Energy-saving heat pump integrated heat management system

Abstract

The invention relates to the technical field of vehicle heat management, in particular to an energy-saving heat pump integrated heat management system which comprises a pipeline module, a motor electric control heat dissipation module, a cab refrigerating and heating module, a single battery refrigerating and heating module and a control module. Cooling liquid circulates to dissipate heat; according to the system, parts with the same functional attributes are integrated, the number of the parts is reduced, the cost is reduced, the efficiency is improved, the cost and energy consumption of the whole vehicle are reduced, refrigerants are directly communicated with the liquid cooling plate, the energy consumption of the whole vehicle is reduced, and the energy consumption of the whole vehicle is reduced. The battery pack is cooled and heated, the heat exchange efficiency is effectively improved, heat absorption and heat release are conducted on a refrigerant, PTC is omitted, waste heat generated by a motor loop is subjected to heat exchange with the refrigerant, the overall temperature of the refrigerant is increased, the waste heat of a motor is utilized, heat loss is avoided, and the endurance mileage of a vehicle is increased.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle thermal management, and in particular to an energy-saving heat pump integrated thermal management system. Background Art

[0002] At present, the thermal management system of new energy commercial vehicles has a low degree of integration. Some thermal management systems of new energy commercial vehicles still use independent cooling systems. The motor and electronic control, battery, and cockpit use independent circuits for thermal management control. This makes the system occupy a large space, the vehicle weight is heavy, and the use and maintenance costs are high.

[0003] In existing integrated thermal management systems, the heating of batteries and cabs often uses PTC to heat the coolant, and then uses a liquid cooling plate or LCC to exchange heat between the battery pack and the refrigerant. This heating mode is inefficient, has severe heat loss, and has high operating and maintenance costs. At the same time, the algorithm control for PTC is relatively complex, the algorithm development cycle is long, and the actual use effect does not achieve the expected purpose, and the heating efficiency is low. In existing thermal management systems, there are also some components with the same functional attributes, which makes the overall system larger, requires a larger space, and significantly increases the weight of the vehicle, seriously affecting the vehicle's endurance. Summary of the invention

[0004] The purpose of the present invention is to provide an energy-saving heat pump integrated thermal management system, aiming to solve the problem that the PTC heating coolant method of the integrated thermal management system causes serious heat loss and affects the vehicle's endurance.

[0005] To achieve the above-mentioned object, the present invention provides an energy-saving heat pump integrated thermal management system, comprising a pipeline module, a motor electronically controlled heat dissipation module, a cab cooling and heating module, a single battery cooling and heating module and a control module, wherein the pipeline module is respectively connected to the motor electronically controlled heat dissipation module, the cab cooling and heating module and the single battery cooling and heating module, and the control module is respectively connected to the motor electronically controlled heat dissipation module, the cab cooling and heating module, the single battery cooling and heating module and the pipeline module;

[0006] The control module is used to control the operation of the pipeline module, the motor electronic control heat dissipation module, the cab cooling and heating module and the single battery cooling and heating module;

[0007] The pipeline module is used to connect the motor electronic control heat dissipation module, the cab cooling and heating module and the single battery cooling and heating module to ensure the normal operation of the system;

[0008] The motor electronic control heat dissipation module is used to dissipate heat through the circulation of coolant when the motor electronic control temperature is too high;

[0009] The cab cooling and heating module is used to heat or cool the cab and recycle waste heat to meet the cab heating and cooling needs;

[0010] The single battery cooling and heating module is used to heat or cool the battery to meet the battery heating and cooling requirements.

[0011] Wherein, the cab cooling and heating module includes a cab cooling unit, a cab heating unit and a waste heat recovery unit;

[0012] The cab refrigeration unit is used to cool the cab;

[0013] The cab heating unit is used to heat the cab;

[0014] The waste heat recovery unit is used to absorb waste heat in the coolant.

[0015] Wherein, the single-battery cooling and heating module includes a single-battery cooling unit and a single-battery heating unit;

[0016] The single battery refrigeration unit is used to cool the battery;

[0017] The single battery heating unit is used to heat the battery.

