A controller and control method for driving an air conditioner compressor and a heater of an electric vehicle

Abstract

The present disclosure relates to a kind of controller and control method for driving air conditioner compressor and heater of electric vehicle, the controller includes: vehicle-mounted battery module, for outputting high-voltage direct current to power two-in-one driver module;Two-in-one driver module is used to drive air conditioner compressor and heater, wherein the air conditioner compressor is used to refrigerate the electric vehicle, and the heater is used to heat the electric vehicle;Acquisition module is used to collect the voltage, current signal of two-in-one driver module and the temperature signal of heater, and after processing the signal collected, it is exported to main control module;Main control module is based on preprocessed voltage signal, current signal and temperature signal, exports PWM signal to control two-in-one driver module work;Low-voltage power module is used to output low voltage to power main control module.The present disclosure reduces the number of power tube, while improve system space utilization, system integration is higher, and cost is lower.

Description

Technical Field

[0001] This disclosure relates to the field of heat pump drivers for new energy electric vehicles, and specifically to a controller and control method for driving an air conditioning compressor and heater in an electric vehicle. Background Technology

[0002] In electric vehicles, both the compressor driver and the PCT controller are used for in-vehicle temperature regulation. Traditionally, these are essentially independent systems with low integration. Designed as separate topologies, the discrete compressor driver requires at least six power transistors, while the PTC for a dual-heating film heater typically uses four (three-heating film requires at least six). A combined dual-heating film controller requires at least ten power transistors (a combined three-heating film controller requires at least twelve). This large number of power transistors increases system cost and size, reduces reliability, and results in some waste. Some newer models integrate the two controllers, but the number of power transistors and sampling circuits is not significantly reduced.

[0003] Traditional heater PTC controllers mostly use a two-phase interleaved control method with dual heating films. Due to the need to suppress bus ripple current, a large number of filters are used, resulting in a large overall size of the heater PTC section. Summary of the Invention

[0004] This disclosure provides a controller and control method for driving an air conditioning compressor and heater in an electric vehicle, which solves the problems of low space utilization and high system cost of traditional electric vehicle compressor drives and PCT controllers. This disclosure provides the following technical solution: A controller for driving the air conditioning compressor and heater of an electric vehicle includes: The vehicle battery module is used to output high-voltage DC power to power the two-in-one drive module; A two-in-one driver module is used to drive an air conditioning compressor and a heater, wherein the air conditioning compressor is used to cool the electric vehicle and the heater is used to heat the electric vehicle; The acquisition module is used to acquire the voltage and current signals of the two-in-one driver module and the temperature signal of the heater, and then process the acquired voltage, current and temperature signals and output them to the main control module. The main control module outputs a PWM signal to control the operation of the two-in-one driver module based on the pre-processed voltage, current and temperature signals. The low-voltage power supply module is used to output low voltage to power the main control module.

[0005] Preferably, the two-in-one driver module includes a filter inductor, a capacitor, a first power transistor, a second power transistor, and a third power transistor, as well as a first sampling resistor, a second sampling resistor, and a third sampling resistor; one end of the filter inductor is connected to the positive terminal of the power supply, and the other end is connected to one end of the capacitor, and the other end of the capacitor is connected to the negative terminal of the power supply; the end of the filter inductor and the capacitor connected together is connected to the drain terminals of the first power transistor, the second power transistor, and the third power transistor.

[0006] Preferably, the heater uses a three-phase alternating control method of a first heating film, a second heating film, and a third heating film to achieve heating; the main control module controls the heating by controlling the on / off of the power supply to the first heating film, the second heating film, and the third heating film of the heater through the first power transistor, the second power transistor, and the third power transistor.

[0007] Preferably, the two-in-one driver module further includes a fourth power transistor, a fifth power transistor, and a sixth power transistor. The source of the first power transistor is connected to the U phase of the air conditioner compressor, the drain of the fourth power transistor, and one end of the first heating film. The source of the second power transistor is connected to the V phase of the air conditioner compressor, the drain of the fifth power transistor, and one end of the second heating film. The source of the third power transistor is connected to the W phase of the air conditioner compressor, the drain of the sixth power transistor, and one end of the third heating film.

