Thermal management simulation test system and thermal management simulation test method

Abstract

The invention provides a thermal management simulation test system and a thermal management simulation test method, relates to the technical field of automobile thermal management test, and is used for solving the problems that a power battery of an existing simulation thermal management system for a real automobile is lack of protection, and safety accidents are likely to happen. The thermal management simulation test system comprises a simulation box, a protection device and a simulation device. A simulation cabin is formed in the simulation box. And the protection device is arranged in the simulation cabin and is used for arranging the power battery and performing protection when the power battery is in thermal runaway. The simulation device is arranged on the simulation box and used for simulating the actual application environment and devices of the vehicle. The thermal management test simulation system can protect the power battery.

Description

Technical Field

[0001] The present application relates to the technical field of automobile thermal management testing, and in particular to a thermal management simulation testing system and a thermal management simulation testing method. Background Art

[0002] With the improvement of people's living standards, cars have gradually become an essential means of transportation for most families. Among them, electric vehicles have gradually occupied the main automobile market with their advantages such as no pollution and energy saving. The thermal management quality of electric vehicles is an important factor affecting the quality and safety performance of electric vehicles.

[0003] In order to test the thermal management system of electric vehicles, a simulation bench is generally used for testing, and then it is applied on the actual vehicle. For example, CN117191422A discloses a bench system for the thermal management system of a vehicle, which includes: multiple environmental simulation modules, which are respectively used to accommodate the cooling system and air-conditioning system of the thermal management system, and simulate the environmental parameters inside and outside the vehicle; multiple heat source simulation modules, each heat source simulation module is respectively used to simulate the corresponding heat source of the vehicle; a control system, which is respectively connected to the environmental simulation module, the heat source simulation module and the thermal management system, and the control system is used to control the working state of the environmental simulation module, the working state of the heat source simulation module and the working state of the thermal management system, so as to test the working performance of the thermal management system. CN 112033702A discloses a test bench for an intelligent thermal management system of an electric vehicle. It includes: a test vehicle, a driving environment virtual simulation subsystem, which is used to simulate the driving scene of the test vehicle in real time, and the driving scene includes a road environment and a driving environment; a drum test subsystem, which is connected to the driving environment virtual simulation subsystem and is used to simulate the vehicle's driving resistance according to the road environment output by the driving environment virtual simulation subsystem; an environmental chamber subsystem, which is connected to the driving environment virtual simulation subsystem and is used to simulate the driving environment output by the driving environment virtual simulation subsystem.

[0004] However, for the simulated thermal management system of a real vehicle, there is a lack of safety protection measures for the power battery during the experiment, which makes it easy for safety accidents to occur during the experiment. Summary of the invention

[0005] The purpose of the present application is to provide a thermal management simulation test system and a thermal management simulation test method, which are used to solve the problem that the power battery lacks protection and is prone to safety accidents in the existing simulated thermal management system for real vehicles.

[0006] In order to achieve the above object, the technical solution adopted by the present invention is as follows:

[0007] In the first aspect, the embodiment of the present application provides a thermal management simulation test system, including a simulation box, a protective device and a simulation device. The interior of the simulation box forms a simulation cabin. The protective device is arranged in the simulation cabin, and is used to set the power battery and provide protection when the power battery is thermally runaway. The simulation device is arranged on the simulation box, and is used to simulate the actual application environment and devices of the vehicle.

[0008] According to the above technical means, the thermal management simulation test system provided in the embodiment of the present application can place the power battery on the protective device when using the power battery for testing. Since the protective device can provide protection when the power battery is under thermal runaway, it plays a protective role and thus avoids the potential safety hazards caused by thermal runaway of the power battery. In this way, when the simulation device is used to simulate the test of the thermal management test system, the safety of the thermal management simulation test system is guaranteed.

[0009] In a possible embodiment, the protection device may include a protection box and a conveying device. The protection box encloses a receiving chamber with an opening. The receiving chamber is used to place the power battery. An inlet is formed at one end of the conveying device, and an outlet is formed at the other end. The outlet is communicated with the receiving chamber, and the inlet is used to communicate with an external waterway.

[0010] According to the above technical means, through the conveying device, when the power battery has a thermal runaway combustion, an external water source can be introduced into the containing cavity to cool down the power battery and extinguish the fire, thereby avoiding safety accidents.

[0011] In a possible implementation, the protection device further includes a protection control system. The protection control system is electrically connected to the conveying device and is used to control the flow and disconnection of the conveying device. The protection control system is also used to connect to the power battery and detect the operating state of the power battery to control the flow and disconnection of the conveying device according to the operating state of the power battery.

[0012] According to the above technical means, the operating status of the power battery can be detected through the protection control system. When the operating status of the power battery is abnormal, the power battery can be controlled to disconnect the circuit. When risks may occur, the conveying device can be controlled to introduce water to avoid safety accidents and further improve safety performance.

[0013] In a possible implementation, the protection device further includes a lifting and moving platform. The protection box is arranged on the lifting and moving platform. The lifting and moving platform is used to lift the protection box, drive the protection box to move, and also to place the protection box.

[0014] According to the above technical means, the protective box can be moved by the lifting and moving platform. In this way, when an accident occurs, the lifting and moving platform can be used to move the protective box without manual movement, thereby ensuring the safety of the operation.

[0015] In a possible implementation, the protective box includes a box body and a plurality of rollers. The box body forms a receiving cavity. The plurality of rollers are connected to the box body and are used to move the box body.

[0016] According to the above technical means, the box body can be driven to move by the rollers, making the movement more convenient.

[0017] In a possible implementation, the simulation device further includes an air conditioning system, which is arranged in the simulation cabin.

[0018] According to the above-mentioned technical means, by testing the operation and heat dissipation of the air-conditioning system in the simulated cabin, the effect of the air-conditioning system in actual application can be obtained.

