As shown, the actuator 103 is communicatively connected to the thermal management controller 101 via a Lin / CAN bus, and the thermal management controller 101 and the instrument controller 102 are communicatively connected via a CAN bus. In this embodiment, the Lin (Lin, Local Interconnect Network) bus is a low-cost serial communication network, and the CAN (CAN, Controller Area Network) bus is an ISO internationally standardized serial communication protocol. Of course, those skilled in the art can also use other existing communication methods to achieve the communication connection between the actuator and the thermal management controller, and between the thermal management controller and the instrument controller; the above description should not be considered as a limitation of this application.

[0079] Furthermore, such as Figure 1 As shown, the actuator 103 includes one or more of the following: a control valve, a fan, a water pump, a compressor, a PTC heater, and a blower.

[0080] The control valve is used to control the flow rate or direction of the heat transfer medium (coolant or refrigerant) in the thermal management system. The control valve is controlled by the valve target opening signal or loop connection position signal of the thermal management controller 101, and can feed back the actual opening or loop connection position through the Lin / CAN bus.

[0081] The fan and the water pump are controlled by the PWM (Pulse Width Modulation Wave) duty cycle signal of the thermal management controller 101, and can provide feedback on their actual operating status through the Lin / CAN bus.

[0082] The compressor is controlled by the target speed signal of the thermal management controller 101 and can provide feedback on its actual operating status through the Lin / CAN bus;

[0083] The PTC heater is controlled by the target temperature signal of the thermal management controller 101 and can provide feedback on its actual operating status through the Lin / CAN bus;

[0084] The blower is controlled by the air volume level signal of the thermal management controller 101 and can provide feedback on its actual operating status through the Lin / CAN bus.

[0085] The sensor is used to detect the temperature and / or pressure of the coolant or refrigerant at the target location and feed it back to the thermal management controller 101.

[0086] The following will combine Figure 2 The commercial vehicle thermal management system described herein illustrates the detection system.

[0087] Preferably, the target loop of the thermal management system includes: a cabin heating loop, a cabin cooling loop, a battery cooling loop, a battery heating loop, and an electric drive cooling loop;

[0088] The control valves include: a BEXV ball valve 201, a TXV thermal expansion valve 202, a first solenoid three-way valve 203, a second solenoid three-way valve 204, a third solenoid three-way valve 205, and a four-way valve 206.

[0089] The fan includes: a front-end electronic fan 207 and a battery-powered electronic fan 208.

[0090] The water pumps include: a heating pump 209, a battery pump 210, and an electric-driven pump 211.

[0091] The compressor includes: a cabin compressor 212 and a battery compressor 213.

[0092] The PTC heater includes: a main WPTC heater 214 and an auxiliary WPTC heater 215.

[0093] The sensors include: a first water temperature sensor 216, a second water temperature sensor 217, a third water temperature sensor 218, a fourth water temperature sensor 219, a fifth water temperature sensor 220, a sixth water temperature sensor 221, a first pressure sensor 222, a second pressure sensor 223, a third pressure sensor 224, a PT pressure-temperature sensor 225, and an ambient temperature sensor 226.

[0094] In the cabin heating circuit, the output end of the main WPTC heater 214 passes sequentially through the first position of the first electromagnetic three-way valve 203, the auxiliary WPTC heater 215, the plate heat exchanger 229, the second position of the four-way valve 206, the first liquid storage tank 236, and the heating pump 209 before being connected to the input end of the main WPTC heater 214; the second position of the first electromagnetic three-way valve 203 is connected to the input end of the heater core 228, and the output end of the heater core 228 is connected to the second position of the four-way valve 206. The sixth water temperature sensor 221 is located at the outlet of the main WPTC heater 214, and the fourth water temperature sensor 219 is located at the outlet of the auxiliary WPTC heater 215.