[0008] Preferably, the two-in-one driver module further includes a seventh power transistor, an eighth power transistor, and a ninth power transistor. The source of the fourth power transistor is connected to the source of the seventh power transistor and to one end of the first sampling resistor. The source of the fifth power transistor is connected to the source of the eighth power transistor and to one end of the second sampling resistor. The source of the sixth power transistor is connected to the source of the ninth power transistor and to one end of the third sampling resistor. The other ends of the first, second, and third sampling resistors are all connected to the negative terminal of the power supply.

[0009] Preferably, the two-in-one driver module further includes: the drain of the seventh power transistor is connected to the other end of the first heating film; the drain of the eighth power transistor is connected to the other end of the second heating film; and the drain of the ninth power transistor is connected to the other end of the third heating film.

[0010] Preferably, the main control module outputs PWM signals to control the operation of the two-in-one driver module, which includes the main control module outputting nine pulse signals, which respectively drive the air conditioner compressor and heater through the first power transistor, the second power transistor, the third power transistor, the fourth power transistor, the fifth power transistor, the sixth power transistor, the seventh power transistor, the eighth power transistor and the ninth power transistor.

[0011] Preferably, the main control module is a DSP module; and / or, the heater is a PTC heater, wherein the first heating film, the second heating film, and the third heating film are all PTC heating films.

[0012] The present invention also provides a control method for an air conditioning compressor and heater that drive an electric vehicle. Using the above-mentioned controller, the main control module controls the operation of the air conditioning compressor or heater by controlling the on and off of the first power transistor, the second power transistor, the third power transistor, the fourth power transistor, the fifth power transistor, the sixth power transistor, the seventh power transistor, the eighth power transistor and the ninth power transistor.

[0013] The present invention also provides a control method for an air conditioning compressor and heater driving an electric vehicle. Using the above-mentioned controller, the seventh, eighth and ninth power transistors are kept off, while the first, second, third, fourth, fifth and sixth power transistors are operated to control the compressor to achieve cooling; and / or, the first, second and third power transistors are kept on, while the fourth, fifth and sixth power transistors are kept off to control the heater to achieve heating.

[0014] Compared to the prior art, the beneficial effects of this disclosure are as follows: 1. This disclosure combines the compressor driver and the heater PTC driver into one, adopts a new circuit topology control, reduces the number of power transistors used, has higher system space utilization, and lower cost.

[0015] 2. The heater PCT section of this disclosure adopts three-phase interleaved control with three heating films, resulting in lower bus current ripple, lower filter cost and size, and the current sampling of each heating film of the heater PTC multiplexes the compressor driver bridge arm sampling circuit, resulting in a smaller system size and lower cost.

[0016] 3. This disclosure utilizes a single DSP to simultaneously control the compressor and the PTC heater, resulting in higher system integration and lower cost. It reuses the upper tube of the compressor's driver bridge arm as the on / off control for each heating film, meeting safety requirements while also reducing system cost. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the controller used to drive the air conditioning compressor and heater of the electric vehicle in Example 1; Figure 2 This is a circuit topology diagram of the air conditioning compressor inverter section and the heater PTC drive section in the controller of Example 1; Figure 3 This is a schematic diagram of the heater PTC and motor phase current sampling circuit sharing the same current sampling circuit in Example 2. Detailed Implementation

[0018] Various exemplary embodiments, features, and aspects of this disclosure will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0019] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0020] In this document, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Furthermore, the term "at least one" in this document means any combination of at least two of any one or more elements. For example, including at least one of A, B, and C can mean including any one or more elements selected from the set consisting of A, B, and C.

[0021] It is understood that the various method embodiments mentioned above in this disclosure can be combined with each other to form combined embodiments without violating the principle and logic. Due to space limitations, this disclosure will not elaborate further.