[0018] Wherein, the energy-saving heat pump integrated thermal management system further includes a first temperature sensor, a second temperature sensor, a third temperature sensor and a pressure sensor, and the first temperature sensor, the second temperature sensor, the third temperature sensor and the pressure sensor are respectively connected to the pipeline module;

[0019] The first temperature sensor is used to measure the refrigerant temperature at the evaporator outlet at normal times and calculate the evaporator outlet superheat together with the pressure sensor;

[0020] The second temperature sensor is used to measure the refrigerant temperature at the outlet of the cooling plate during refrigeration, and calculate the superheat degree at the outlet of the cooling plate together with the pressure sensor;

[0021] The third temperature sensor is used to measure the temperature of the coolant;

[0022] The pressure sensor is used to measure the coolant pressure and cooperate with the first temperature sensor and the second temperature sensor to calculate the outlet superheat.

[0023] Wherein, the energy-saving heat pump integrated thermal management system further includes a first temperature and pressure sensor, a second temperature and pressure sensor and a third temperature and pressure sensor, and the first temperature and pressure sensor, the second temperature and pressure sensor and the third temperature and pressure sensor are respectively connected to the pipeline module;

[0024] The first temperature and pressure sensor is used to measure the exhaust temperature and exhaust pressure of the compressor;

[0025] The second temperature and pressure sensor is used to measure the refrigerant pressure and refrigerant temperature at the condenser outlet;

[0026] The third temperature and pressure sensor is used to measure the coolant pressure and coolant temperature at the outlet of the liquid cooling plate during heating.

[0027] The present invention provides an energy-saving heat pump integrated thermal management system, wherein the control module controls the operation of the pipeline module, the motor electronic control heat dissipation module, the cab cooling and heating module and the single battery cooling and heating module; the pipeline module is connected to the motor electronic control heat dissipation module, the cab cooling and heating module and the single battery cooling and heating module to ensure the normal operation of the system; when the motor electronic control temperature is too high, the motor electronic control heat dissipation module dissipates heat through coolant circulation; the cab cooling and heating module heats or cools the cab and can recycle waste heat to meet the heating and cooling requirements of the cab; the single battery cooling and heating module heats or cools the battery to meet the heating and cooling requirements of the battery. The system integrates components with the same functional attributes, minimizes the number of parts, simplifies the architecture and control, reduces costs and improves efficiency, and achieves In order to reduce the cost and energy consumption of the whole vehicle, compared with most of the existing thermal management system structures, the Chiller and the battery pack coolant loop are deleted. The battery pack is cooled and heated by passing the refrigerant directly through the liquid cold plate. This solution can effectively improve the heat exchange efficiency and simplify the overall architecture. The outdoor condenser is deleted, and the high-temperature and high-pressure refrigerant is passed into the water-cooled condenser LCC for heat exchange. Since the coolant in the water-cooled condenser is a radiator loop, the radiator can be used as an outdoor condenser, and the refrigerant is absorbed and released through the outdoor radiator. The PTC is deleted. When the refrigerant temperature is not enough in winter, the waste heat generated by the motor loop can be exchanged with the refrigerant through the water-cooled condenser, thereby increasing the overall temperature of the refrigerant and meeting the compressor usage requirements. In this way, the motor waste heat can be effectively utilized, heat loss can be avoided, and the vehicle's cruising range can be increased. The problem of the integrated thermal management system PTC heating coolant method, which causes serious heat loss and affects the vehicle's cruising range, is solved. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0029] Figure 1It is a connection diagram of modules required for an energy-saving heat pump integrated thermal management system provided by the present invention.

[0030] Figure 2 It is a schematic diagram of component connections of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0031] Figure 3 It is a schematic diagram of a motor electronically controlled heat dissipation mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0032] Figure 4 It is a schematic diagram of a single cab refrigeration mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0033] Figure 5 It is a schematic diagram of a single-battery cooling mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0034] Figure 6 It is a schematic diagram of a cab & battery cooling mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0035] Figure 7 It is a schematic diagram of a single cab heating (heat pump) mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0036] Figure 8 It is a schematic diagram of a single cab heating (heat pump + waste heat recovery) mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0037] Fig. 9 It is a circuit diagram of a single cab heating (heat pump + heat dissipation) mode of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0038] Fig.10 It is a schematic diagram of a single-battery heating (heat pump) mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0039] Fig.11 It is a schematic diagram of a single-battery heating (heat pump + motor waste heat) mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0040] Fig.12 It is a schematic diagram of a single-battery heating (heat pump + heat dissipation) mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0041] Fig.13 It is a schematic diagram of a cab & battery heating (heat pump) mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0042] Fig.14It is a schematic diagram of a cab & battery heating (heat pump + motor waste heat) mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0043] Fig.15 It is a schematic diagram of a cab & battery heating (motor waste heat + heat dissipation) mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0044] Fig.16 It is a schematic diagram of a dehumidification mode circuit of an energy-saving heat pump integrated thermal management system provided by the present invention.