[0095] In the cabin cooling circuit, the output end of the cabin compressor 212 passes sequentially through the cabin condenser 230, the TXV thermal expansion valve 202, and the evaporator 232 before being connected to the input end of the cabin compressor 212. The front-end electric fan 207 is located near the cabin condenser 230, the blower 227 is located near the evaporator 232, the first pressure sensor 222 is located at the outlet of the cabin condenser 230, and the second pressure sensor 223 is located at the outlet of the evaporator 232.

[0096] The battery cooling circuit includes a first battery cooling circuit and a second battery cooling circuit.

[0097] In the first battery cooling circuit, the output end of the power battery 233 passes sequentially through the second liquid storage tank 237, the battery pump 210, the first position of the second electromagnetic three-way valve 204, and the battery Chiller integrated cooling and heating machine 234 before being connected to the input end of the power battery 233; the second position of the second electromagnetic three-way valve 204 passes through the plate heat exchanger 229 before being connected to the input end of the power battery 233, wherein the first water temperature sensor 216 is located at the inlet of the power battery 233;

[0098] In the second battery cooling circuit, the output end of the battery compressor 213 passes sequentially through the battery condenser 235, the BEXV ball valve 201, and the battery Chiller integrated cooling and heating unit 234 before being connected to the input end of the battery compressor 213. The third pressure sensor 224 is located at the outlet of the battery condenser 235, the PT pressure and temperature sensor 225 is located at the inlet of the battery compressor 213, and the battery electronic fan 208 is located near the battery condenser 235.

[0099] In the electric drive cooling circuit, the output end of the motor radiator 231 is connected to the input end of the motor radiator 231 after passing through the first position of the four-way valve 206, the third liquid storage tank 238, the electric drive pump 211, the high-voltage accessory, the MCU controller, the TM gearbox, and the first position of the third electromagnetic three-way valve 205 in sequence; the second position of the third electromagnetic three-way valve 205 is connected to the output end of the motor radiator 231, wherein the third water temperature sensor 218 is set at the inlet of the four-way valve 206, the fifth water temperature sensor 220 is set at the inlet of the high-voltage accessory, and the second water temperature sensor 217 is set at the outlet of the TM gearbox.

[0100] Furthermore, in the battery heating circuit, the first position of the first electromagnetic three-way valve 203 and the second position of the second electromagnetic three-way valve 204 are turned on, so that the coolant in the cabin heating circuit and the coolant in the first battery cooling circuit exchange heat in the plate heat exchanger 229 to achieve heating of the power battery.

[0101] It is worth noting that this application Figure 2 In the diagram, ① indicates the first position of the connecting control valve, and ② indicates the second position. Specifically, referring to the arrow directions in the diagram, the first and second positions of each control valve are explained as follows:

[0102] The first electromagnetic three-way valve 203 includes three valve ports. In this embodiment, the valve port located at the top is defined as the first valve port of the first electromagnetic three-way valve, the valve port located on the left is defined as the second valve port, and the valve port located on the right is defined as the third valve port. At this time, the first position of the first electromagnetic three-way valve indicates that the cooling medium flows from the second valve port of the first electromagnetic three-way valve to the third valve port of the first electromagnetic three-way valve; the second position of the first electromagnetic three-way valve indicates that the cooling medium flows from the second valve port of the first electromagnetic three-way valve to the first valve port of the first electromagnetic three-way valve.

[0103] The second electromagnetic three-way valve 204 includes three valve ports. In this embodiment, the valve port located at the bottom is defined as the first valve port of the second electromagnetic three-way valve, the valve port located on the left is defined as the second valve port, and the valve port located on the right is defined as the third valve port. At this time, the first position of the second electromagnetic three-way valve indicates that the cooling medium flows from the third valve port of the second electromagnetic three-way valve to the second valve port of the second electromagnetic three-way valve; the second position of the second electromagnetic three-way valve indicates that the cooling medium flows from the third valve port of the second electromagnetic three-way valve to the first valve port of the second electromagnetic three-way valve.

