A new energy vehicle motor controller thermal management system coupled with an air conditioner and a wide temperature range control method

Abstract

The application belongs to the field of new energy automobile motor controller thermal management, and particularly relates to a new energy automobile motor controller thermal management system coupled with an air conditioner and a wide-temperature-range control method. According to the heat generation characteristics and the optimal working temperature range of different components in the electric drive power system of the new energy automobile, the coupling conditions of the motor and the motor controller thermal management system, the battery thermal management system and the air conditioner system are adjusted according to the working condition characteristics and the thermal management requirements of the thermal management objects under the conditions of ordinary temperature environment or low load working condition, summer temperature environment or medium load working condition and extremely high temperature temperature environment or high load working condition, so that the cooling effect can be improved while the system energy consumption is reduced, and the purposes of improving the cruising range of the new energy automobile and enhancing the thermal safety of the new energy automobile are achieved.

Description

Technical Field

[0001] This invention belongs to the field of thermal management of new energy vehicle motor controllers, specifically relating to a thermal management system for new energy vehicle motor controllers coupled with air conditioning and a wide temperature range control method. Background Technology

[0002] In recent years, the new energy vehicle industry has developed rapidly, with its market share increasing quickly. The electric drive system is the core of new energy vehicles. Under high-temperature operating environments or other high-load conditions, the heat generated by the motor controller is enormous and cannot be ignored. Furthermore, with the upgrading of power device materials and the increase in power output, the heat generated by the motor controller continues to increase, which will have a certain impact on the driving range and thermal safety of new energy vehicles. Therefore, the motor controller also requires more efficient cooling methods. Summary of the Invention

[0003] The core of this invention is to provide a thermal management system and method for a new energy vehicle motor controller coupled with an air conditioner. Based on the heat generation characteristics and optimal operating temperature range of different components in the electric drive system of a new energy vehicle, and considering the operating conditions of normal temperature environments or low-load conditions, summer temperature environments or medium-load conditions, and extreme high-temperature environments or high-load conditions, as well as the thermal management requirements of the thermally managed object, efficient cooling of the motor controller is achieved under different ambient temperature and load conditions. Furthermore, it can reduce system energy consumption while improving cooling efficiency, thereby increasing the driving range and enhancing the thermal safety of new energy vehicles. Attached Figure Description

[0004] Figure 1 A schematic diagram of a thermal management system for a new energy vehicle motor controller coupled with an air conditioner, provided as an embodiment of the present invention;

[0005] Figure 2 The air conditioning system provided in this embodiment of the invention provides separate cooling, while the power battery pack cooling system is connected in series with the motor and the motor controller cooling system.

[0006] Figure 3 The air conditioning system provided in this embodiment of the invention provides separate cooling, a power battery pack cooling system, and a parallel motor and motor controller cooling system.

[0007] Figure 4 The power battery pack cooling system provided in this embodiment of the invention is connected in parallel with the motor and motor controller cooling system and coupled with the air conditioning system.

[0008] In the attached diagram: 1. Compressor; 2. Condenser; 3. Expansion valve; 4. Evaporator; 5. Refrigerant tank; 6. Passenger compartment; 7. First Chiller; 8. Motor controller; 9. Motor; 10. First radiator; 11. First circulation pump; 12. Second radiator; 13. Power battery pack; 14. Second circulation pump; 15. Second Chiller; 16. Control valves V1-V11. Detailed Implementation

[0009] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0010] The specific implementation of the present invention will be described in detail below with reference to specific embodiments:

[0011] As attached Figure 1 As shown, the compressor 1, condenser 2, expansion valve 3, evaporator 4, refrigerant tank 5, and first control valve V1 combine to form an air conditioning system. This air conditioning system is responsible for regulating the temperature of the passenger compartment 6. It can also be coupled to the motor and motor controller cooling system and the battery cooling system via a first chiller 7 or a second chiller 15. In this coupled system, the high-temperature coolant flowing through the electric drive system exchanges heat with the low-temperature refrigerant from the air conditioning system, rapidly reducing the coolant temperature and improving cooling efficiency. The first chiller 7, motor controller 8, motor 9, first radiator 10, and second, third, fourth, and fifth control valves V2-V5 constitute the motor and motor controller cooling system. In this system, the cooling method for the coolant varies depending on the object of thermal management. The flow path of the coolant is controlled by adjusting the opening and closing of the control valves: the coolant can be cooled through the first chiller 7 or the first radiator 10 to cool the motor controller 8; or cooled through the first radiator 10 to cool the motor 9. The second radiator 12, the power battery pack 13, the second circulation pump 14, the second chiller 15, and the sixth and seventh control valves V6 and V7 constitute the power battery cooling system. The coolant in this system can be cooled either through the chiller or the radiator. The power battery cooling system and the motor and motor controller cooling system can be connected in series via the pipes containing the eighth and ninth control valves V8 and V9. Since the maximum temperatures that the power battery and the motor can withstand differ, the coolant that has cooled the power battery still has cooling capacity for the motor. Therefore, the coolant flowing through the power battery pack 13 is controlled to continue flowing through the motor 9 to cool the motor 9, thereby reducing system energy consumption.