[0045] In the figure: 10-pipeline module, 20-motor electronic control cooling module, 30-cab cooling and heating module, 40-single battery cooling and heating module, 50-control module, 31-cab cooling unit, 32-cab heating unit, 33-waste heat recovery unit, 41-single battery cooling unit, 42-single battery heating unit, 60-first temperature sensor, 70-second temperature sensor, 80-third temperature sensor, 90-pressure sensor, 100-first temperature and pressure sensor, 110-second temperature and pressure sensor, 120-third temperature and pressure sensor. DETAILED DESCRIPTION

[0046] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0047] See also Figures 1 to 16 The present invention provides an energy-saving heat pump integrated thermal management system, comprising a pipeline module 10, a motor electronically controlled heat dissipation module 20, a cab cooling and heating module 30, a single battery cooling and heating module 40 and a control module 50, wherein the pipeline module 10 is respectively connected to the motor electronically controlled heat dissipation module 20, the cab cooling and heating module 30 and the single battery cooling and heating module 40, and the control module 50 is respectively connected to the motor electronically controlled heat dissipation module 20, the cab cooling and heating module 30, the single battery cooling and heating module 40 and the pipeline module 10;

[0048] The control module 50 is used to control the operation of the pipeline module 10, the motor electronic control heat dissipation module 20, the cab cooling and heating module 30 and the single battery cooling and heating module 40;

[0049] The pipeline module 10 is used to connect the motor electronic control heat dissipation module 20, the cab cooling and heating module 30 and the single battery cooling and heating module 40 to ensure the normal operation of the system;

[0050] The motor electronic control heat dissipation module 20 is used to dissipate heat through the circulation of coolant when the motor electronic control temperature is too high;

[0051] The cab cooling and heating module 30 is used to heat or cool the cab and recycle waste heat to meet the cab heating and cooling requirements;

[0052] The single battery cooling and heating module 40 is used to heat or cool the battery to meet the heating and cooling requirements of the battery.

[0053] In the embodiment of the present invention, the control module 50 controls the operation of the pipeline module 10, the motor electronic control heat dissipation module 20, the cab cooling and heating module 30 and the single battery cooling and heating module 40; the pipeline module 10 is connected to the motor electronic control heat dissipation module 20, the cab cooling and heating module 30 and the single battery cooling and heating module 40 to ensure the normal operation of the system; when the motor electronic control temperature is too high, the motor electronic control heat dissipation module 20 dissipates heat through coolant circulation; the cab cooling and heating module 30 heats or cools the cab and can recycle waste heat to meet the heating and cooling requirements of the cab; the single battery cooling and heating module 40 heats or cools the battery to meet the heating and cooling requirements of the battery. The system integrates components with the same functional attributes, minimizes the number of parts, simplifies the architecture and control, and reduces costs. Improve efficiency and achieve the goal of reducing vehicle cost and energy consumption. Compared with most existing thermal management system structures, the Chiller and battery pack coolant loop are deleted. The battery pack is cooled and heated by passing the refrigerant directly through the liquid cold plate. This solution can effectively improve the heat exchange efficiency and simplify the overall architecture. The outdoor condenser is deleted, and the high-temperature and high-pressure refrigerant is passed into the water-cooled condenser LCC for heat exchange. Since the coolant in the water-cooled condenser is a radiator loop, the radiator can be used as an outdoor condenser, and the refrigerant is absorbed and released through the outdoor radiator. PTC is deleted. When the refrigerant temperature is not enough in winter, the waste heat generated by the motor loop can be exchanged with the refrigerant through the water-cooled condenser, thereby increasing the overall temperature of the refrigerant and meeting the compressor usage requirements. In this way, the motor waste heat can be effectively utilized to avoid heat loss and increase the vehicle's cruising range. The problem of PTC heating coolant in the integrated thermal management system is solved, which causes serious heat loss and affects the vehicle's cruising range.

[0054] Furthermore, the cab cooling and heating module 30 includes a cab cooling unit 31, a cab heating unit 32 and a waste heat recovery unit 33;

[0055] The cab refrigeration unit 31 is used to cool the cab;

[0056] The cab heating unit 32 is used to heat the cab;

[0057] The waste heat recovery unit 33 is used to absorb waste heat in the coolant.

