A heat dissipation method for a motor controller of a new energy vehicle

Abstract

The present invention relates to the field of controller heat dissipation, and specifically to a heat dissipation method for a motor controller of a new energy vehicle. The heat dissipation method reasonably selects air cooling or liquid cooling according to the external environment to quickly control the actual temperature of the motor controller below a threshold temperature. Then, by further adjusting the heat dissipation of a heat dissipation module, the heat generation efficiency of the motor controller is balanced with the heat dissipation efficiency of the heat dissipation module, thereby keeping the temperature of the motor controller stable and reducing temperature fluctuations during the heat dissipation process. In the event of cooling and heat dissipation failure, a fault diagnosis and an alarm are performed, thereby reducing costs while achieving good heat dissipation and temperature control effects, high equipment operation reliability, and a reasonable and efficient heat dissipation strategy.

Description

Technical Field

[0001] The present invention relates to the field of controller heat dissipation, and in particular to a heat dissipation method for a motor controller of a new energy vehicle. Background Art

[0002] The motor controller of a new energy vehicle is the core control device that controls the motor's starting, running, stopping, and speed change. The IGBT is the most important component within the motor controller. The IGBT module controls the motor according to control commands. Due to the high current flowing through the IGBT, the IGBT generates a large amount of heat during operation. Excessive temperature can affect IGBT performance and even cause IGBT failure, which in turn affects the normal operation of the entire control system. Therefore, timely heat dissipation from the controller is necessary. Related technologies generally use a combination of air cooling and liquid cooling to cool and dissipate heat from the motor controller. Air cooling is used when the IGBT temperature exceeds a first temperature threshold, while liquid cooling is used when the IGBT temperature exceeds a second temperature threshold, where the second temperature threshold is greater than the first temperature threshold. However, this method, which relies solely on IGBT temperature to select air cooling or water cooling, fails to properly select a heat dissipation method based on the external environment and fails to balance the heat generation efficiency of the motor controller with the heat dissipation efficiency of the heat dissipation device. This results in large temperature fluctuations in the motor controller. Furthermore, there is no reasonable fault detection measure in the event of heat dissipation failure, resulting in an unreasonable heat dissipation strategy. Summary of the Invention

[0003] In view of the deficiencies of the prior art, the present invention proposes a heat dissipation method for a motor controller of a new energy vehicle to solve the problem that the heat dissipation strategy of the prior heat dissipation method is unreasonable.

[0004] A heat dissipation method for a new energy vehicle motor controller of the present invention specifically comprises the following steps:

[0005] Set the motor controller temperature threshold and the external air humidity threshold;

[0006] Get the actual temperature of the motor controller and the actual humidity of the outside air;

[0007] When the actual temperature of the motor controller is greater than the motor controller temperature threshold, if the actual humidity of the outside air is less than the outside air humidity threshold, the air cooling module of the heat dissipation module is turned on to dissipate heat to the motor controller; if the actual humidity of the outside air is greater than the outside air humidity threshold, the liquid cooling module of the heat dissipation module is turned on to dissipate heat to the motor controller;

[0008] If the actual temperature of the motor controller after cooling is still greater than the motor controller temperature threshold, the fault object is determined and an alarm is issued;

[0009] After heat dissipation, the actual temperature of the motor controller is lower than the temperature threshold of the motor controller, and the heat dissipation of the heat dissipation module is adjusted until the actual temperature of the motor controller remains unchanged.

[0010] Optionally, the liquid cooling module dissipates heat at a preset amount for a preset time, thereby reducing the temperature of the motor controller;

[0011] The air cooling module dissipates heat at a maximum heat dissipation capacity for a preset time, thereby reducing the temperature of the motor controller.

[0012] Optionally, if the actual temperature of the motor controller is still greater than the motor controller temperature threshold after the air cooling module dissipates heat at the maximum heat dissipation for a preset time, the liquid cooling module is turned on and dissipates heat at a preset heat dissipation for a preset time, thereby reducing the temperature of the motor controller.

[0013] Optionally, after the air cooling module dissipates heat at the maximum heat dissipation for a preset time, the actual temperature of the motor controller is lower than a temperature threshold of the motor controller, and the heat dissipation of the air cooling module is reduced until the temperature of the motor controller remains unchanged.