[0022] Example 1 This embodiment provides a controller for driving an air conditioning compressor and heater in an electric vehicle, such as... Figure 1 As shown, the system includes: an on-board battery module for outputting high-voltage DC power to supply power to the two-in-one drive module; a two-in-one driver module for driving an air conditioning compressor and a heater, wherein the air conditioning compressor is used to cool the electric vehicle, and the heater is used to heat the electric vehicle, and the heater is a PTC heater; a data acquisition module for acquiring voltage and current signals from the two-in-one driver module and temperature signals from the heater, and processing the acquired voltage, current, and temperature signals before outputting them to the main control module; a main control module for outputting PWM signals to control the operation of the two-in-one driver module based on the preprocessed voltage, current, and temperature signals, and the main control module is a DSP module; and a low-voltage power supply module for outputting low voltage to supply power to the main control module.

[0023] In this embodiment, the circuit topology includes a compressor inverter section and a heater PTC drive section, such as... Figure 2As shown. The two-in-one driver module includes a filter inductor L1, a capacitor C, a first power transistor Q1, a second power transistor Q2, a third power transistor Q3, a fourth power transistor Q4, a fifth power transistor Q5, a sixth power transistor Q6, a seventh power transistor Q7, an eighth power transistor Q8, and a ninth power transistor Q9, a first sampling resistor R1, a second sampling resistor R2, and a third sampling resistor R3; one end of the filter inductor L1 is connected to the positive terminal of the power supply, and the other end is connected to one end of the capacitor C, and the other end of the capacitor C is connected to the negative terminal of the power supply; the end where the filter inductor L1 and the capacitor C are connected is connected to the drain terminals of the first power transistor Q1, the second power transistor Q2, and the third power transistor Q3.

[0024] Furthermore, the source of the first power transistor Q1 is connected to the U phase of the air conditioner compressor, the drain of the fourth power transistor Q4, and one end of the first heating film TC1; the source of the second power transistor Q2 is connected to the V phase of the air conditioner compressor, the drain of the fifth power transistor Q5, and one end of the second heating film TC2; the source of the third power transistor Q3 is connected to the W phase of the air conditioner compressor, the drain of the sixth power transistor Q6, and one end of the third heating film TC3.

[0025] In this embodiment, the heater uses a three-phase alternating control method of the first heating film TC1, the second heating film TC2, and the third heating film TC3 to achieve heating; the main control module controls the heating by controlling the on / off of the power supply to the first heating film TC1, the second heating film TC2, and the third heating film TC3 through the first power transistor Q1, the second power transistor Q2, and the third power transistor Q3. The first heating film TC1, the second heating film TC2, and the third heating film TC3 are all PTC heating films.

[0026] Furthermore, the source of the fourth power transistor Q4 is connected to the source of the seventh power transistor Q7, and to one end of the first sampling resistor R1; the source of the fifth power transistor Q5 is connected to the source of the eighth power transistor Q8, and to one end of the second sampling resistor R2; the source of the sixth power transistor Q6 is connected to the source of the ninth power transistor Q9, and to one end of the third sampling resistor R3; the other ends of the first sampling resistor R1, the second sampling resistor R2, and the third sampling resistor R3 are all connected to the negative terminal of the power supply. The drain of the seventh power transistor Q7 is connected to the other end of the first heating film TC1; the drain of the eighth power transistor Q8 is connected to the other end of the second heating film TC2; and the drain of the ninth power transistor Q9 is connected to the other end of the third heating film TC3.

[0027] Furthermore, the main control module outputs PWM signals to control the operation of the two-in-one driver module, which includes the main control module outputting 9 pulse signals, namely PWM1 to PWM9, which respectively drive the air conditioner compressor and heater through the first power transistor Q1, the second power transistor Q2, the third power transistor Q3, the fourth power transistor Q4, the fifth power transistor Q5, the sixth power transistor Q6, the seventh power transistor Q7, the eighth power transistor Q8 and the ninth power transistor Q9.

[0028] Example 2 This embodiment also provides a control method for an air conditioning compressor and heater that drive an electric vehicle. Using the controller described above, the main control module controls the operation of the air conditioning compressor or heater by controlling the on / off state of the first power transistor Q1, the second power transistor Q2, the third power transistor Q3, the fourth power transistor Q4, the fifth power transistor Q5, the sixth power transistor Q6, the seventh power transistor Q7, the eighth power transistor Q8, and the ninth power transistor Q9.

