An intelligent thermal management control system and method

Abstract

This invention relates to an intelligent thermal management control system and method. The fan, starting system, instrument system, retarder system, air conditioning system, and engine control system (ECM) are communicatively or hardwired connected to the intelligent thermal management control system. Based on the different input signal states of the starting system, instrument system, retarder system, air conditioning system, and engine control system (ECM), and their cooling requirements, the intelligent thermal management control system automatically selects different fan control schemes, controlling the fans to operate at different speeds, taking into account the cooling system type, ambient temperature, and vehicle speed. This invention features a limp-around function, enabling the vehicle to achieve optimal cooling under different operating conditions and speeds, reducing accessory power consumption and fuel consumption, thus meeting the requirements of intelligent thermal management control.

Description

Technical Field

[0001] This invention relates to the field of automotive thermal management technology, and in particular to an intelligent thermal management control system and method. Background Technology

[0002] Traditional thermal management control systems rely on coolant and intake air temperatures, using electric fans for stepped regulation or electronically controlled silicone oil fans for single linear regulation. With the development of the commercial vehicle industry, the types of powertrains and cooling units are increasing, and the requirements for cooling systems are becoming more complex under different environmental conditions and vehicle speeds. Traditional thermal management control systems can no longer meet the complex cooling needs of various powertrains, cooling units, and different environmental conditions and vehicle speeds. Failure to achieve precise, effective, and safe cooling control can lead to overheating of cooling units, damaging them, or increasing overall vehicle energy consumption. Summary of the Invention

[0003] The purpose of this invention is to provide an intelligent thermal management control system and method to address the shortcomings of existing technologies.

[0004] This invention is achieved using the following technical solution:

[0005] An intelligent thermal management control system includes a fan, a starting system, an instrument system, a retarder system, an air conditioning system, an engine control system (ECM), and an intelligent thermal management control system.

[0006] The fan, the starting system, the instrument system, the retarder system, the air conditioning system, and the engine control system (ECM) are connected to the intelligent thermal management control system via communication or hardwired connection. The intelligent thermal management control system automatically selects different fan control schemes and controls the fan to execute different speeds based on the different input signal states of the starting system, the instrument system, the retarder system, the air conditioning system, and the engine control system (ECM), as well as the cooling requirements of the retarder system, the air conditioning system, and the engine control system (ECM), combined with the cooling system type, ambient temperature, and vehicle speed.

[0007] As a further explanation of the invention, the fan is provided with a fan speed sensor, which is used to convert the frequency signal into an electrical signal and transmit it to the intelligent thermal management control system. The intelligent thermal management control system calculates the actual fan speed based on the converted electrical signal after filtering and using a formula.

[0008] As a further explanation of the invention, the starting system is installed in the driver's cab and is used to transmit or send the key position signal of the starting system to the intelligent thermal management control system in the form of an electrical signal or a CAN message signal.

[0009] As a further explanation of the invention, the instrument system is installed in the driver's cab and is used to send vehicle information, real-time vehicle speed information and fault alarm information to the intelligent thermal management control system via CAN message signals.

[0010] As a further explanation of the invention, the retarder system includes a retarder controller, which is installed in the cab and is used to send retarder switch position information, actual retarder torque percentage information, and retarder coolant outlet temperature information to the intelligent thermal management control system via CAN message signals.

[0011] As a further explanation of the invention, the air conditioning system includes an air conditioning controller, which is installed in the driver's cab and is used to transmit or send the air conditioning three-state pressure switch status information, condenser pipe pressure value information, air conditioning switch status information and indoor and outdoor temperature information to the intelligent thermal management control system via electrical signals or CAN message signals.

[0012] As a further explanation of the invention, the engine control system (ECM) is mounted on the vehicle frame engine and is used to send engine speed information, engine intake air temperature information, and engine coolant temperature information to the intelligent thermal management control system via CAN message signals.

[0013] An intelligent thermal management control method, based on a vehicle configuration character flashing method, enables the intelligent thermal management control system to automatically adapt to different models of retarder systems, air conditioning systems, and engine control mechanisms (ECMs); the method includes:

[0014] The intelligent thermal management and control system acquires the key position signal from the starting system;

[0015] When the intelligent thermal management control system detects that the vehicle is in the starting state, the intelligent thermal management control system acquires the electrical signal of the fan sensor and calculates the current actual fan speed;

[0016] The intelligent thermal management control system acquires indoor and outdoor temperature information of the air conditioning system, automatically adapts to winter or summer control methods, and dynamically adjusts the engine coolant temperature, engine intake air temperature, and the corresponding target fan speed and fan direct connection temperature threshold according to the lookup table. It also acquires electrical signals related to the air conditioning system's air conditioning switch status, air conditioning three-state pressure switch status, and condenser pressure value. Alternatively, the intelligent thermal management control system receives message signals related to the cooling request fan speed percentage sent by the air conditioning system, automatically selects the fan control scheme for different target fan speeds, and the target fan speed varies depending on the vehicle speed sent by the instrument system.