[0014] Optionally, the liquid cooling module dissipates heat at a preset heat dissipation amount for a preset time, and the actual temperature of the motor controller is less than a temperature threshold of the motor controller; the heat dissipation amount of the liquid cooling module is reduced until the temperature of the motor controller remains unchanged.

[0015] Optionally, after the liquid cooling module dissipates heat at a preset amount for a preset time, the actual temperature of the motor controller is still greater than the motor controller temperature threshold;

[0016] Increase the heat dissipation of the liquid cooling module, thereby reducing the temperature of the motor controller.

[0017] Optionally, after the heat dissipation of the liquid cooling module reaches a maximum, if the actual temperature of the motor controller is still greater than a temperature threshold of the motor controller, the liquid cooling module is cleaned.

[0018] Optionally, the liquid cooling module can dissipate heat normally after cleaning, and the motor controller fault alarm;

[0019] After cleaning, the liquid cooling module cannot dissipate heat normally, and a liquid cooling module fault alarm is issued.

[0020] Optionally, the outside air humidity is obtained using a humidity sensor.

[0021] Optionally, the liquid cooling module is cleaned using high pressure air or high pressure water.

[0022] The beneficial effects of the present invention are as follows: a heat dissipation method for a motor controller of a new energy vehicle of the present invention reasonably selects air cooling or liquid cooling according to the external environment, and gives priority to the lower-cost air cooling when environmental conditions permit, so as to reduce costs. At the same time, when dissipating heat, the actual temperature of the motor controller is first quickly controlled to be below the threshold temperature, and then the heat dissipation of the heat dissipation module is further adjusted to balance the heat generation efficiency of the motor controller with the heat dissipation efficiency of the heat dissipation module, thereby keeping the temperature of the motor controller stable, that is, the balance of heat generation and heat dissipation is ensured by combining coarse adjustment and fine adjustment, thereby maintaining the temperature stability of the motor controller and reducing temperature fluctuations during the heat dissipation process; in the case of failure of cooling and heat dissipation, the fault is judged and an alarm is issued, which is convenient for operators to repair the equipment. The present invention integrates environmental factors, temperature control effects, and fault detection to reduce costs while achieving good heat dissipation and temperature control effects, high equipment operation reliability, and a reasonable and efficient heat dissipation strategy. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. 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 any creative work. Those skilled in the art should understand that these drawings are not necessarily drawn to scale.

[0024] Figure 1 This is a flow chart of a heat dissipation method for a new energy vehicle motor controller according to the present invention. DETAILED DESCRIPTION

[0025] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0026] The heat dissipation method of the motor controller of a new energy vehicle of the present invention is used to dissipate heat of the motor controller of a new energy vehicle, and more specifically, to adjust the temperature of the controller of the motor controller of a new energy vehicle. Figure 1 , Figure 1 The flowchart of the heat dissipation method provided in the embodiment of the present invention may specifically include the following steps:

[0027] Step S1: Setting the motor controller temperature threshold and the outside air humidity threshold;

[0028] Step S2: Acquire the actual temperature of the motor controller and the actual humidity of the outside air;

[0029] Step S3: When the actual temperature of the motor controller is greater than the motor controller temperature threshold, if the actual humidity of the outside air is less than the outside air humidity threshold, the air cooling module of the heat dissipation module is turned on to dissipate heat from the motor controller; if the actual humidity of the outside air is greater than the outside air humidity threshold, the liquid cooling module of the heat dissipation module is turned on to dissipate heat from the motor controller;

[0030] Step S4: After heat dissipation, if the actual temperature of the motor controller is still greater than the motor controller temperature threshold, the fault object is determined and an alarm is issued;

[0031] Step S5: After heat dissipation, the actual temperature of the motor controller is less than the motor controller temperature threshold, and the heat dissipation of the heat dissipation module is adjusted until the actual temperature of the motor controller remains unchanged.