[0104] Similarly, the third electromagnetic three-way valve 205 includes three valve ports. In this embodiment, the valve port located at the top is defined as the first valve port of the third electromagnetic three-way valve, the valve port located on the left is the second valve port, and the valve port located on the right is the third valve port. At this time, the first position of the third electromagnetic three-way valve indicates that the cooling medium flows from the third valve port of the third electromagnetic three-way valve to the second valve port of the third electromagnetic three-way valve; the second position of the third electromagnetic three-way valve indicates that the cooling medium flows from the third valve port of the third electromagnetic three-way valve to the first valve port of the third electromagnetic three-way valve.

[0105] The four-way valve 206 includes four valve ports. In this embodiment, the valve port located at the top is defined as the first valve port of the four-way valve, the valve port located on the left is defined as the second valve port, the valve port located on the right is defined as the third valve port, and the valve port located at the bottom is defined as the fourth valve port of the four-way valve. At this time, the first position of the four-way valve indicates that the cooling medium flows from the first valve port of the four-way valve to the third valve port of the four-way valve; the second position of the four-way valve indicates that the cooling medium flows from the fourth valve port of the four-way valve to the second valve port of the four-way valve.

[0106] At the same time, Figure 2 In this context, HVAS represents high-voltage accessories; FTM represents the front gearbox; RTM represents the rear gearbox; FMCU represents the front motor controller; and RMCU represents the rear motor controller.

[0107] certainly, Figure 2 The number, location, and connection relationship of each component are merely illustrative descriptions and should not be construed as limiting this application.

[0108] Furthermore, such as Figure 1 As shown, the commercial vehicle thermal management detection system includes: an instrument panel button 106 for receiving detection commands triggered by the testing personnel, the instrument panel button 106 being connected to the instrument controller 102, wherein the instrument panel button 106 includes at least one or more of the following: cabin heating button, cabin cooling button, battery cooling button, battery heating button, and electric drive cooling button.

[0109] In this embodiment, the instrument button is used to receive a test command triggered by the tester, and the instrument controller responds to the test command to detect the current thermal management test requirements, and at the same time sends the test command to the thermal management controller via the CAN bus.

[0110] When a commercial vehicle is not in a driving state (stationary), the detection system described in this application can detect the communication, power supply, and operating status of various components in the commercial vehicle's thermal management system. Combined with... Figures 4 to 8As shown, technical engineers (testing personnel) access the instrument engineering interface via the instrument buttons. The left side of this interface displays function buttons for various thermal management requirements, while the right side displays test buttons for actuators, sensors, and on / off states involved in the thermal management requirement loop. Specifically, the instrument engineering interface includes five categories of thermal management requirement tests: cabin heating (refer to...). Figure 4 ), cabin cooling (refer to) Figure 5 ), battery cooling (refer to) Figure 6 ), battery heating (refer to) Figure 7 ), electric drive cooling (refer to) Figure 8 ).

[0111] In another embodiment of this application, such as Figure 3 As shown, a detection method for a commercial vehicle thermal management testing system is proposed, applicable to a commercial vehicle thermal management testing system as described in any of the above embodiments. The detection method includes:

[0112] Step S1: Turn off the cabin heating and cabin cooling functions; control the actuator 103 in the commercial vehicle thermal management system to either turn off or maintain the initial on position;

[0113] Step S2: The instrument controller in the commercial vehicle thermal management detection system responds to the detection command input by the instrument button 106 and sends the detection command to the thermal management controller.

[0114] Step S3: The thermal management controller controls the operating state of the actuator and / or the sensor according to the received detection command, and detects whether the feedback signal in the actuator and / or the sensor meets the preset test requirements.

[0115] Step S4: The thermal management controller feeds back the feedback signals from the actuator and / or the sensor to the instrument controller to visualize the detection results of the operating status of the actuator and / or the sensor.