[0029] In this configuration, the seventh power transistor Q7, the eighth power transistor Q8, and the ninth power transistor Q9 remain off, while the first power transistor Q1, the second power transistor Q2, the third power transistor Q3, the fourth power transistor Q4, the fifth power transistor Q5, and the sixth power transistor Q6 operate to control the compressor and achieve cooling; and / or, the first power transistor Q1, the second power transistor Q2, and the third power transistor Q3 remain on, while the fourth power transistor Q4, the fifth power transistor Q5, and the sixth power transistor Q6 remain off to control the heater and achieve heating.

[0030] In heating mode, when the heater PTC is working, the current sampling part of the heater PTC three heating films in the two-in-one driver module reuses the first sampling resistor R1, the second sampling resistor R2 and the third sampling resistor R3 of the motor three-phase bridge arm current, and simultaneously reuses the current sampling amplification circuit module. The first sampling resistor R1 collects the current of the first heating film TC1, the second sampling resistor R2 collects the current of the second heating film TC2, and the third sampling resistor R3 collects the current of the third heating film TC3.

[0031] In this embodiment, when the heater PTC is operating, PWM4~PWM6 are off. Within one control cycle, PWM1 and PWM7 are chopped for the first 1 / 3 of the time; PWM2 and PWM8 are chopped for the second 1 / 3 of the time; and PWM3 and PWM9 are chopped for the third 1 / 3 of the time. The switching frequency of PWM1~PWM3 is 1kHz, and the duty cycle does not exceed 0.3; the switching frequency of PWM7~PWM9 is 10kHz. The output power of the heater PTC is adjusted by adjusting the duty cycle of PWM7~PWM9.

[0032] In this embodiment, the heater PTC and motor phase current sampling share the same current sampling circuit. The description will focus on one of these current sampling circuits. Figure 3 As shown. One end of the first resistor r1 is connected to the positive terminal of the sampling resistor, and the second end is connected to the first capacitor C1 and the third resistor r3; the second end of the third resistor r3 is connected to the fifth resistor r5 and the sixth resistor r6 and connected to pin 3 of the operational amplifier U1. The second end of the fifth resistor r5 is connected to the 3.3V power supply, and the second end of the sixth resistor r6 is connected to GND; one end of the second resistor r2 is connected to the negative terminal of the sampling resistor, and the second end is connected to the second end of the first capacitor C1 and the first end of the fourth resistor r4; the second end of the fourth resistor r4 is connected to the first end of the seventh resistor r7 and connected to pin 4 of the operational amplifier U1; pins 5 and 6 of the operational amplifier U1 are connected to the 3.3V power supply, pin 2 is connected to GND, and pin 1 is connected to the second end of the seventh resistor r7 and the first end of the eighth resistor r8; the second end of the eighth resistor r8 is connected to the first end of the fourth capacitor C4 and connected to the DSP sampling port U_I; the second end of the fourth capacitor C4 is connected to the GND power supply; the first ends of the second capacitor C2 and the third capacitor C3 are connected to the 3.3V power supply, and the second ends of both are connected to the GND power supply.

[0033] The two-in-one driver module uses a DSP module to simultaneously drive the compressor and the PTC power section of the heater. The feedback signal is fed back to the DSP module through the sampling circuit module for adjustment and fault diagnosis.

[0034] Based on the description of the above embodiments, it can be seen that the embodiments of this disclosure can achieve the following technical effects: 1. This disclosure combines the compressor driver and the heater PTC driver into one, adopts a new circuit topology control, reduces the number of power transistors used, has higher system space utilization, and lower cost.

[0035] 2. The heater PCT section of this disclosure adopts three-phase interleaved control with three heating films, resulting in lower bus current ripple, lower filter cost and size, and the current sampling of each heating film of the heater PTC multiplexes the compressor driver bridge arm sampling circuit, resulting in a smaller system size and lower cost.

[0036] 3. This disclosure utilizes a single DSP to simultaneously control the compressor and the PTC heater, resulting in higher system integration and lower cost. It reuses the upper tube of the compressor's driver bridge arm as the on / off control for each heating film, meeting safety requirements while also reducing system cost.