[0019] In a possible implementation, the simulation device further includes an independent air intake system. The independent air intake system includes a shell and a sub-air conditioning system. A cavity is formed inside the shell, and the sub-air conditioning system is arranged inside the shell to provide different environmental conditions inside the shell. The air conditioning system is connected to the shell to adjust the internal environment of the shell.

[0020] According to the above technical means, the interior of the shell can be used to simulate the passenger compartment. Through the sub-air conditioning system, different environmental conditions can be created inside the shell to simulate passenger compartments with different environmental conditions. Since the air conditioning system is connected to the shell, the air conditioning system can adjust the environment of the shell, thereby simulating the adjustment of the air conditioning system in the actual vehicle to passenger compartments with different environmental conditions.

[0021] In a possible implementation, the simulation device includes an environment adjustment device, which is used to adjust at least one of the temperature and humidity in the simulation cabin.

[0022] According to the above technical means, the environment in the simulation cabin can be adjusted through the environmental simulation adjustment device to simulate the working state of the vehicle in different scenarios.

[0023] In a possible implementation, the simulation device includes a charging and discharging device, which is used to be electrically connected to the power battery to realize charging or discharging of the power battery.

[0024] According to the above technical means, the charging and discharging process of the power battery can be simulated through the charging and discharging device.

[0025] In a possible implementation, the simulation device includes a heat load simulation device, which is used to simulate at least one of the heat source of the engine, the heat source of the drive motor, and the heat source of the electronic control system of the vehicle.

[0026] According to the above technical means, through the heat load simulation device, it is possible to simulate the components that generate heat on the vehicle, and then simulate the thermal management effect of the thermal management system on the above heat source, so as to obtain the actual management effect of the thermal management system.

[0027] In a possible implementation, the simulation device includes a refrigerant control system. The refrigerant control system is used to connect with the component to be cooled and perform refrigerant cooling on the cooling component.

[0028] According to the above technical means, the direct-cooled battery can be thermally managed through the refrigerant control system, and a simulation test of the thermal management of the direct-cooled battery can be realized.

[0029] In a possible implementation, the simulation device includes a control device, which is used to control the thermal management simulation system.

[0030] According to the above technical means, the thermal management simulation test system can be controlled through the control device.

[0031] In a second aspect, an embodiment of the present application provides a thermal management simulation test method, using the thermal management simulation system described in any one of the first aspects. The thermal management simulation test method includes: placing a power battery on a protective device. Connecting the power battery to the simulation device, and performing a thermal management test on the power battery.

[0032] Since the above-mentioned thermal management simulation test method uses the thermal management simulation test system described in any one of the first aspects, it can solve the same technical problems as the above-mentioned thermal management simulation test system and achieve the same technical effects, and will not be repeated here. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 One of the structural schematic diagrams of a thermal management simulation test system provided in an embodiment of the present application;

[0034] Figure 2 A schematic diagram of the structure of a protective device provided in an embodiment of the present application;

[0035] Figure 3 A schematic diagram of the structure of a lifting and moving platform provided in an embodiment of the present application;

[0036] Figure 4 A second structural diagram of a thermal management simulation test system provided in an embodiment of the present application;

[0037] Figure 5 A schematic diagram of the structure of the air conditioning system and the protective device provided in the embodiment of the present application;

[0038] Figure 6 A schematic diagram of the structure of an air conditioning system provided in an embodiment of the present application;

[0039] Figure 7 A schematic diagram of the structure of an independent air intake system provided in an embodiment of the present application;

[0040] Figure 8 A partial structural schematic diagram of a thermal management simulation test system provided in an embodiment of the present application;

[0041] Fig. 9 The third structural schematic diagram of a thermal management simulation test system provided in an embodiment of the present application.

[0042] Reference numerals:

[0043] 100-thermal management simulation test system; 10-simulation box; 20-protective device; 21-protective box; 211-box body; 212-roller; 22-conveying device; 221-water pipe; 222-water supply pipe; 23-lifting and moving platform; 231-mobile vehicle; 232-lifting mechanism; 30-simulation device; 40-environmental adjustment device; 41-temperature adjustment device; 42-humidity adjustment device; 50-charging and discharging device; 61-air conditioning system; 611-front-end condensing component; 612-air conditioning box component; 613-compressor component; 614-controller component; 615-tooling bracket; 62-independent air intake system; 621-housing; 622-test bench; 70-power battery; 80-heat load simulation system; 90-refrigerant control system. DETAILED DESCRIPTION

[0044] In order to enable ordinary persons in the art to better understand the technical solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings.

[0045] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchangeable where appropriate, so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present application. On the contrary, they are merely examples of devices and methods consistent with some aspects of the present application as detailed in the attached claims.

[0046] The present application embodiment provides a thermal management simulation test system, such as Figure 1 As shown, Figure 1One of the structural schematic diagrams of a thermal management simulation test system 100 provided in an embodiment of the present application, the thermal management simulation test system 100 may include a simulation box 10, a protective device 20 and a simulation device 30. Among them, the interior of the simulation box 10 can form a simulation cabin, and the simulation cabin can be used to simulate different environments in which the vehicle is located. The protective device 20 is arranged in the simulation cabin, and is used to set the power battery 70 to protect the power battery 70 when it is thermally runaway. The simulation device 30 is arranged on the simulation box 10, and is used to simulate the actual application environment and devices of the vehicle.

[0047] The thermal management simulation test system 100 provided in the embodiment of the present application can place the power battery 70 on the protective device 20 when using the power battery 70 for testing. Since the protective device 20 can provide protection when the power battery 70 is in thermal runaway, it plays a protective role, thereby avoiding the potential safety hazards caused by the thermal runaway of the power battery 70. In this way, when the simulation device 30 is used to simulate the test of the thermal management test system, the safety of the thermal management simulation test system 100 is guaranteed.

[0048] In some embodiments, Figure 1 As shown, the simulation device 30 may include an environment adjustment device 40. The environment adjustment device 40 is used to adjust at least one of the temperature and humidity in the simulation cabin. Thus, the environment in the simulation cabin can be adjusted by the environment adjustment device 40 to simulate the working state of the vehicle in different scenarios.