[0017] The intelligent thermal management control system acquires electrical signals related to the retarder's on / off position and message signals related to the actual torque percentage of the retarder, enabling the fan to use the maximum fan speed at the current engine speed as the target fan speed; or, the intelligent thermal management control system receives message signals related to the cooling request fan speed percentage from the retarder system, and automatically selects the fan control scheme corresponding to different target fan speeds; and the intelligent thermal management control system calculates the call time of the retarder system during combined braking, and when the call time exceeds a set threshold and the retarder coolant outlet temperature exceeds the fan direct connection temperature, enables the fan to use the maximum fan speed at the current engine speed as the target fan speed.

[0018] The intelligent thermal management control system selects the maximum value of the target fan speed corresponding to the engine system, air conditioning system, retarder system, and combined braking system as the final target fan speed. It controls the fan request duty cycle PWM frequency signal to control the fan operation. Based on the difference between the final target fan speed and the current actual fan speed, it dynamically adjusts the fan request duty cycle PWM frequency signal according to PID control to make the actual fan speed approach the target fan speed. When the target fan speed exceeds the physical maximum value, the physical maximum value is used as the target fan speed.

[0019] As a further explanation of the invention, the intelligent thermal management control system acquires the electrical signal from the fan sensor and calculates the current actual fan speed; including:

[0020] The intelligent thermal management control system acquires the electrical signal converted from the fan sensor frequency signal. After filtering, it sets effective low-level voltages below a set threshold as active low and effective high-level voltages above a set threshold as active high. Combining this with the n pulses per revolution determined by the fan's mechanical characteristics, the current actual fan speed is calculated using the following formula:

[0021] Current actual fan speed = (number of pulses ÷ counting time) × 60 ÷ (number of pulses per revolution).

[0022] As a further explanation of the invention, based on PID control adjustment, the PWM frequency signal of the fan request duty cycle is dynamically adjusted to make the actual fan speed approach the target fan speed; including

[0023] The intelligent thermal management control system selects P / I / D control parameters based on the hysteresis of the difference between the fan's final target speed and the current actual fan speed. When the speed difference is greater than the set speed, proportional P adjustment is performed; when the speed difference is less than the set speed, integral I and derivative D adjustment are performed. The P / I / D control adjusts the PWM frequency signal of the fan request duty cycle, so that the actual fan speed quickly and smoothly approaches the target speed. The P / I / D adjustment value is configured and flashed according to different models of retarder systems, air conditioning systems, and engine control system ECMs, automatically selecting different control values.

[0024] Compared with the prior art, the present invention has the following beneficial technical effects:

[0025] This invention features a limp-around function, comprehensively considering the fan, starting system, instrument system, retarder system, air conditioning system, and engine control system (ECM). The intelligent thermal management control system automatically selects different control paths and controls the fan to operate at different speeds based on the different input signal states of the starting system, instrument system, retarder system, air conditioning system, and engine control system (ECM), as well as the cooling requirements of these systems, combined with factors such as cooling system type, ambient temperature, and vehicle speed. This invention makes comprehensive decisions based on multiple cooling requirements, automatically adjusting the control strategy and controlling the fan speed to achieve optimal cooling for the vehicle under different operating conditions and speeds, reducing accessory power consumption and fuel consumption, thus meeting the requirements of intelligent thermal management control. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the intelligent thermal management control system of the present invention. Detailed Implementation

[0027] Example 1

[0028] An intelligent thermal management control system includes a fan, a starting system, an instrument system, a retarder system, an air conditioning system, an engine control system (ECM), and an intelligent thermal management control system.

[0029] The fan, starting system, instrument system, retarder system, air conditioning system, and engine control system (ECM) are connected to the intelligent thermal management control system via communication or hard wiring. The intelligent thermal management control system automatically selects different fan control schemes and controls the fans to run at different speeds based on the different input signal states of the starting system, instrument system, retarder system, air conditioning system, and engine control system (ECM) and their cooling requirements, combined with the cooling system type, ambient temperature, and vehicle speed.