[0116] Step S5: When the detection command is switched, control the actuator in the commercial vehicle thermal management system to close or maintain the initial on position, and repeat steps S2 to S4 according to another detection command;

[0117] Alternatively, upon completion of the detection, the actuators in the commercial vehicle thermal management system may be shut down or kept in their initial on position.

[0118] In this embodiment, before entering the instrumentation engineering interface, the cabin heating and cooling functions need to be manually turned off. After entering the engineering test interface, the thermal management controller controls the BEXV ball valve and TXV thermal expansion valve in the thermal management system to close, while other control valves in the thermal management system remain in the loop-on position as before entering the engineering test. Actuators such as fans, water pumps, and blowers in the thermal management system stop operating.

[0119] Since the detection commands input via the instrument buttons are independent of each other, when detection is enabled, the thermal management controller only drives and controls the operation of the relevant actuators and sensors according to the current test requirements, and detects whether the actuators are functioning properly and whether the sensors are in an effective working state. When the detection command is switched off or disabled, the thermal management controller controls the actuators and sensors of the thermal management system to return to the initial detection state.

[0120] Further, in step S1, the detection method includes:

[0121] The actuator controls the BEXV ball valve and TXV thermal expansion valve to close, and controls the first solenoid three-way valve, the second solenoid three-way valve, the third solenoid three-way valve, and the four-way valve in the actuator to remain in their initial closed positions. At the same time, the actuator controls the fan, water pump, compressor, PTC heater, and blower in the actuator to stop operating.

[0122] Furthermore, in step S2 or step S5,

[0123] The detection commands include: cabin heating circuit detection, cabin cooling circuit detection, battery cooling circuit detection, battery heating circuit detection, and electric drive cooling circuit detection;

[0124] Step S3 also includes:

[0125] During cabin heating circuit testing, the feedback signals of the heating pump, main WPTC heater, blower, second position of the first electromagnetic three-way valve, first position of the four-way valve, and sixth water temperature sensor in the cabin heating circuit are tested to see if they meet the preset test requirements.

[0126] During cabin cooling circuit testing, the feedback signals of the cabin compressor, front-end electric fan, blower, TXV thermal expansion valve, first pressure sensor, and second pressure sensor in the cabin cooling circuit are tested to see if they meet the preset test requirements.

[0127] When testing the battery cooling circuit, the feedback signals of the battery compressor, battery electric fan, battery pump, BEXV ball valve, first position of the second battery three-way valve, PT pressure and temperature sensor, first water temperature sensor, and third pressure sensor in the battery cooling circuit are tested to see if they meet the preset test requirements.

[0128] When testing the battery heating circuit, the feedback signals of the heating pump, auxiliary WPTC heater, battery pump, first position of the first electromagnetic three-way valve, second position of the second battery three-way valve, first position of the four-way valve, fourth water temperature sensor, and first water temperature sensor in the battery heating circuit are tested to see if they meet the preset test requirements.

[0129] During the testing of the electric drive cooling circuit, the feedback signals of the electric drive pump, the front-end electric fan, the first position of the third electromagnetic three-way valve, the first position of the four-way valve, the third water temperature sensor, the ambient temperature sensor, the second water temperature sensor, and the fifth water temperature sensor in the electric drive cooling circuit are tested to see if they meet the preset test requirements.

[0130] Specifically, in this embodiment, the desired states received by the instrument controller of the detection system from the feedback of each actuator and sensor are shown in Table 1:

[0131] Table 1 Expected State Feedback Table for Actuators and Sensors in the Target Loop

[0132]

[0133]

[0134] As can be seen from the above, the thermal management controller in this embodiment can combine a preset detection command signal with the actual feedback signals of the actuator and sensor to determine whether the feedback signal meets the preset test requirements. For example, when the feedback signal of the actuator and / or the sensor is consistent with the preset test requirements, it is determined that the actuator and / or the sensor is in a normal state; when the feedback signal of the actuator and / or the sensor is inconsistent with the preset test requirements, it is determined that the actuator and / or the sensor is in a fault state. It is understood that the relevant conditions of the above-mentioned preset test requirements can be set by those skilled in the art in combination with the actual application scenario.