[0012] The working principle of the present invention is explained below with reference to the embodiments and accompanying drawings:

[0013] As attached Figure 2 As shown, under normal temperature conditions or low load conditions, the air conditioning system operates independently, while the power battery pack cooling system is connected in series with the motor and motor controller cooling system. In the air conditioning system, control valve V1 is open, and refrigerant flows from refrigerant tank 5, passing through compressor 1, condenser 2, expansion valve 3, evaporator 4, and finally returning to refrigerant tank 5. At this time, the air conditioning system is a separate system and is not coupled with other systems. In the power battery pack cooling system, control valves V6 and V7 remain closed, while V8 and V9 are open. The coolant flowing through the power battery pack 13 flows to the motor 9 through the pipeline containing control valve V8, cooling the motor 9 before flowing through the pipeline containing control valve V9 to the second radiator 12 for further cooling. The cooled coolant then continues to circulate in the above circuit. In the motor and motor controller cooling system, control valve V3 is open, while V2, V4, and V5 remain closed. The coolant flows through the motor controller 8 and then along the flow pipeline to the first radiator 10 for further cooling, before continuing to circulate in the above circuit.

[0014] In this embodiment, the power battery pack cooling system is connected in series with the motor and motor controller cooling system. The main feature is that the power battery pack 13 and the motor 9 are cooled in the same coolant circulation loop. This is applicable to normal temperature environments or low load conditions, and can effectively cool without relying on the air conditioning system to provide cooling capacity.

[0015] As attached Figure 3 As shown, in summer temperature environments or under medium load conditions, the air conditioning system provides cooling independently, while the power battery pack cooling system is connected in parallel with the motor and motor controller cooling system. The air conditioning system and... Figure 2 The embodiments shown are the same. In the power battery pack cooling system, control valve V6 is open, and V7, V8, and V9 are closed. The high-temperature coolant flowing through the power battery pack 13 is cooled by the second radiator 12, and the cooled coolant continues to circulate in the above-mentioned circuit. In the motor and motor controller cooling system, control valves V3, V4, and V5 are open, and V2 is closed. The motor 9 and the motor controller 8 are connected in parallel. The high-temperature coolant flowing through the motor 9 and the motor controller 8 is cooled by the first radiator 10, and then continues to circulate in the above-mentioned circuit.

[0016] In this embodiment, the power battery pack cooling system is connected to the parallel motor and motor controller cooling system, which can operate independently. Depending on environmental or load conditions, the temperature of the electric drive system is relatively... Figure 2 The illustrated embodiment will show a significant increase. In order to ensure the cooling effect, the power battery pack cooling system is connected in parallel with the motor and motor controller cooling system.

[0017] As attached Figure 4As shown, for extreme high-temperature environments or high-load conditions, the power battery pack cooling system is connected in parallel with the motor and motor controller cooling system and coupled to the air conditioning system. In the air conditioning system, control valves V1, V10, and V11 are open, and the refrigerant, after passing through expansion valve 3, is divided into two paths: one flows to the evaporator 4, and the other flows to the first chiller 7 and the second chiller 15, and then flows back to the refrigerant tank 5 through the return line. In the power battery pack cooling system, control valve V7 is open, and V6, V8, and V9 are closed. The coolant flowing through the power battery pack 13 exchanges heat with the refrigerant of the air conditioning system through the second chiller 15, achieving a significant temperature reduction, and then continues to circulate in the above loop. In the motor and motor controller cooling system, control valves V2, V4, and V5 are open, and V3 is closed. The coolant in the system flows from the main circuit into two branches: one branch cools the motor controller 8 and then flows through the first chiller 7, where it exchanges heat with the low-temperature refrigerant of the air conditioning system before flowing into the main circuit; the other branch cools the motor 9 and then flows through the first radiator 10 to cool down before flowing into the main circuit to continue circulating in the above circuit.