[0030] The fan is equipped with a fan speed sensor, which converts the frequency signal into an electrical signal and transmits it to the intelligent thermal management control system. The intelligent thermal management control system then calculates the actual fan speed based on the converted electrical signal through filtering and formulas.

[0031] The starting system is located in the driver's cab and is used to transmit or send the key position signal of the starting system to the intelligent thermal management control system via electrical signal or CAN message signal.

[0032] The instrument system is located in the driver's cab and is used to send vehicle information, real-time vehicle speed information, and fault alarm information to the intelligent thermal management control system via CAN message signals.

[0033] The retarder system includes a retarder controller, which is located in the cab and is used to send retarder switch position information, actual retarder torque percentage information, and retarder coolant outlet temperature information to the intelligent thermal management control system via CAN message signals.

[0034] The air conditioning system includes an air conditioning controller, which is located in the driver's cab. The controller is used to transmit or send the air conditioning three-state pressure switch status information, condenser pipe pressure value information, air conditioning switch status information, and indoor and outdoor temperature information to the intelligent thermal management control system via electrical signals or CAN message signals.

[0035] The engine control system (ECM) is mounted on the engine of the vehicle frame. It is used to send engine speed information, engine intake air temperature information, and engine coolant temperature information to the intelligent thermal management control system via CAN message signals.

[0036] Example 2

[0037] An intelligent thermal management control method, based on a vehicle configuration character flashing method, enables the intelligent thermal management control system to automatically adapt to different models of retarder systems, air conditioning systems, and engine control mechanisms (ECMs); the method includes:

[0038] The intelligent thermal management and control system acquires the key position signal from the starting system;

[0039] When the intelligent thermal management control system detects that the vehicle is in the starting state, the intelligent thermal management control system acquires the electrical signal of the fan sensor and calculates the current actual fan speed;

[0040] The intelligent thermal management control system acquires indoor and outdoor temperature information of the air conditioning system, automatically adapts to winter or summer control methods, and dynamically adjusts the engine coolant temperature, engine intake air temperature, and the corresponding target fan speed and fan direct connection temperature threshold according to the lookup table. It also acquires electrical signals related to the air conditioning system's air conditioning switch status, air conditioning three-state pressure switch status, and condenser pressure value. Alternatively, the intelligent thermal management control system receives message signals related to the cooling request fan speed percentage sent by the air conditioning system, automatically selects the fan control scheme for different target fan speeds, and the target fan speed varies depending on the vehicle speed sent by the instrument system.

[0041] The intelligent thermal management control system acquires electrical signals related to the retarder's on / off position and message signals related to the actual torque percentage of the retarder, enabling the fan to use the maximum fan speed at the current engine speed as the target fan speed; or, the intelligent thermal management control system receives message signals related to the cooling request fan speed percentage from the retarder system, and automatically selects the fan control scheme corresponding to different target fan speeds; and the intelligent thermal management control system calculates the call time of the retarder system during combined braking, and when the call time exceeds a set threshold and the retarder coolant outlet temperature exceeds the fan direct connection temperature, enables the fan to use the maximum fan speed at the current engine speed as the target fan speed.

[0042] The intelligent thermal management control system selects the maximum value of the target fan speed corresponding to the engine system, air conditioning system, retarder system, and combined braking system as the final target fan speed. It controls the fan's request duty cycle PWM frequency signal to control fan operation. Based on the difference between the final target fan speed and the current actual fan speed, it dynamically adjusts the fan request duty cycle PWM frequency signal using PID control to bring the actual fan speed closer to the target speed. When the target fan speed exceeds the physical maximum value, the physical maximum value is used as the target fan speed. Due to the inherent characteristics of the fan, its response speed sensitivity is not high. The intelligent thermal management control system, through the above control method, when the system detects the need for a significant increase in fan speed, initially controls the electronically controlled silicone oil fan clutch valve to open to a larger or full extent by increasing the PWM frequency signal, precisely controlling the duration of the larger or full opening, and then reverting to the PWM frequency signal calculated based on the above principle. This solves the problem of low response speed sensitivity caused by the inherent characteristics of the electronically controlled silicone oil fan and improves the response rate.