[0135] Furthermore, the thermal management controller feeds back the feedback signals from the actuator and / or the sensor to the instrument controller. Preferably, when the feedback value received by the instrument controller matches the preset expected value, the background of the text displayed by the actuator / sensor on the instrument engineering interface can be set to green; when the feedback value received by the instrument controller does not match the preset expected value, the background of the text displayed by the actuator / sensor on the instrument engineering interface can be set to red. This allows different background colors to indicate the normal or faulty status of the components, facilitating the assessment of the component's operating condition by the testing personnel.

[0136] In summary, the technical solution of this application achieves at least the following technical effects: It provides a commercial vehicle thermal management testing system and method for detecting target loops in the commercial vehicle thermal management system. Through an instrument controller, it responds to a testing command and sends the command to the thermal management controller. The thermal management controller controls the operating status of the actuators and / or sensors according to the received testing command and detects whether the feedback signals from the actuators and / or sensors meet preset test requirements. Simultaneously, the thermal management controller also feeds back the feedback signals from the actuators and / or sensors to the instrument controller to visualize the detection results of the operating status of the actuators and / or sensors. This application, based on the automatic testing of the vehicle thermal management system, can intuitively display the operating status of each component within the system. During vehicle off-line testing or fault repair, it can quickly detect faults in the vehicle thermal management system, improve intelligent testing efficiency and production efficiency, ensure the safe operation of the vehicle thermal management system, and thus achieve the technical effect of reducing testing and maintenance costs.

[0137] It should be noted that the above embodiments are illustrative of this application and not limiting of it, and that those skilled in the art can devise alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses should not be construed as limiting the claims. The word "comprising" does not exclude the presence of elements or steps not listed in the claims. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. This application can be implemented by means of hardware comprising several different elements and by means of a suitably programmed computer. In the unit claims enumerating several means, several of these means may be embodied by the same item of hardware.

[0138] The use of words such as first, second, and third does not indicate any order. These words can be interpreted as names.