[0049] In some embodiments, Figure 1 As shown, the environment adjustment device 40 includes a temperature adjustment device 41. The temperature adjustment device 41 may include a cooling device and a heating device. The heating device is used to increase the temperature in the simulation box 10. Thus, the simulation cabin can be heated by the heating device, so that the temperature in the simulation cabin is increased, simulating the scenario of the vehicle being in a high temperature environment. Exemplarily, the heating device can be provided by an electric heating wire or a heating pump, and a fan can be used to increase the air flow in the simulation cabin to ensure uniform temperature distribution inside the simulation cabin.

[0050] Similarly, the cooling device can be used to reduce the temperature in the simulation box 10. Thus, the simulation cabin can be cooled by the cooling device, so that the temperature in the simulation cabin is reduced, simulating the situation that the vehicle is in a low temperature environment. Exemplarily, the cooling device can discharge the hot air by circulating refrigerant or cooling water and using a fan to drive the air flow in the simulation cabin.

[0051] In some embodiments, Figure 1As shown, the environment conditioning device 40 also includes a humidity conditioning device 42. The humidity conditioning device 42 may include a humidifying device and a dehumidifying device. The humidifying device may be used to increase the humidity in the simulation cabin, and the dehumidifying device may be used to reduce the humidity in the simulation cabin.

[0052] The humidification device can increase the humidity in the simulation cabin to simulate the vehicle being in a high humidity environment. For example, the humidification device can provide continuous humidification conditions for the simulation cabin by means of boiler humidification, fixed humidifier or ultrasonic humidification.

[0053] The dehumidification device can reduce the humidity in the simulation cabin to simulate the vehicle being in a dry environment. For example, the dehumidification device can provide continuous dehumidification conditions for the simulation cabin by means of a rotary dehumidifier or the like.

[0054] In some embodiments, the environment conditioning device 40 further includes an air circulation device. The air circulation device is used to adjust the air flow in the simulation cabin. The air circulation device can ensure the air flow in the simulation cabin. Exemplarily, the air circulation device may include an inner circulation fan and an outer circulation fan.

[0055] The internal circulation fan achieves a mixing of cooling and heating energies in the simulation cabin, so that the temperature of each area in the cabin is balanced and the temperature is maintained to meet the test requirements. The size of the external circulation damper can be selectively opened and closed according to the static pressure difference between the inside and outside of the simulation cabin to achieve air pressure balance inside and outside the simulation cabin. At the same time, the external circulation fan has an outward ventilation function. When the power battery 70 has thermal runaway, the smoke in the simulation cabin can be quickly evacuated.

[0056] In some embodiments, Figure 1 As shown, the simulation device 30 further includes a charging and discharging device 50. The charging and discharging device 50 is used to be electrically connected to the power battery 70 to realize charging or discharging of the power battery 70. Thus, through the charging and discharging device 50, the simulation of the charging and discharging process of the power battery 70 can be realized.

[0057] In some embodiments, the charging and discharging device 50 may include a high-voltage charging and discharging device, a low-voltage charging and discharging device, a charging and discharging communication device, and a charging and discharging control and display device. Among them, the charging and discharging control and display device may be electrically connected to the high-voltage charging and discharging device and the low-voltage charging and discharging device. The high-voltage charging and discharging device and the low-voltage charging and discharging device may be electrically connected to the power battery 70, respectively. Among them, the high-voltage charging and discharging device and the low-voltage charging and discharging device may realize the output and conversion of different voltages, currents, and powers for charging, and may also realize constant voltage, constant current, and constant power charging and discharging operations.

[0058] Therefore, the charging and discharging device 50 can simulate the scenario of the power battery 70 being charged at a DC charging pile and an AC charging pile, and can also simulate the charging and discharging scenario of kinetic energy recovery during driving, and can also simulate the scenario of the power battery performing steady-state discharge, instantaneous high-power discharge, and transient discharge during driving when the actual vehicle is in different operating conditions.

[0059] The charge and discharge communication device can be electrically connected to the power battery 70 and the charge and discharge control display device. The charge and discharge communication device can perform communication functions such as data collection, data monitoring, command issuance, and signal feedback on the power battery 70. The charge and discharge control display device can realize the control of the high-voltage charge and discharge device and the low-voltage charge and discharge device, and can display the operating parameters, control parameters, monitoring parameters, and curves of the charge and discharge device 50.

[0060] It is understandable that the type and composition of the power battery 70 provided in the embodiment of the present application can be selected according to actual conditions. Exemplarily, the power battery 70 may include battery cells, battery modules, heat dissipation circuits (cooling circuits and heating circuits), high-pressure and low-pressure circuits. Depending on the refrigeration method, the power battery 70 may be an air-cooled battery (without an internal heat exchanger, relying on external air cooling for heat exchange), a liquid-cooled battery (through antifreeze passing through the water-cooled plate inside the battery for heat exchange) or a direct-cooled battery (through the refrigerant directly entering the heat exchange plate inside the battery and the outlet throttle valve to achieve heat exchange inside the battery). In addition, depending on the heating method, the power battery 70 may be a membrane thermal battery, a PTC water heating battery or a heat pump heating battery.

[0061] In some embodiments, Figure 2 As shown, Figure 2 The present invention provides a schematic diagram of a protective device 20 according to an embodiment of the present invention. The protective device 20 may include a protective box 21 and a conveying device 22. The protective box 21 is surrounded by a receiving cavity with an opening. The receiving cavity is used to place a power battery 70 ( Figure 1 ). An inlet is formed at one end of the conveying device 22, and an outlet is formed at the other end. The inlet is connected to the accommodating chamber, and the outlet is used to communicate with an external waterway. Therefore, through the conveying device 22, when the power battery 70 is thermally runaway and burns, an external water source can be introduced into the accommodating chamber to cool down the power battery 70 and extinguish the fire, thereby avoiding safety accidents.