[0058] In the embodiment of the present invention, the cab refrigeration unit 31 cools the cab, the cab heating unit 32 heats the cab, and the waste heat recovery unit 33 is used to absorb waste heat in the coolant.

[0059] Further, the single battery cooling and heating module 40 includes a single battery cooling unit 41 and a single battery heating unit 42;

[0060] The single battery refrigeration unit 41 is used to cool the battery;

[0061] The single battery heating unit 42 is used to heat the battery.

[0062] In the embodiment of the present invention, the single battery refrigeration unit 41 cools the battery; and the single battery heating unit 42 heats the battery.

[0063] Further, the energy-saving heat pump integrated thermal management system further includes a first temperature sensor 60, a second temperature sensor 70, a third temperature sensor 80 and a pressure sensor 90, and the first temperature sensor 60, the second temperature sensor 70, the third temperature sensor 80 and the pressure sensor 90 are respectively connected to the pipeline module 10;

[0064] The first temperature sensor 60 is used to measure the refrigerant temperature at the evaporator outlet at ordinary times, and calculate the evaporator outlet superheat together with the pressure sensor 90;

[0065] The second temperature sensor 70 is used to measure the refrigerant temperature at the outlet of the cooling plate during refrigeration, and calculate the superheat degree at the outlet of the cooling plate together with the pressure sensor 90;

[0066] The third temperature sensor 80 is used to measure the temperature of the coolant;

[0067] The pressure sensor 90 is used to measure the coolant pressure, and cooperates with the first temperature sensor 60 and the second temperature sensor 70 to calculate the outlet superheat.

[0068] In an embodiment of the present invention, the first temperature sensor 60 is used to measure the refrigerant temperature at the evaporator outlet at normal times, and calculates the evaporator outlet superheat together with the pressure sensor 90; the second temperature sensor 70 is used to measure the refrigerant temperature at the cooling plate outlet during refrigeration, and calculates the cooling plate outlet superheat together with the pressure sensor 90; the third temperature sensor 80 is used to measure the temperature of the coolant; the pressure sensor 90 is used to measure the coolant pressure, and cooperates with the first temperature sensor 60 and the second temperature sensor 70 to calculate the outlet superheat.

[0069] Further, the energy-saving heat pump integrated thermal management system further includes a first temperature and pressure sensor 100, a second temperature and pressure sensor 110 and a third temperature and pressure sensor 120, wherein the first temperature and pressure sensor 100, the second temperature and pressure sensor 110 and the third temperature and pressure sensor 120 are respectively connected to the pipeline module 10;

[0070] The first temperature and pressure sensor 100 is used to measure the exhaust temperature and exhaust pressure of the compressor;

[0071] The second temperature and pressure sensor 110 is used to measure the refrigerant pressure and refrigerant temperature at the condenser outlet;

[0072] The third temperature and pressure sensor 120 is used to measure the coolant pressure and coolant temperature at the outlet of the liquid cooling plate during heating.

[0073] In an embodiment of the present invention, the first temperature and pressure sensor 100 is used to measure the exhaust temperature and exhaust pressure of the compressor; the second temperature and pressure sensor 110 is used to measure the refrigerant pressure and refrigerant temperature at the condenser outlet; the third temperature and pressure sensor 120 is used to measure the coolant pressure and coolant temperature at the liquid cooling plate outlet during heating.

[0074] In order to better understand the present technical solution, the following embodiments are provided for further explanation:

[0075] Table 1 is a description of the components of the modules used in the energy-saving heat pump integrated thermal management system.

[0076]

[0077]

[0078] Considering the cooling / heating of the cab, the cooling / heating of the battery pack, and the cooling requirements of the motor alone, different coupling modes exist under the different cooling and heating requirements of each module. The specific working modes are as follows:

[0079] Motor electronic control cooling mode (motor electronic control cooling module 20 operates, component circuit connection as follows Figure 3 (shown)

[0080] The motor electronic control temperature is too high, water pump 1, water pump 2 and the fan are turned on, and the motor heat is taken away by the coolant circulation and discharged to the outside through the radiator on the motor circuit.

[0081] Working conditions: In charging mode or idling condition, when the motor electronic control temperature is ≥40℃.

[0082] Execution action: The water pump is turned on, channels 1 and 3 of the three-way valve are connected, and the fan is working.