[0139] The above description is merely an embodiment of this application and is not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A commercial vehicle thermal management detection system, characterized in that, Used to detect target loops in the thermal management system of commercial vehicles. The detection system includes: a thermal management controller, an instrument controller, actuators in the commercial vehicle thermal management system, and sensors in the commercial vehicle thermal management system. The instrument controller, the actuators, and the sensors are all communicatively connected to the thermal management controller. The instrument controller responds to a detection command and sends the detection command to the thermal management controller; The thermal management controller controls the operating state of the actuator and / or the sensor according to the received detection command, and detects whether the feedback signals in the actuator and / or the sensor meet the preset test requirements. The thermal management controller is also used to feed back the feedback signals of the actuator and / or the sensor to the instrument controller, so as to visualize the detection results of the operating status of the actuator and / or the sensor; The actuator includes one or more of the following: a control valve, a fan, a water pump, a compressor, a PTC heater, and a blower. The target loops of the thermal management system include: cabin heating loop, cabin cooling loop, battery cooling loop, battery heating loop, and electric drive cooling loop; The control valves include: a ball valve, a TXV thermostatic expansion valve, a first solenoid three-way valve, a second solenoid three-way valve, a third solenoid three-way valve, and a four-way valve. The fan includes: a front-end electronic fan and a battery-powered electronic fan. The water pumps include: heating pumps, battery pumps, and electric pumps. The compressor includes: a cabin compressor and a battery compressor. The PTC heater includes: a main heater and an auxiliary heater. The sensors include: a first water temperature sensor, a second water temperature sensor, a third water temperature sensor, a fourth water temperature sensor, a fifth water temperature sensor, a sixth water temperature sensor, a first pressure sensor, a second pressure sensor, a third pressure sensor, a pressure-temperature sensor, and an ambient temperature sensor; In the cabin heating circuit, the output end of the main heater sequentially passes through the first position of the first electromagnetic three-way valve, the auxiliary heater, the plate heat exchanger, the second position of the four-way valve, the first liquid storage tank, and the heating pump before connecting to the input end of the main heater; the second position of the first electromagnetic three-way valve is connected to the input end of the heater core, and the output end of the heater core is connected to the second position of the four-way valve; wherein the sixth water temperature sensor is located at the outlet of the main heater, and the fourth water temperature sensor is located at the outlet of the auxiliary heater. In the cabin cooling circuit, the output end of the cabin compressor passes through the cabin condenser, TXV thermal expansion valve, and evaporator in sequence, and is then connected to the input end of the cabin compressor. The front-end electric fan is located near the cabin condenser, the blower is located near the evaporator, the first pressure sensor is located at the outlet of the cabin condenser, and the second pressure sensor is located at the outlet of the evaporator. The battery cooling circuit includes a first battery cooling circuit and a second battery cooling circuit. In the first battery cooling circuit, the output end of the power battery passes through the second liquid storage tank, the battery pump, the first position of the second electromagnetic three-way valve, and the battery Chiller integrated cooling and heating machine in sequence, and is then connected to the input end of the power battery; the second position of the second electromagnetic three-way valve passes through the plate heat exchanger and is then connected to the input end of the power battery, wherein the first water temperature sensor is set at the inlet of the power battery. In the second battery cooling circuit, the output end of the battery compressor passes through the battery condenser, ball valve, and battery Chiller integrated cooling and heating unit in sequence, and is then connected to the input end of the battery compressor. The third pressure sensor is located at the outlet of the battery condenser, the pressure and temperature sensor is located at the inlet of the battery compressor, and the battery electric fan is located near the battery condenser. In the electric drive cooling circuit, the output end of the motor radiator sequentially passes through the first position of the four-way valve, the third liquid storage tank, the electric drive pump, the high-voltage accessory, the MCU controller, the gearbox, and the first position of the third electromagnetic three-way valve before connecting to the input end of the motor radiator; the second position of the third electromagnetic three-way valve is connected to the output end of the motor radiator, wherein the third water temperature sensor is located at the inlet of the four-way valve, the fifth water temperature sensor is located at the inlet of the high-voltage accessory, and the second water temperature sensor is located at the outlet of the gearbox.

2. The commercial vehicle thermal management detection system according to claim 1, characterized in that, Also includes: A display screen for displaying the instrument engineering interface, the display screen being connected to the instrument controller.

3. The commercial vehicle thermal management detection system according to claim 1, characterized in that, The actuators are connected to the thermal management controller via a Lin / CAN bus, and the thermal management controller and the instrument controller are connected via a CAN bus.

4. The commercial vehicle thermal management detection system according to claim 3, Its features are, in, The control valve is used to control the flow rate or direction of coolant or refrigerant in the thermal management system. The control valve is controlled by the valve target opening signal or loop connection position signal of the thermal management controller, and can feed back the actual opening or loop connection position through the Lin / CAN bus. The fan and the water pump are controlled by the PWM duty cycle signal of the thermal management controller and can provide feedback on their actual operating status through the Lin / CAN bus. The compressor is controlled by the target speed signal of the thermal management controller and can provide feedback on its actual operating status through the Lin / CAN bus; The PTC heater is controlled by the target temperature signal of the thermal management controller and can provide feedback on its actual operating status through the Lin / CAN bus; The blower is controlled by the air volume level signal of the thermal management controller and can provide feedback on its actual operating status through the Lin / CAN bus; The sensor is used to detect the temperature and / or pressure of the coolant or refrigerant at the target location and feed it back to the thermal management controller.