[0062] For example, Figure 2 As shown, the conveying device 22 may include a water delivery pipe 221 and a water delivery pipe 222. One end of the water delivery pipe 221 and the water delivery pipe 222 may be connected to the receiving chamber. In this way, external water may be discharged into the receiving chamber through the water delivery pipe 221 to cool down and extinguish the fire. Correspondingly, the water in the receiving chamber may also be delivered through the water delivery pipe 222.

[0063] In some embodiments, the protection device 20 further includes a protection control system. The protection control system may be electrically connected to the conveying device 22 to control the flow and disconnection of the conveying device 22. The protection control system may also be connected to the power battery 70 to detect the operating state of the power battery 70 to control the flow and disconnection of the conveying device 22 according to the operating state of the power battery 70.

[0064] Therefore, through the protection control system, the operating status of the power battery 70 can be detected. When the operating status of the power battery 70 is abnormal, the power battery 70 can be controlled to disconnect the circuit. When a risk may occur, the conveying device can be controlled to introduce water to avoid safety accidents and further improve safety performance.

[0065] Exemplarily, the protection control system may include a water level detector. The water level detector may be disposed in the receiving chamber. Meanwhile, the water delivery pipe 221 may be connected to a water valve device. Thus, when the water level in the receiving chamber contacts the water level detector, the water level detector may send a water level alarm signal, thereby controlling the water valve device to stop adding water to the receiving chamber.

[0066] In some embodiments, continue to refer to Figure 2 , the protection device 20 may further include a lifting and moving platform 23. The protection box 21 is arranged on the lifting and moving platform 23. The lifting and moving platform 23 is used to lift the protection box 21 and drive the protection box 21 to move. The lifting and moving platform 23 is also used to place the protection box 21. Therefore, the protection box 21 can be moved by the lifting and moving platform 23. In this way, when an accident occurs, the lifting and moving platform 23 can be used to move the protection box 21 without manual movement, thereby ensuring the safety of the operation.

[0067] For example, Figure 3 As shown, Figure 3 The structural diagram of a lifting and moving platform 23 provided in an embodiment of the present application is shown, and the lifting and moving platform 23 may include a moving vehicle 231 and a lifting mechanism 232. The user may operate the lifting mechanism 232 to lift and lower by remote control wirelessly, and control the moving vehicle 231 to move, and the user may also operate the lifting and moving platform 23 by manual control.

[0068] In some embodiments, the protection device 20 may also include a battery management system. The battery management system can be used to monitor the parameters of the power battery 70 (such as the internal and external temperature of the power battery 70, the ambient temperature, the system pressure, the battery voltage, and the charge and discharge current). Among them, the battery management system can be electrically connected to the protection control system. In this way, the working state of the battery can be monitored in real time through the battery management system. When an abnormality occurs in the power battery 70, a signal can be sent to the protection control system so that the protection control system can control the conveying device 22 to convey water to avoid accidents.

[0069] For example, the battery management system can be designed with corresponding alarm thresholds and protection thresholds. When the battery management system reaches the alarm threshold, the battery management system can send an alarm signal and alarm, and remind the staff of abnormal conditions through telephone messages and other means. When the battery management system reaches the protection threshold, the battery management system can automatically cut off the power source and other circuit connections, and control the above-mentioned conveying device 22 to inject water to ensure safety.

[0070] In some embodiments, Figure 2 As shown, the protective box 21 may include a box body 211 and rollers 212. The box body 211 forms the above-mentioned accommodating cavity. A plurality of rollers 212 are connected to the box body 211, and are used to move the box body 211. Thus, the box body 211 can be driven to move by the rollers 212, and the movement is more convenient.

[0071] In some embodiments, Figure 4 As shown, Figure 4 The second structural diagram of a thermal management simulation test system 100 provided in an embodiment of the present application, the simulation device 30 may also include an air conditioning system 61. The air conditioning system 61 is arranged in the simulation cabin. Thus, by testing the operation and heat dissipation of the air conditioning system 61 in the simulation cabin, the effect of the air conditioning system 61 in the actual application process can be obtained. Among them, the air conditioning system 61 can directly use the air conditioning system used in the actual vehicle.

[0072] For example, Figure 5 As shown, Figure 5 The air conditioning system 61 and the protective device 20 provided in the embodiment of the present application are schematically shown. The air conditioning system 61 can be arranged on the protective box 21, above the power battery 70. At this time, the position of the air conditioning system 61 can match the position setting of the actual vehicle, so as to better simulate the actual vehicle.

[0073] In some embodiments, Figure 6 As shown, Figure 6A schematic diagram of the structure of an air conditioning system 61 provided in an embodiment of the present application, the air conditioning system 61 may include a front-end condensing component 611, an air conditioning box component 612, a compressor component 613, a controller component 614, a pipeline component (not shown in the figure), a throttling device (not shown in the figure) and a circuit component (not shown in the figure). The pipeline component may connect the front-end condensing component 611, the air conditioning box component 612, the compressor component 613 and the throttling component to form a circulation loop.

[0074] In addition, if Figure 6 As shown, in some embodiments, the air-conditioning system 61 may further include a tooling bracket 615, and the front-end condensing component 611, the air-conditioning box component 612, the compressor component 613 and the controller component 614 of the above-mentioned air-conditioning system 61 may be arranged on the tooling bracket 615. The tooling bracket 615 may be used to better arrange the various components of the air-conditioning system 61, and the arrangement may be more convenient.

[0075] The size of the tooling bracket 615 can be adapted to the size of the protection box 21, so that the tooling bracket 615 can be more conveniently set on the protection box 21. When the tooling bracket 615 is set on the protection box 21, the protection box 21 and the tooling bracket 615 can be designed with a limited position structure so that the tooling bracket 615 can be stably set on the protection box 21. The size of the tooling bracket 615 can also be designed to match the size of the cabin and cockpit of the actual vehicle.