[0018] In this embodiment, the power battery pack cooling system and the motor and motor controller cooling system operate independently and are not coupled. Because the motor generates a large amount of heat, to match the cooling capacity of the air conditioning system, the coolant after cooling the motor is not cooled using a chiller. Therefore, in this embodiment, two cooling methods are used for the coolant used to cool the motor and motor controller.

Claims

1. A thermal management system for a new energy vehicle motor controller coupled with an air conditioner, characterized in that, Mainly includes: The air conditioning system can cool the passenger compartment independently, or it can exchange heat with the coolant of the power battery pack cooling system, motor and motor controller cooling system to rapidly cool the coolant. The power battery pack cooling system allows for the selection of either radiator cooling or chiller cooling based on different operating conditions, adjusting the flow path of the coolant in the circulation loop to achieve better cooling performance. The motor and motor controller cooling system is described above. In this system, the motor and motor controller are not simply connected in parallel within the coolant circulation loop. The coolant flowing in the motor's branch can only be cooled by a radiator. The coolant flowing in the motor controller's branch can be cooled using either a radiator or a chiller, depending on the specific operating conditions. In extreme high-temperature environments or under high-load conditions, the coolant in the motor and motor controller cooling system splits into two branches from the main circuit: one branch cools the motor controller, passes through a first chiller, exchanges heat with the low-temperature refrigerant in the air conditioning system, and then flows into the main circuit; the other branch cools the motor, passes through a first radiator for cooling, and then flows into the main circuit.

2. The thermal management system for a new energy vehicle motor controller coupled with an air conditioner according to claim 1, characterized in that... The power battery pack cooling system and the motor and motor controller cooling system can be connected in series through pipelines. The purpose of this connection is to take advantage of the difference in the optimal operating temperature range between the power battery and the motor, and to use the coolant that has cooled the power battery to continue cooling the motor, thereby achieving the goal of energy saving and consumption reduction in the system.

3. A wide-temperature-range thermal management control method for a new energy vehicle motor controller coupled with air conditioning, comprising a thermal management system for a new energy vehicle motor controller coupled with air conditioning as described in claim 1 or claim 2, characterized in that... The coolant flow path is adjusted according to the characteristics of the operating conditions, such as normal temperature environment or low load, summer temperature environment or medium load, and extreme high temperature environment or high load, and the thermal management needs of the thermal management object, so as to achieve the thermal management objectives under different operating conditions.

4. The wide-temperature-range thermal management control method for a new energy vehicle motor controller coupled with air conditioning according to claim 3, characterized in that... Under normal temperature conditions or low load conditions, the air conditioning system operates independently, while the power battery pack cooling system is connected in series with the motor and motor controller cooling system: the coolant flowing through the power battery pack continues to cool the motor, and then the coolant is cooled through the radiator. After cooling, the coolant is recirculated. After flowing through the motor controller, the coolant flows along the flow pipe to the radiator for cooling, and then continues to circulate in the above loop.

5. The wide-temperature-range thermal management control method for a new energy vehicle motor controller coupled with an air conditioner according to claim 3, characterized in that... In summer temperature environments or under medium load conditions, the air conditioning system provides independent cooling, while the power battery pack cooling system is connected in parallel with the motor and motor controller cooling system: the high-temperature coolant flowing through the power battery pack is cooled by the radiator, and the cooled coolant continues to circulate in this circuit; the motor and motor controller are connected in parallel, and the high-temperature coolant flowing through the motor and motor controller is cooled by the radiator, and then continues to circulate in this circuit.

6. The wide-temperature-range thermal management control method for a new energy vehicle motor controller coupled with air conditioning according to claim 3, characterized in that... In extreme high-temperature environments or high-load conditions, the power battery pack cooling system is connected in parallel with the motor and motor controller cooling system and coupled with the air conditioning system: the refrigerant of the air conditioning system flows to the evaporator (4), the first chiller and the second chiller after passing through the expansion valve; the coolant flowing through the power battery pack (13) exchanges heat with the refrigerant of the air conditioning system through the second chiller to achieve a significant reduction in temperature, and then continues to circulate in the above loop; the coolant in the motor and motor controller cooling system flows from the main circuit into two branches: one branch cools the motor controller and then flows through the first chiller, exchanges heat with the low-temperature refrigerant of the air conditioning system and then flows into the main circuit; the other branch cools the motor and then flows through the first radiator to cool down and then flows into the main circuit.

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