[0083] Single cab cooling mode (cabin cooling unit 31 is in operation, component circuit connections are as follows Figure 4 (shown)

[0084] The cab has cooling requirements, but the battery has no cooling or heating requirements. The high-temperature and high-pressure refrigerant releases heat through the outdoor radiator, changes to a low-temperature and low-pressure state through the electronic expansion valve EXV1, and absorbs heat through the indoor evaporator to achieve a cooling effect in the cab.

[0085] Working conditions: The air conditioning cooling switch is turned on, the knob is turned to the cooling position, and the maximum battery temperature is ≤35℃.

[0086] Execution action: SOV1 is opened, SOV2, 3, and 4 are closed, the opening of the electronic expansion valve EXV1 is adjusted according to the subcooling of the refrigerant at the evaporative condenser, EXV2 and 3 are closed, the fan and compressor are started, water pump 2 is turned on, and the three-way valve 1 and 2 channels are connected.

[0087] Single battery cooling mode (single battery cooling unit 41 operates, component circuit connections are as follows Figure 5 (shown)

[0088] When there is no cooling demand in the cab and the battery temperature is too high and needs to be cooled, the high-temperature and high-pressure refrigerant releases heat through the outdoor radiator, passes through the electronic expansion valve EXV3 and becomes a low-temperature and low-pressure state, and cools the battery pack through the liquid cooling plate.

[0089] Working conditions: The air conditioning refrigeration switch is turned off, the knob is turned to the cooling position, and the maximum battery temperature is greater than 35°C.

[0090] Execution action: SOV1 and 4 are opened, SOV2 and 3 are closed, the opening of the electronic expansion valve EXV3 is adjusted according to the subcooling degree of the refrigerant at the liquid cooling plate, EXV1 and 2 are closed, the fan and compressor are started, water pump 2 is turned on, and the three-way valve 1 and 2 channels are connected.

[0091] Cab & Battery Cooling Mode (cab cooling unit 31 and single battery cooling unit 41 operate, component circuit connections are as follows Figure 6 (shown)

[0092] When the cab and the battery need cooling at the same time, the high-temperature and high-pressure refrigerant releases heat through the outdoor radiator, changes to a low-temperature and low-pressure state through the electronic expansion valves EXV1 and 3, and passes through the liquid cooling plate and the indoor evaporator respectively to cool the cab and the battery pack.

[0093] Working conditions: The air conditioning cooling switch is turned on, the knob is turned to the cooling position, and the maximum battery temperature is greater than 35°C.

[0094] Execution action: SOV1 and 4 are opened, SOV2 and 3 are closed, the opening of the electronic expansion valve EXV3 is adjusted according to the subcooling of the refrigerant at the liquid cooling plate, the opening of the electronic expansion valve EXV1 is adjusted according to the subcooling of the refrigerant at the evaporative condenser, EXV2 is closed, the fan and compressor are started, water pump 2 is turned on, and the three-way valve 1 and 2 channels are connected.

[0095] Single cab heating (heat pump) mode (cab heating unit 32 operates, component circuit connections are as follows Figure 7 (shown)

[0096] The cab needs to be heated, but the battery has no need for cooling or heating. When the temperature difference between the water temperature and the ambient temperature is insufficient, the refrigerant absorbs heat from the environment and heats up through the outdoor radiator. The temperature difference between the refrigerant and the water temperature is very small. Therefore, the water pump is turned off and only heat is absorbed from the outdoor environment.

[0097] Working conditions: 0<water temperature<25℃ and water temperature - ambient temperature<5℃.

[0098] Execution action: SOV2 and 3 are opened, SOV1 and 4 are closed, the opening of the electronic expansion valve EXV2 is adjusted according to the superheat of the refrigerant at the indoor condenser, EXV1 and 3 are closed, the fan and compressor are started, water pump 2 is turned on, and the three-way valve 1 and 2 channels are connected.

[0099] Single cab heating (heat pump + waste heat recovery) mode (cab heating unit 32 and waste heat unit operate, component circuit connection as follows Figure 8 (shown)

[0100] When the air conditioner is turned on for heating, the battery has no cooling or heating needs, the ambient temperature is too low, or the water temperature is high enough, the fan is turned off and the motor coolant circuit is connected. The refrigerant no longer absorbs heat from the outside, but absorbs heat from the coolant when passing through the LCC.

[0101] Working conditions: water temperature ≥25℃.