[0076] Of course, the tooling bracket 615 can also be directly set up separately, and the specific selection can be made according to the actual situation. The specific structure of the tooling bracket 615 can also be designed according to the actual situation, and no further limitation is made here. In addition, the bottom of the tooling bracket 615 can also be provided with a roller, and the roller can be detachably connected to the tooling bracket 615 so as to remove or install the roller in different situations. The tooling bracket 615 can be made of aluminum material.

[0077] The front-end condensation component 611 may include a condensation module, a low-temperature heat dissipation module, a high-temperature heat dissipation module, and a cooling fan module, which may be used to perform thermal management on the refrigerant side and the high and low temperature water sides of the thermal management simulation test system 100. Experiments may be conducted on the above-mentioned different modules according to needs, or combined experiments may be conducted on multiple different modules.

[0078] The air conditioning box assembly 612 may include an evaporator module, an evaporation fan, a PTC heating assembly, a heating element, an air conditioning box body, and an air duct. The air conditioning box assembly 612 may be used to perform heat exchange with the interior of the simulated passenger compartment, thereby realizing the functions of simulating cold and heat transport in the passenger compartment.

[0079] The compressor component 613 can be responsible for compressing and recovering the refrigerant, and the speed of the compressor can be controlled through the controller component 614, thereby controlling the refrigerant flow rate, suction and exhaust pressure and other parameters. The controller component 614 can be responsible for collecting, monitoring and analyzing various parameters, which can be connected to various components through circuit components, and can output execution commands according to software strategies and analysis results to control the execution of various related system interaction components.

[0080] The pipeline assembly may include a refrigerant pipeline assembly and a water pipeline assembly. The refrigerant pipeline assembly may be used to connect system components such as a compressor, a heat exchanger, and a throttle valve. The water side pipeline assembly is responsible for connecting system components such as electric drive, electric control, engine, heat exchanger, and throttle device.

[0081] The throttling device may include components such as a thermal expansion valve, an electronic expansion valve, a capillary tube, a one-way valve, a stop valve, etc., to complete the flow control on the refrigerant side, the water side and other locations to achieve the throttling effect of the system.

[0082] The circuit assembly may include a high-voltage power supply harness, a low-voltage power supply harness, a communication harness, a sensor, and an accompanying harness to achieve electrical connection and debugging control of the entire thermal management simulation test system 100 .

[0083] In some embodiments, Figure 4 and Figure 5 As shown, the simulation device 30 may also include an independent air intake system 62. The independent air intake system 62 may include a housing 621 and a sub-air conditioning system (not shown in the figure). The interior of the housing 621 forms a cavity. The sub-air conditioning system may be arranged in the housing 621 to provide different environmental conditions inside the housing 621.

[0084] Among them, the air conditioning system 61 can be connected to the shell 621 to adjust the internal environment of the shell 621. Therefore, the interior of the shell 621 can be used to simulate the passenger compartment. Through the sub-air conditioning system, the interior of the shell 621 can have different environmental conditions to simulate the passenger compartment with different environmental conditions. Since the air conditioning system 61 is connected to the shell 621, the air conditioning system 61 can adjust the environment of the shell 621, thereby simulating the adjustment of the air conditioning system 61 in the actual vehicle to the passenger compartment with different environmental conditions.

[0085] Exemplarily, the air inlet of the air conditioning box assembly 612 may be connected to the shell 621 of the independent air intake system 62 to simulate the temperature and humidity environment inside the passenger compartment to supply air to the air conditioning box assembly 612 alone.

[0086] It is understandable that the sub-air conditioning system may include components such as a condensing module, an evaporating module, a cooling fan simulation, a heating module, a throttling device, and a controller to achieve environmental regulation inside the shell 621.

[0087] In addition, if Figure 7 As shown, Figure 7 The schematic diagram of the structure of an independent air intake system 62 provided in an embodiment of the present application. The independent air intake system 62 may further include a stand 622. The stand 622 may also be made of aluminum material.

[0088] At the same time, the independent air intake system 62 may also include a heat preservation air duct (not shown in the figure), the two ends of which are connected to the shell 621 and the air conditioning box assembly 612. The air in the shell 621 can enter the heat preservation air duct and enter the interior of the air conditioning box assembly 612 to provide an independent temperature and humidity air supply environment for the air conditioning box assembly 612.

[0089] In some embodiments, Figure 8 and Fig. 9 As shown, Figure 8 A partial structural diagram of a thermal management simulation test system 100 provided in an embodiment of the present application, Fig. 9 The third structural diagram of a thermal management simulation test system 100 provided in an embodiment of the present application, the simulation device 30 may also include a thermal load simulation system 80. The thermal load simulation system 80 is used to simulate at least one of the engine heat source, the drive motor heat source, and the electronic control system heat source of the vehicle. Thus, through the thermal load simulation system 80, it is possible to simulate the heat-generating components on the vehicle, and then simulate the thermal management effect of the thermal management system on the above-mentioned heat sources, so as to obtain the actual management effect of the thermal management system.

[0090] In some embodiments, the thermal load simulation system 80 may include a battery thermal load simulation system. Among them, for the liquid-cooled battery thermal load simulation system, the thermal load simulation system 80 may include a high and low temperature antifreeze coolant device, which can be used to provide high temperature antifreeze or low temperature antifreeze with different flow requirements to meet the test requirements. It can replace the power battery 70 entity and connect to the thermal management simulation test system 100 provided in the embodiment of the present application to achieve the effect of simulating the water circulation and thermal load of the liquid-cooled battery.

[0091] In some embodiments, the heat load simulation system 80 may also include an electric drive and electric control heat load simulation system. In this case, the heat load simulation system 80 may include a high and low temperature antifreeze coolant device, and the required water temperature is controlled by an external high and low temperature antifreeze coolant device, which is connected to the thermal management simulation test system 100 provided in the embodiment of the present application to achieve the effect of a circulation system simulating the heat load of the electric drive and electric control.