[0037] Although embodiments of the present disclosure have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present disclosure, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A controller for driving an air conditioning compressor and heater in an electric vehicle, characterized in that, include: The vehicle battery module is used to output high-voltage DC power to power the two-in-one drive module; A two-in-one driver module is used to drive an air conditioning compressor and a heater, wherein the air conditioning compressor is used to cool the electric vehicle and the heater is used to heat the electric vehicle; The acquisition module is used to acquire the voltage and current signals of the two-in-one driver module and the temperature signal of the heater, and then process the acquired voltage, current and temperature signals and output them to the main control module. The main control module outputs a PWM signal to control the operation of the two-in-one driver module based on the pre-processed voltage, current and temperature signals. The low-voltage power supply module is used to output low voltage to power the main control module. The two-in-one driver module includes a filter inductor, a capacitor, a first power transistor, a second power transistor, and a third power transistor, as well as a first sampling resistor, a second sampling resistor, and a third sampling resistor; one end of the filter inductor is connected to the positive terminal of the power supply, and the other end is connected to one end of the capacitor, and the other end of the capacitor is connected to the negative terminal of the power supply; one end of the filter inductor and the capacitor is connected to the drain terminals of the first power transistor, the second power transistor, and the third power transistor. The two-in-one driver module also includes a fourth power transistor, a fifth power transistor, and a sixth power transistor. The source of the first power transistor is connected to the U phase of the air conditioner compressor, the drain of the fourth power transistor, and one end of the first heating film. The source of the second power transistor is connected to the V phase of the air conditioner compressor, the drain of the fifth power transistor, and one end of the second heating film. The source of the third power transistor is connected to the W phase of the air conditioner compressor, the drain of the sixth power transistor, and one end of the third heating film. The two-in-one driver module further includes a seventh power transistor, an eighth power transistor, and a ninth power transistor. The source of the fourth power transistor is connected to the source of the seventh power transistor and to one end of the first sampling resistor. The source of the fifth power transistor is connected to the source of the eighth power transistor and to one end of the second sampling resistor. The source of the sixth power transistor is connected to the source of the ninth power transistor and to one end of the third sampling resistor. The other ends of the first, second, and third sampling resistors are all connected to the negative terminal of the power supply. The heater employs a three-phase alternating control method involving a first heating film, a second heating film, and a third heating film to achieve heating. The main control module controls the heating process by switching the power supply to the first heating film, the second heating film, and the third heating film through the first power transistor, the second power transistor, and the third power transistor.

2. The controller for driving an air conditioning compressor and heater in an electric vehicle as described in claim 1, characterized in that, The drain of the seventh power transistor is connected to the other end of the first heating film; the drain of the eighth power transistor is connected to the other end of the second heating film; and the drain of the ninth power transistor is connected to the other end of the third heating film.

3. The controller for driving an air conditioning compressor and heater in an electric vehicle as described in claim 2, characterized in that, The main control module outputs PWM signals to control the operation of the two-in-one driver module, including: the main control module outputs 9 pulse signals, which are respectively used by the first power transistor, the second power transistor, the third power transistor, the fourth power transistor, the fifth power transistor, the sixth power transistor, the seventh power transistor, the eighth power transistor and the ninth power transistor to drive the air conditioner compressor and the heater of the two-in-one driver module.

4. The controller for driving an air conditioning compressor and heater in an electric vehicle as described in claim 1, characterized in that, The main control module is a DSP module; and / or, the heater is a PTC heater, and the first heating film, the second heating film and the third heating film are all PTC heating films.

5. A control method for driving an air conditioning compressor and heater in an electric vehicle, characterized in that, Using the controller as described in claim 3, the main control module controls the operation of the air conditioning compressor or heater by controlling the on / off state of the first power transistor, the second power transistor, the third power transistor, the fourth power transistor, the fifth power transistor, the sixth power transistor, the seventh power transistor, the eighth power transistor, and the ninth power transistor.

6. The control method for the air conditioning compressor and heater driving an electric vehicle as described in claim 5, characterized in that, The seventh, eighth, and ninth power transistors remain off, while the first, second, third, fourth, fifth, and sixth power transistors operate to control the compressor and achieve cooling; and / or, the first, second, and third power transistors remain on, while the fourth, fifth, and sixth power transistors remain off to control the heater and achieve heating.

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