[0102] Execution action: SOV2 and 3 are opened, SOV1 and 4 are closed, the opening of the electronic expansion valve EXV2 is adjusted according to the superheat of the refrigerant at the indoor condenser, EXV1 and 3 are closed, the three-way valve 2 and 3 channels are connected, and the water pump 1 and the compressor are started.

[0103] Single cab heating (heat pump + cooling) mode (cab heating unit 32 operates, component circuit connections are as follows Fig. 9 (shown)

[0104] The air conditioner is turned on for heating, and the battery has no cooling or heating requirements. However, when the water temperature is too high, the fan is turned on, and the three-way valve is fully opened. Part of the coolant is diverted to the radiator for heat dissipation, and the other part transfers heat to the refrigerant through the LCC.

[0105] Working conditions: 0<water temperature<25℃ and water temperature-ambient temperature ≥5℃ and ambient temperature>-10℃.

[0106] Execution action: SOV2 and 3 are opened, SOV1 and 4 are closed, the opening of the electronic expansion valve EXV2 is adjusted according to the superheat of the refrigerant at the indoor condenser, EXV1 and 3 are closed, the three-way valve 1, 2, and 3 channels are connected, and the water pump 1, fan, and compressor are started.

[0107] Single battery heating (heat pump) mode (single battery heating unit 42 operates, component circuit connections are as follows Fig.10 (shown)

[0108] There is no demand for cooling or heating in the cab, but there is a demand for heating in the battery. When the temperature difference between the water temperature and the ambient temperature is insufficient, the compressor, fan and water pump 2 are turned on, and the refrigerant absorbs heat from the external environment.

[0109] Working conditions: 0≤water temperature<25℃ and water temperature-ambient temperature<5℃.

[0110] Execution action: SOV2 and 3 are opened, SOV1 and 4 are closed, the opening of the electronic expansion valve EXV3 is adjusted according to the superheat of the refrigerant at the liquid cooling plate, EXV1 and 2 are closed, water pump 2, fan and compressor are started, and the three-way valve 1 and 2 channels are connected.

[0111] Single battery heating (heat pump + motor waste heat) mode (single battery heating unit 42 operates, component circuit connection as follows Fig.11 (shown)

[0112] There is no demand for cooling or heating in the cab, but there is a demand for heating the battery. When the ambient temperature is too low, turn off the fan, and the refrigerant releases heat through the liquid cooling plate and then absorbs the heat in the coolant of the motor circuit through the LCC.

[0113] Working conditions: 0<water temperature<25℃ and water temperature-ambient temperature≥5℃ and ambient temperature<-10℃.

[0114] Execution action: SOV2 and 3 are opened, SOV1 and 4 are closed, the opening of the electronic expansion valve EXV3 is adjusted according to the superheat of the refrigerant at the liquid cooling plate, EXV1 and 2 are closed, the three-way valve channels 2 and 3 are connected, and the water pump 1 and the compressor are started.

[0115] Single battery heating (heat pump + cooling) mode (single battery heating unit 42 operates, component circuit connection as follows Fig.12 (shown)

[0116] The battery pack needs to be heated, and the cab has no cooling or heating requirements. However, when the water temperature is too high, the fan is turned on, the three-way valve is fully opened, part of the coolant is diverted to the radiator for heat dissipation, and the other part transfers heat to the refrigerant through the LCC.

[0117] Working conditions: 0<water temperature<25℃ and water temperature-ambient temperature ≥5℃ and ambient temperature>-10℃.

[0118] Execution action: SOV2 and 3 are opened, SOV1 and 4 are closed, the opening of the electronic expansion valve EXV2 is adjusted according to the superheat of the refrigerant at the indoor condenser, EXV1 and 3 are closed, the three-way valve 1, 2, and 3 channels are connected, and the water pump 1, fan, and compressor are started.

[0119] Cab & Battery Heating (Heat Pump) Mode (Cab Heating Unit 32 and Single Battery Heating Unit 42 are in operation, component circuit connections are as follows Fig.13 (shown)

[0120] When the cab needs to be heated, the battery needs to be heated, and the ambient temperature is moderate, turn on the fan, and the refrigerant first absorbs heat from the environment through the outdoor heat exchanger, then absorbs heat from the coolant through the LCC, and then supplies heat to the cab and battery at the same time.

[0121] Working conditions: 0≤water temperature<25℃ and motor water temperature - battery water temperature<5℃ and ambient temperature>-10℃.