[0092] In some embodiments, the heat load simulation system 80 may also include an engine heat load simulation system. In this case, the heat load simulation system 80 may include a high and low temperature antifreeze coolant device, and the required water temperature is controlled by an external high and low temperature antifreeze coolant device, and connected to the thermal management simulation test system 100 provided in the embodiment of the present application, so as to achieve the effect of a circulation system simulating the heat load of the engine.

[0093] In some embodiments, the thermal management simulation test system 100 may also include at least one of a battery thermal load system, an electric drive and electronic control thermal load system, and an engine thermal load system. By connecting the water systems of the above-mentioned different thermal load systems to the thermal management simulation test system 100 provided in the embodiment of the present application, it is possible to implement testing using thermal management for the actual battery thermal load system, the electric drive and electronic control thermal load system, and the engine thermal load system, and the test effect is more accurate.

[0094] Exemplarily, by connecting the water system of the electric drive and electronic control system to the experimental system of the present application, a heat load system of the electric drive and electronic control system can be formed, and simulation and thermal management can be performed on the system. The power battery 70 entity cooperates with the charging and discharging device 50 and the corresponding electrical and piping to form a heat load, and the battery heat load system of the actual vehicle can be simulated. By connecting the engine, generator and other systems to the thermal management simulation test system 100 provided in the embodiment of the present application, the high-temperature water circulation generated by the engine or generator during the operation of the actual vehicle can be simulated, and the radiation effect of the front-end cooling module on the above-mentioned heat load system can be simulated.

[0095] In some embodiments, Figure 8 As shown, the simulation device 30 also includes a refrigerant control system 90. The refrigerant control system 90 is used to connect with the component to be cooled and perform refrigerant cooling on the cooling component. The refrigerant control system 90 can be used to perform thermal management on the direct-cooled battery, thereby realizing a simulation test on the thermal management of the direct-cooled battery.

[0096] In some embodiments, the simulation device 30 further includes a control device. The control device is used to control the thermal management simulation test system 100. Thus, the thermal management simulation test system 100 can be controlled by the control device. Exemplarily, the control device may include an air conditioning control system. The air conditioning control system may monitor and control various parts of the air conditioning system 61.

[0097] The control device may also include a battery control system, which can monitor and control the power battery 70 system and its components.

[0098] The control device may further include a charge and discharge control system, which may control the charge and discharge device 50 .

[0099] The control device may further include an environmental equipment control system, and the environmental equipment control system may control the environmental adjustment device 40 .

[0100] The control device may also include an antifreeze liquid control system, which may control the high and low temperature antifreeze coolant device.

[0101] The control device may further include a combined control system, which may monitor and control the entire thermal management simulation test system 100 .

[0102] The control device may further include an independent air intake control system, which may control the independent air intake system 62 .

[0103] The control device may also include a lifting platform control system, and the lifting platform control system may control the lifting mobile platform 23 .

[0104] Among them, the above-mentioned air-conditioning control system, battery control system, charging and discharging control system, environmental equipment control system, antifreeze control system, combined control system, independent air intake control system and lifting platform control system can be linked to achieve linkage control of the large system.

[0105] On the other hand, an embodiment of the present application provides a thermal management simulation test method, which includes steps S100-S200.

[0106] S100: Install the power battery on the protective device.

[0107] For example, Figure 5 As shown, the power battery 70 is placed on the receiving cavity of the protection box 21. Then, the protection box 21 is placed in the simulation cabin.

[0108] S200: Connect the power battery to the simulation device and perform a thermal management test on the power battery.

[0109] Exemplarily, the high-voltage terminal of the power battery is connected to the high-voltage end of the charging and discharging device through a high-voltage wiring harness, the low-voltage control circuit of the battery management system of the power battery and the low-voltage power supply end of the charging and discharging device and the charging and discharging communication device are electrically connected, and the communication and charging and discharging control between the charging and discharging device and the power battery are controlled through a charging and discharging control display device.

[0110] In some embodiments, connecting the power battery to the simulation device and performing a thermal management test on the power battery includes step S201 or S202.

[0111] S201: Connect the power battery to the high and low temperature antifreeze coolant device, and use the high and low temperature antifreeze coolant device to perform thermal management on the power battery. At this time, the power battery can be a liquid-cooled power battery, and the high and low temperature antifreeze coolant device outputs the required temperature and flow rate of antifreeze, and directly performs thermal management on the liquid-cooled battery through the pipeline.

[0112] S202: Connect the power battery to the refrigerant control system so that the refrigerant control system performs thermal management on the power battery. At this time, the power battery can be a direct-cooled power battery. By connecting the refrigerant control system to the power battery, the refrigerant system can control the pre-valve pressure, pre-valve temperature, outlet superheat and other parameters of the refrigerant system so that the refrigerant control system can perform thermal management on the power battery according to the system response, and at the same time, the heat exchange capacity and boundary performance of the direct-cooled battery can be tested.

[0113] After completing the above steps, one end of the fire hose can be connected to one end of the water pipe, and the other end can be connected to the fire hydrant water inlet or the fully automatic fire water injection valve. At the same time, the mobile lifting platform can be set under the protection box to prepare for lifting the protection box.

[0114] After completing the above connections, you can debug the equipment. First, the environmental conditioning device can be controlled by the environmental equipment control system so that the simulation cabin is in different environments, and the power battery can be simulated and tested for different environments. For example, under high temperature, low temperature and variable temperature conditions, the charging and discharging device is used to simulate the power battery's DC fast charging, AC slow charging, full charging and discharging and other charging and discharging scenarios. At the same time, the charging and discharging device can be used to complete constant current discharge, constant power charging and discharging, power battery MAP charging and discharging, extreme instantaneous high voltage charging and discharging, extreme instantaneous high current charging and discharging, etc.

[0115] During the above-mentioned charging and discharging, the power battery will generate heat, causing the temperature inside the battery pack to rise. At this time, the battery management system of the power battery can send a cooling signal according to the temperature data changes detected by it, and cool the power battery through the above-mentioned high and low temperature antifreeze coolant device or refrigerant control system. When the battery management system detects that the temperature of the power battery returns to the normal range, it sends a signal to stop cooling, and controls the high and low temperature antifreeze coolant device or refrigerant control system to stop cooling the power battery.