[0032] The motor controller temperature threshold is the critical value at which the heat dissipation module activates. In practical applications, the motor controller temperature threshold can be appropriately set based on the different motor controller models. When controlling heat dissipation from the heat dissipation module, the present invention takes into account ambient air humidity and then selects between an air cooling module and a liquid cooling module based on environmental conditions. Air cooling directly utilizes natural resources, and air cooling modules are typically simple in structure and easy to maintain, making air cooling cost-effective. However, the external environment significantly impacts air cooling, particularly humidity. When humidity is high (e.g., during rain), the circulating air can easily dampen the motor controller, affecting performance. Therefore, when heat dissipation is required, the ambient air humidity is first measured. This humidity can be obtained using a humidity sensor. If environmental conditions permit, the air cooling module is preferentially used for heat dissipation. If not, the liquid cooling module is used. This ensures heat dissipation efficiency while improving cost-effectiveness. If the heat dissipation module fails to dissipate heat effectively, the fault is identified and an alarm is issued, allowing personnel to conduct targeted equipment maintenance. If the actual motor controller temperature is less than the motor controller temperature threshold after heat dissipation, the heat dissipation of the heat dissipation module is adjusted to maintain the actual motor controller temperature. This means that by adjusting the heat dissipation of the heat dissipation module, the heat generated by the motor controller is balanced with the heat dissipation of the heat dissipation module, thereby preventing the actual motor controller temperature from changing (remaining unchanged), thereby reducing temperature fluctuations during the heat dissipation process. By integrating environmental factors, temperature control effects, and fault diagnosis, this present invention reduces costs while achieving effective heat dissipation and temperature control, high equipment operational reliability, and a rational and efficient heat dissipation strategy.

[0033] In a further embodiment, the liquid cooling module dissipates heat at a preset heat amount for a preset time, thereby reducing the temperature of the motor controller; the air cooling module dissipates heat at a maximum heat amount for a preset time, thereby reducing the temperature of the motor controller.

[0034] The air-cooling module is greatly affected by the environment, and dissipates heat at the maximum heat dissipation (that is, the maximum wind speed) for a preset time; the liquid-cooling module is less affected by the environment and has a better heat dissipation effect. It dissipates heat at a preset flow rate for a preset time to quickly cool the motor controller and control the temperature of the motor controller below the threshold. The heat dissipation of the heat dissipation module is then adjusted. Through a combination of coarse and fine adjustments, the heat generation efficiency and heat dissipation efficiency are balanced, thereby maintaining the temperature stability of the motor controller and reducing temperature fluctuations during the heat dissipation process.

[0035] The present invention provides a temperature sensor on the motor controller to obtain the temperature of the motor controller, and provides an air humidity sensor on the outside of the air cooling module to obtain the external air humidity.

[0036] Furthermore, the air cooling module can dissipate heat directly from the motor controller via a cooling fan or through a circulating air duct. The liquid cooling module can cool the motor controller using a separate water cooling system or a refrigerant. When using refrigerant cooling, the refrigerant in the motor controller's circulating liquid cooling tube is exchanged with the refrigerant in the vehicle's air conditioning system through a heat exchanger, thereby cooling the motor controller.

[0037] In a further embodiment, if the actual temperature of the motor controller is still greater than a motor controller temperature threshold after the air cooling module dissipates heat at its maximum capacity for a preset period of time, the liquid cooling module is activated and dissipates heat at a preset capacity for a preset period of time, thereby lowering the temperature of the motor controller. If the air cooling module is unable to lower the motor controller temperature below the threshold, the air cooling module and the water cooling module are used simultaneously to control the temperature of the motor controller.

[0038] In a further embodiment, after the air cooling module dissipates heat at the maximum heat dissipation for a preset time, the actual temperature of the motor controller is lower than the motor controller temperature threshold, and the heat dissipation of the air cooling module is reduced until the temperature of the motor controller remains unchanged.

[0039] In a further embodiment, the liquid cooling module dissipates heat at a preset amount for a preset time, and the actual temperature of the motor controller is less than the motor controller temperature threshold; the heat dissipation of the liquid cooling module is reduced until the temperature of the motor controller remains unchanged.

[0040] After the motor controller cools down rapidly, the actual temperature of the motor controller is lower than the motor controller temperature threshold and tends to continue to decrease. At this time, by gradually reducing the heat dissipation of the heat dissipation module, the cooling trend of the motor controller is gradually reduced, and the actual temperature of the motor controller gradually stabilizes. After the actual temperature of the motor controller stabilizes, the heat dissipation module only needs to maintain the current heat dissipation.

[0041] In a further embodiment, after the liquid cooling module dissipates heat at a preset amount for a preset time, the actual temperature of the motor controller is still greater than the motor controller temperature threshold; the heat dissipation of the liquid cooling module is increased to reduce the temperature of the motor controller.