[0122] Execution action: SOV2 and 3 are opened, SOV1 and 4 are closed, the opening of the electronic expansion valve EXV3 is adjusted according to the superheat of the refrigerant at the liquid cooling plate, the opening of the electronic expansion valve EXV2 is adjusted according to the superheat of the refrigerant at the indoor condenser, EXV1 is closed, the three-way valve 1 and 2 channels are connected, and the water pump 2, fan, and compressor are started.

[0123] Cab & battery heating (heat pump + motor waste heat) mode (cab heating unit 32 and single battery heating unit 42 operate, component circuit connection as follows Fig.14 (shown)

[0124] The cab needs to be heated, the battery needs to be heated, and when the ambient temperature is too low, the fan is turned off. After the refrigerant releases heat through the liquid cooling plate, it absorbs the heat in the motor circuit coolant through the LCC.

[0125] Working conditions: 0<water temperature<25℃ and water temperature-ambient temperature≥5℃ and ambient temperature<-10℃.

[0126] Execution action: SOV2 and 3 are opened, SOV1 and 4 are closed, the opening of the electronic expansion valve EXV3 is adjusted according to the superheat of the refrigerant at the liquid cooling plate, the opening of the electronic expansion valve EXV2 is adjusted according to the superheat of the refrigerant at the indoor condenser, EXV1 is closed, the three-way valve channels 2 and 3 are connected, and the water pump 1 and the compressor are started.

[0127] Cab & battery heating (motor waste heat + heat dissipation) mode (cab heating unit 32 and single battery heating unit 42 operate, component circuit connection as follows Fig.15 (shown)

[0128] The cab has a heating demand, the battery has a heating demand, and when the coolant temperature is too high, the three-way valve is fully opened, part of the coolant is diverted to the radiator to release heat, and part of the coolant passes through the LCC to transfer the heat to the refrigerant, and then supplies the indoor condenser and liquid cooling plate to heat the interior and battery pack.

[0129] Working conditions: water temperature ≥35℃.

[0130] Execution action: SOV2 and 3 are opened, SOV1 and 4 are closed, the opening of the electronic expansion valve EXV3 is adjusted according to the superheat of the refrigerant at the liquid cooling plate, the opening of the electronic expansion valve EXV2 is adjusted according to the superheat of the refrigerant at the indoor condenser, EXV1 is closed, the three-way valve 1, 2, and 3 channels are connected, and the water pump 1, fan, and compressor are started.

[0131] Dehumidification mode (component circuit connection as follows Fig.16 (shown)

[0132] When the dehumidification switch is turned on, the indoor evaporator and indoor condenser are turned on at the same time. The air with high humidity is first cooled down through the evaporator, the water is condensed and discharged, and then passes through the indoor condenser to absorb heat and heat up to become dry air.

[0133] Working condition: when the dehumidification switch is turned on.

[0134] Execution action: SOV3 is opened, SOV1, 2, and 4 are closed, the opening of the electronic expansion valve EXV1 is adjusted according to the superheat of the refrigerant at the indoor evaporator, the opening of the electronic expansion valve EXV2 is adjusted according to the superheat of the refrigerant at the indoor condenser, EXV1 is closed, and the compressor is started.

[0135] In order to reduce the overall energy consumption of the system, the system removes the W-PTC element and uses waste heat recovery to provide the necessary heat for the compressor to start up for the refrigerant circuit. The specific implementation is as follows Figure 2 shown.

[0136] The red mark is the refrigerant circuit, and the orange mark is the motor electronic control coolant circuit. When the external ambient temperature is low, the coolant temperature is higher than the ambient temperature. At this time, it is impossible to obtain heat from the outside by absorbing heat through the radiator. Therefore, at this time, three-way valves 2 and 3 are connected, and water pump 1 starts to work, completing the self-circulation of the motor electronic control circuit coolant. After releasing heat through the indoor condenser and throttling the electronic expansion valve, the high-temperature and high-pressure refrigerant becomes a low-temperature and low-pressure refrigerant. It needs to be heated and pressurized before entering the compressor to start the compressor normally. Because the outside temperature is low, the radiator coolant circuit cannot be opened to absorb heat from the outside. It can only be recovered through the heat generated by the motor electronic control when it is working. The refrigerant is heated by the water-cooled condenser LCC to heat the refrigerant and pressurize it, which is enough to meet the normal start-up of the compressor.