[0116] On the contrary, when the temperature of the power battery is too low, the battery management system of the power battery can send a heating signal according to the changes in the temperature data it detects, and heat the power battery through the above-mentioned high and low temperature antifreeze coolant device or refrigerant control system. When the battery management system detects that the temperature of the power battery returns to the normal range, it sends a signal to stop heating and controls the high and low temperature antifreeze coolant device or refrigerant control system to stop heating the power battery. In order to monitor the temperature of the power battery, multiple temperature sensors are set inside and outside the battery pack. In this way, the temperature of the power battery can be effectively monitored through multiple temperature sensors.

[0117] Based on this, the thermal management simulation test system provided in the embodiment of the present application can simulate different real vehicle environments, and perform charging and discharging tests on the power battery in different situations for different real vehicle environments. At the same time, during the charging and discharging test, the temperature of the power battery can be thermally managed, the power battery can be heated and cooled, and the overall heat generation of the power battery under different working conditions, the highest and lowest temperatures inside the battery pack, and the temperature uniformity performance inside the power battery during the cooling or heating of the battery pack, the cooling rate under extreme working conditions, the maximum temperature boundary, the maximum heat exchange capacity of the battery cold plate, and the heat exchange capacity of the direct-cooled battery, the extreme boundary temperature, the opening degree of the refrigerant system valve, and the overheating degree and other control parameters are tested.

[0118] In addition, the thermal management simulation test system provided in the embodiment of the present application can also perform thermal management test simulation on the air-conditioning system, and the specific steps are as follows.

[0119] First, you can build a tooling bracket according to actual needs, and then install the front-end condensing assembly, air conditioning box assembly, compressor assembly, controller assembly, pipeline assembly, throttling device and circuit assembly on the tooling bracket one by one according to the layout position of the actual vehicle. Then connect the control device. Then set the independent air intake system on one side of the tooling bracket. Among them, temperature sensors can be arranged at the air outlet, air inlet of the air conditioning box assembly, and the air outlet side of the evaporation module of the sub-air conditioning system. At the same time, temperature sensors can be arranged at the air inlet, air outlet and surface of the condensation module of the front-end condensation assembly. PT sensors are set at the exhaust port and air intake port of the compressor, the condensation outlet end, the evaporation outlet end and other positions. After that, conduct a line check to check whether the pipelines, electrical system lines, high and low voltage power supply circuits and communication control circuits are normal.

[0120] Next, connect the two ends of the insulation channel to the air conditioning box assembly and the shell respectively. Then place the above-built equipment in the simulation cabin. The environmental adjustment device is controlled by the environmental equipment control system, so that the simulation cabin is in different environments, and the air conditioning system is simulated and tested for different environments. At the same time, the combined control system can be used to command the air conditioning control system and the independent air intake control system to achieve normal operation control and dynamic control of the air conditioning system.

[0121] According to different application scenarios, the simulation cabin can simulate different external environmental conditions through environmental adjustment devices. For example, extremely cold environment of -30℃, winter of -5℃, spring of 15℃, normal temperature of 25℃, high temperature of 35℃, extremely hot environment of 49℃, etc. The sub-air conditioning system can also be used to simulate the air inlet environmental conditions of different air conditioning box components, for example, -30℃, 15℃, 25℃, 50℃, etc. The sub-air conditioning system is used to simulate different air conditioning modes, such as cooling, heating, internal and external circulation, temperature, windshield, defrosting and defogging, AUTO and other mode settings.

[0122] Based on the above conditions, data detection can be performed on each temperature monitoring point and PT detection point of the air-conditioning system, and the operating parameters of each system component can be controlled to realize the overall performance test, boundary capacity test, and air outlet temperature uniformity test of the air-conditioning system. In addition, according to different operating conditions, the system control parameter calibration, boundary control parameter confirmation, and capacity acceptance can be simulated for the compressor speed, expansion valve opening, system high and low pressure protection, evaporator anti-freeze protection, system refrigerant filling amount, etc. The thermal management simulation test system provided in the embodiment of the present application can also be used to verify the reliability and robustness of the air-conditioning system strategy, that is, to develop an automatic variable working condition ambient temperature and variable setting mode program, automatically operate and monitor the entire air-conditioning system in real time, when the system detects an operating failure or fails to simulate the execution action according to the actual setting, the system will alarm and prompt, and record the operation log and data, through the variable working condition test and extreme high and low temperature endurance test, fully and in advance expose the invisible problems including but not limited to the thermal management system.

[0123] In addition, the thermal management simulation test system provided in the embodiment of the present application can also perform simulation tests on the combined thermal management of the power battery and the air-conditioning system, and its specific connection and implementation methods are as follows.

[0124] First, as mentioned above, the high-voltage terminal of the power battery is connected to the high-voltage end of the charging and discharging device through the high-voltage wire harness, the low-voltage control circuit of the battery management system of the power battery is electrically connected to the low-voltage power supply end of the charging and discharging device and the charging and discharging communication device, and the communication and charging and discharging control between the charging and discharging device and the power battery are controlled through the charging and discharging control display device. Next, the relevant devices of the above-mentioned air-conditioning system are placed in the simulation cabin, and the air-conditioning system is positioned above the power battery.

[0125] As mentioned above, for liquid-cooled batteries, the water cooling management of the power battery can be connected to the water-cooled heat exchanger of the air conditioning system. If it is a direct-cooled battery, as mentioned above, the refrigerant pipeline of the power battery is connected to the refrigerant circuit interface of the air conditioning system.

[0126] Next, the air conditioning box assembly and the shell are connected through the heat preservation air duct. Then, for the heat load simulation system, the electric drive and electronic control heat load simulation system and the engine heat load simulation system are connected to the low-temperature radiator module and high-temperature radiator module of the front-end condensation component, and the heat load of the motor and electronic control and the engine of the real vehicle is simulated by adjusting the temperature of the low-temperature antifreeze and high-temperature antifreeze.