[0042] In a further embodiment, if the actual temperature of the motor controller remains above the motor controller temperature threshold after the liquid cooling module has reached maximum heat dissipation, the liquid cooling module is cleaned. Cleaning the liquid cooling module primarily involves cleaning the outer walls of the module to prevent dust and sludge from prolonged use. Cleaning the module primarily aims to eliminate the effects of external factors on the heat dissipation module. High-pressure air or high-pressure water cleaning can be used for cleaning the module.

[0043] After cleaning, the liquid cooling module can dissipate heat normally, but the temperature of the motor controller cannot be controlled within the threshold. Then the motor controller fault alarm will be issued and the staff can repair the motor controller.

[0044] If the liquid cooling module fails to dissipate heat properly after cleaning, it may be faulty. A fault alarm will be issued, prompting staff to inspect and repair the module. To verify proper heat dissipation, temperature sensors can be installed at the module's inlet and outlet. The temperature difference can be used to determine if the module is functioning properly.

[0045] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A heat dissipation method for a new energy vehicle motor controller, characterized in that: The following steps are involved: Set the motor controller temperature threshold and the external air humidity threshold; Get the actual temperature of the motor controller and the actual humidity of the outside air; When the actual temperature of the motor controller is greater than the motor controller temperature threshold, if the actual humidity of the outside air is less than the outside air humidity threshold, the air cooling module of the heat dissipation module is turned on to dissipate heat from the motor controller at the maximum heat dissipation for a preset time. After the air cooling module dissipates heat at the maximum heat dissipation for the preset time, the actual temperature of the motor controller is still greater than the motor controller temperature threshold, the liquid cooling module is turned on to dissipate heat at the preset heat dissipation for the preset time so that the temperature of the motor controller is controlled below the motor controller temperature threshold. If the actual humidity of the outside air is greater than the outside air humidity threshold, the liquid cooling module of the heat dissipation module is turned on to dissipate heat to the motor controller. When the liquid cooling module dissipates heat, it dissipates heat at a preset amount for a preset time to control the temperature of the motor controller below the motor controller temperature threshold. After the liquid cooling module has dissipated heat at a preset heat dissipation rate for a preset time, the actual temperature of the motor controller is still greater than the motor controller temperature threshold. The liquid cooling module has dissipated heat at a maximum heat dissipation rate for a preset time. After the liquid cooling module dissipates heat at the maximum, the actual temperature of the motor controller is still greater than the motor controller temperature threshold. Clean the outer wall of the liquid cooling module. At the same time, judge whether the liquid cooling module can dissipate heat normally based on the inlet and outlet temperature difference of the liquid cooling module. If the liquid cooling module can dissipate heat normally after cleaning, but the motor controller temperature cannot be controlled within the threshold, a motor controller fault alarm is triggered. If the liquid cooling module cannot dissipate heat normally after cleaning, a liquid cooling module fault alarm is triggered. After heat dissipation, the actual temperature of the motor controller is lower than the motor controller temperature threshold. The heat dissipation of the heat dissipation module is adjusted to balance the heat generation of the motor controller and the heat dissipation of the heat dissipation module, thereby keeping the actual temperature of the motor controller unchanged.

2. A heat dissipation method for a new energy vehicle motor controller according to claim 1, characterized in that: After the air cooling module dissipates heat at the maximum heat dissipation for a preset time, the actual temperature of the motor controller is lower than the motor controller temperature threshold, and the heat dissipation of the air cooling module is reduced until the temperature of the motor controller remains unchanged.

3. The heat dissipation method for a new energy vehicle motor controller according to claim 1, characterized in that: The liquid cooling module dissipates heat at a preset heat dissipation amount for a preset time, and the actual temperature of the motor controller is lower than the motor controller temperature threshold; the heat dissipation amount of the liquid cooling module is reduced until the temperature of the motor controller remains unchanged.

4. The heat dissipation method for a new energy vehicle motor controller according to claim 1, characterized in that: The outside air humidity is obtained using a humidity sensor.

5. The heat dissipation method for a new energy vehicle motor controller according to claim 1, characterized in that: The liquid cooling module is cleaned with high-pressure air or high-pressure water.

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