5. The commercial vehicle thermal management detection system according to claim 1, characterized in that, In the battery heating circuit, the first position of the first electromagnetic three-way valve and the second position of the second electromagnetic three-way valve are turned on, so that the coolant in the cabin heating circuit and the coolant in the first battery cooling circuit exchange heat in the plate heat exchanger to achieve heating of the power battery.

6. The commercial vehicle thermal management detection system according to claim 5, characterized in that, include: An instrument button is used to receive testing commands triggered by the testing personnel. The instrument button is connected to the instrument controller. The instrument panel buttons include at least one or more of the following: cabin heating button, cabin cooling button, battery cooling button, battery heating button, and electric drive cooling button.

7. A testing method for a commercial vehicle thermal management testing system, characterized in that, The detection method, applied to the commercial vehicle thermal management detection system as described in any one of claims 1 to 6, comprises: Step S1: Turn off the cabin heating and cabin cooling functions; control the actuators in the commercial vehicle thermal management system to either turn off or maintain their initial on position; Step S2: The instrument controller in the commercial vehicle thermal management detection system responds to the detection command input by the instrument key and sends the detection command to the thermal management controller. Step S3: The thermal management controller controls the operating state of the actuator and / or the sensor according to the received detection command, and detects whether the feedback signal in the actuator and / or the sensor meets the preset test requirements. Step S4: The thermal management controller feeds back the feedback signals from the actuator and / or the sensor to the instrument controller to visualize the detection results of the operating status of the actuator and / or the sensor. Step S5: When the detection command is switched, control the actuator in the commercial vehicle thermal management system to close or maintain the initial on position, and repeat steps S2 to S4 according to another detection command; Alternatively, upon completion of the detection, the actuators in the commercial vehicle thermal management system may be shut down or kept in their initial on position.

8. The detection method according to claim 7, characterized in that, Step S1 includes: The ball valve and TXV thermal expansion valve in the actuator are controlled to close, and the first solenoid three-way valve, the second solenoid three-way valve, the third solenoid three-way valve, and the four-way valve in the actuator are controlled to remain in their initial closed positions. At the same time, the fan, water pump, compressor, PTC heater, and blower in the actuator are controlled to stop operating.

9. The detection method according to claim 7, characterized in that, In step S2 or step S5, The detection commands include: cabin heating circuit detection, cabin cooling circuit detection, battery cooling circuit detection, battery heating circuit detection, and electric drive cooling circuit detection; Step S3 also includes: During the cabin heating circuit test, the feedback signals of the heating pump, main heater, blower, second position of the first electromagnetic three-way valve, first position of the four-way valve, and sixth water temperature sensor in the cabin heating circuit are tested to see if they meet the preset test requirements. During cabin cooling circuit testing, the feedback signals of the cabin compressor, front-end electric fan, blower, TXV thermal expansion valve, first pressure sensor, and second pressure sensor in the cabin cooling circuit are tested to see if they meet the preset test requirements. When testing the battery cooling circuit, the feedback signals of the battery compressor, battery electric fan, battery pump, ball valve, first position of the second battery three-way valve, pressure and temperature sensor, first water temperature sensor and third pressure sensor in the battery cooling circuit are tested to see if they meet the preset test requirements. When testing the battery heating circuit, the feedback signals of the heating pump, auxiliary heater, battery pump, first position of the first electromagnetic three-way valve, second position of the second battery three-way valve, first position of the four-way valve, fourth water temperature sensor, and first water temperature sensor in the battery heating circuit are tested to see if they meet the preset test requirements. During the testing of the electric drive cooling circuit, the feedback signals of the electric drive pump, the front-end electric fan, the first position of the third electromagnetic three-way valve, the first position of the four-way valve, the third water temperature sensor, the ambient temperature sensor, the second water temperature sensor, and the fifth water temperature sensor in the electric drive cooling circuit are tested to see if they meet the preset test requirements.

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