[0137] On the basis of the existing heat pump system, the outdoor condenser is removed. Since the outdoor radiator in the coolant loop and the outdoor condenser in the refrigerant loop have similar functions, they can be integrated into one part. The water-cooled condenser LCC completes the heat exchange between the refrigerant and the coolant, thus replacing the outdoor condenser.

[0138] The battery side uses a refrigerant direct liquid cooling plate method for heat exchange. Compared with the existing system using Chiller for heat exchange, the heat exchange efficiency is significantly improved, while saving system installation space and reducing system use costs.

[0139] Thermal system control integration of the whole vehicle: Develop thermal management from the perspective of whole vehicle energy management, absorb as much energy as possible from the environment and waste heat, with high energy efficiency and low cost. In theory, it can significantly increase the driving range, thereby improving the competitiveness of the whole vehicle.

[0140] The above disclosure is only a preferred embodiment of an energy-saving heat pump integrated thermal management system of the present invention. Of course, it cannot be used to limit the scope of rights of the present invention. Ordinary technicians in this field can understand that all or part of the processes of the above embodiments and equivalent changes made according to the claims of the present invention still fall within the scope of the invention.

Claims

1. An energy-saving heat pump integrated thermal management system, characterized in that ； It includes a pipeline module, a motor electronic control heat dissipation module, a cab cooling and heating module, a single battery cooling and heating module and a control module, wherein the pipeline module is respectively connected to the motor electronic control heat dissipation module, the cab cooling and heating module and the single battery cooling and heating module, and the control module is respectively connected to the motor electronic control heat dissipation module, the cab cooling and heating module, the single battery cooling and heating module and the pipeline module; The control module is used to control the operation of the pipeline module, the motor electronic control heat dissipation module, the cab cooling and heating module and the single battery cooling and heating module; The pipeline module is used to connect the motor electronic control heat dissipation module, the cab cooling and heating module and the single battery cooling and heating module to ensure the normal operation of the system; The motor electronic control heat dissipation module is used to dissipate heat through the circulation of coolant when the motor electronic control temperature is too high; The cab cooling and heating module is used to heat or cool the cab and recycle waste heat to meet the cab heating and cooling needs; The single battery cooling and heating module is used to heat or cool the battery to meet the battery heating and cooling requirements.

2. The energy-saving heat pump integrated thermal management system according to claim 1, characterized in that; The cab cooling and heating module includes a cab cooling unit, a cab heating unit and a waste heat recovery unit; The cab refrigeration unit is used to cool the cab; The cab heating unit is used to heat the cab; The waste heat recovery unit is used to absorb waste heat in the coolant.

3. The energy-saving heat pump integrated thermal management system according to claim 1, characterized in that ； The single-battery cooling and heating module includes a single-battery cooling unit and a single-battery heating unit; The single battery refrigeration unit is used to cool the battery; The single battery heating unit is used to heat the battery.

4. The energy-saving heat pump integrated thermal management system according to claim 1, characterized in that ； The energy-saving heat pump integrated thermal management system further includes a first temperature sensor, a second temperature sensor, a third temperature sensor and a pressure sensor, wherein the first temperature sensor, the second temperature sensor, the third temperature sensor and the pressure sensor are respectively connected to the pipeline module; The first temperature sensor is used to measure the refrigerant temperature at the evaporator outlet at normal times and calculate the evaporator outlet superheat together with the pressure sensor; The second temperature sensor is used to measure the refrigerant temperature at the outlet of the cooling plate during refrigeration, and calculate the superheat degree at the outlet of the cooling plate together with the pressure sensor; The third temperature sensor is used to measure the temperature of the coolant; The pressure sensor is used to measure the coolant pressure and cooperate with the first temperature sensor and the second temperature sensor to calculate the outlet superheat.

5. The energy-saving heat pump integrated thermal management system according to claim 1, characterized in that ； The energy-saving heat pump integrated thermal management system further includes a first temperature and pressure sensor, a second temperature and pressure sensor, and a third temperature and pressure sensor, wherein the first temperature and pressure sensor, the second temperature and pressure sensor, and the third temperature and pressure sensor are respectively connected to the pipeline module; The first temperature and pressure sensor is used to measure the exhaust temperature and exhaust pressure of the compressor; The second temperature and pressure sensor is used to measure the refrigerant pressure and refrigerant temperature at the condenser outlet; The third temperature and pressure sensor is used to measure the coolant pressure and coolant temperature at the outlet of the liquid cooling plate during heating.

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