[0127] Next, the above-mentioned air-conditioning control system, battery control system, charging and discharging control system, environmental equipment control system, antifreeze control system, independent air intake control system, lifting platform control system, etc. are connected to the combined control system to realize control, early warning, monitoring and interaction of each system through the combined control system.

[0128] Based on this, the thermal management simulation test system provided in the embodiment of the present application can control different ambient temperatures, charging and discharging scenarios, and air-conditioning scenarios according to different needs with the same combination control system, to achieve special performance testing of the integrated thermal management system with power batteries, extreme operating condition testing, comprehensive operating condition performance testing, system parameter calibration, as well as re-inspection of problem rectification and simulation of system reliability and durability testing.

[0129] As mentioned above, the thermal management simulation test system provided in the embodiment of the present application can play a good protective role when the power battery is in thermal runaway. Specifically, by setting sensors at various positions of the protection box, using a control device for monitoring, and using a lifting and moving platform to remotely move the protection box, there is no need for manual close contact with the power battery, thereby ensuring safety performance.

[0130] For example, during the experiment, the combined control system can detect the battery control system, air conditioning control system, and some current sensors, voltage sensors, and smoke sensors, etc., and issue different action instructions when different alarm information appears. For example, the combined control system can make different responses according to the alarm level, cut-off level, and emergency disposal level signals that appear.

[0131] When an alarm-level signal appears, the experimenter can be reminded through system alarms, pop-up windows, and flashing lights without shutting down the entire system. At this time, during the inspection and disposal process of the staff, continuous monitoring is also carried out so that higher-level dangerous situations can be detected at any time, and the alarm-level signal can be lifted after the risk is eliminated.

[0132] When a cut-off signal appears, the control device will control the cutting off of the power source of the entire system, and use alarms, pop-up windows, flashing lights, etc. to remind the experimenter. At this time, the control device will also continue to monitor so that it can detect the occurrence of higher-level dangerous situations at any time, and remove the alarm signal after the risk is eliminated.

[0133] When an emergency disposal-level signal appears, the control device will cut off the power source of the entire system, and use alarms, pop-up windows, and flashing lights to remind the experimenters. In addition, if smoke, gas fire, etc. are detected, the control device will control the opening of the fire water valve and supply water to the protection box through the water pipe. At the same time, turn on the ventilation of the simulation cabin to dissipate the smoke inside. If no fire or smoke is detected in the battery pack, disconnect the various connecting parts of the power battery, and use a lifting and moving platform to move the power battery protection box out of the simulation cabin and move it to a safe area.

[0134] The above are only specific implementations of the present application, but the protection scope of the present application is not limited thereto, and any changes or substitutions within the technical scope disclosed in the present application should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A thermal management simulation test system, characterized in that: include: A simulation box, wherein the interior of the simulation box forms a simulation cabin; A protection device is arranged in the simulation cabin and is used to set the power battery and provide protection when the power battery is in thermal runaway; The simulation device can be arranged on the simulation box or placed separately, and is used to simulate the actual application environment and components of the vehicle.

2. The thermal management simulation test system according to claim 1, characterized in that: The protective device comprises: A protective box, the protective box enclosing a accommodating cavity with an opening; the accommodating cavity is used to place the power battery; and a conveying device, one end of the conveying device is formed with an inlet and the other end is formed with an outlet; the outlet is connected to the accommodating cavity; the inlet is used to communicate with an external waterway.

3. The thermal management simulation test system according to claim 2, characterized in that: The protective device also includes: A protection control system is electrically connected to the conveying device and is used to control the flow and disconnection of the conveying device; the protection control system is also used to be connected to a power battery and is used to detect the operating status of the power battery to control the flow and disconnection of the conveying device according to the operating status of the power battery.

4. The thermal management simulation test system according to claim 2, characterized in that: The protective device also includes: A lifting and moving platform, the protection box is arranged on the lifting and moving platform, the lifting and moving platform is used to lift the protection box and drive the protection box to move; the lifting and moving platform is also used to place the protection box.

5. The thermal management simulation test system according to claim 2, characterized in that: The protective box comprises: a box body, the box body forming the accommodating cavity; and A plurality of rollers are connected to the box body, and the rollers are used to move the box body.

6. The thermal management simulation test system according to claim 1, characterized in that: The simulation device comprises: An air conditioning system is arranged in the simulation cabin.

7. The thermal management simulation test system according to claim 6, characterized in that: The simulation device also includes: An independent air intake system, the independent air intake system comprising a shell and a sub-air conditioning system; a cavity is formed inside the shell; the sub-air conditioning system is arranged inside the shell to make the inside of the shell have different environmental conditions; Wherein, the air conditioning system is connected to the shell and is used to adjust the internal environment of the shell.

8. The thermal management simulation test system according to claim 1, characterized in that: The simulation device comprises: An environmental regulating device is used to regulate at least one of the temperature and humidity in the simulation cabin.

9. The thermal management simulation test system according to claim 1, characterized in that: The simulation device comprises: The charging and discharging device is used to be electrically connected to the power battery to realize the charging or discharging of the power battery.

10. The thermal management simulation test system according to claim 1, characterized in that: The simulation device comprises: a heat load simulation system, the heat load simulation system being used to simulate at least one of an engine heat source, a drive motor heat source and an electronic control system heat source of the vehicle; and / or, The refrigerant control system is used to connect with the component to be cooled and perform refrigerant cooling on the component to be cooled.

11. The thermal management simulation test system according to claim 1, characterized in that: The simulation device comprises: A control device is used to control a thermal management simulation test system.

12. A thermal management simulation test method, using the thermal management simulation test system according to any one of claims 1 to 11, characterized in that: The thermal management simulation test method comprises: Placing a power battery on the protective device; The power battery is connected to the simulation device to perform a thermal management test on the power battery.

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