[0043] The intelligent thermal management control system acquires electrical signals from the fan sensor and calculates the current actual fan speed; including:

[0044] The intelligent thermal management control system acquires the electrical signal converted from the fan sensor frequency signal. After filtering, it sets effective low-level voltages below a set threshold as active low and effective high-level voltages above a set threshold as active high. Combining this with the n pulses per revolution determined by the fan's mechanical characteristics, the current actual fan speed is calculated using the following formula:

[0045] Current actual fan speed = (number of pulses ÷ counting time) × 60 ÷ (number of pulses per revolution).

[0046] Based on PID control, the PWM frequency signal of the fan request duty cycle is dynamically adjusted to make the actual fan speed closer to the target fan speed; including...

[0047] The intelligent thermal management control system selects P / I / D control parameters based on the hysteresis of the difference between the fan's final target speed and the current actual fan speed. When the speed difference is greater than the set speed, proportional P adjustment is performed; when the speed difference is less than the set speed, integral I and derivative D adjustment are performed. The P / I / D control adjusts the PWM frequency signal of the fan request duty cycle, so that the actual fan speed quickly and smoothly approaches the target speed. The P / I / D adjustment value is configured and flashed according to different models of retarder systems, air conditioning systems, and engine control system ECMs, automatically selecting different control values.

[0048] As described above, this invention features a limp-around function, comprehensively considering the fan, starting system, instrument system, retarder system, air conditioning system, and engine control system (ECM). The intelligent thermal management control system automatically selects different control paths and controls the fan to execute different speeds based on the different input signal states of the starting system, instrument system, retarder system, air conditioning system, and engine control system (ECM), as well as the cooling requirements of these systems, combined with factors such as cooling system type, ambient temperature, and vehicle speed. This invention makes comprehensive decisions based on multiple cooling requirements, automatically adjusting the control strategy and controlling the fan speed to achieve optimal cooling for the vehicle under different operating conditions and speeds, reducing accessory power consumption while lowering fuel consumption, thus meeting the requirements of intelligent thermal management control.

Claims

1. An intelligent thermal management control method, characterized in that, Based on the vehicle configuration character flashing method, the intelligent thermal management control system can automatically adapt to different models of retarder systems, air conditioning systems, and engine control mechanisms (ECMs); the method includes: The intelligent thermal management and control system acquires the key position signal from the starting system; When the intelligent thermal management control system detects that the vehicle is in the starting state, the intelligent thermal management control system acquires the electrical signal of the fan sensor and calculates the current actual fan speed; The intelligent thermal management control system acquires indoor and outdoor temperature information of the air conditioning system, automatically adapts to winter or summer control methods, and dynamically adjusts the engine coolant temperature, engine intake air temperature, and the corresponding target fan speed and fan direct connection temperature threshold according to the lookup table. It also acquires electrical signals related to the air conditioning system's air conditioning switch status, air conditioning three-state pressure switch status, and condenser pressure value. Alternatively, the intelligent thermal management control system receives message signals related to the cooling request fan speed percentage sent by the air conditioning system, automatically selects the fan control scheme for different target fan speeds, and the target fan speed varies depending on the vehicle speed sent by the instrument system. The intelligent thermal management control system acquires electrical signals related to the retarder's on / off position and message signals related to the actual torque percentage of the retarder, enabling the fan to use the maximum fan speed at the current engine speed as the target fan speed; or, the intelligent thermal management control system receives message signals related to the cooling request fan speed percentage from the retarder system, and automatically selects the fan control scheme corresponding to different target fan speeds; and the intelligent thermal management control system calculates the call time of the retarder system during combined braking, and when the call time exceeds a set threshold and the retarder coolant outlet temperature exceeds the fan direct connection temperature, enables the fan to use the maximum fan speed at the current engine speed as the target fan speed. The intelligent thermal management control system selects the maximum value of the target fan speed corresponding to the engine system, air conditioning system, retarder system, and combined braking system as the final target fan speed. It controls the fan request duty cycle PWM frequency signal to control the fan operation. Based on the difference between the final target fan speed and the current actual fan speed, it dynamically adjusts the fan request duty cycle PWM frequency signal according to PID control to make the actual fan speed approach the target fan speed. When the target fan speed exceeds the physical maximum value, the physical maximum value is used as the target fan speed.

2. The intelligent thermal management control method as described in claim 1, characterized in that, The intelligent thermal management control system acquires electrical signals from the fan sensor and calculates the current actual fan speed; including: The intelligent thermal management control system acquires the electrical signal converted from the fan sensor frequency signal. After filtering, it sets effective low-level voltages below a set threshold as active low and effective high-level voltages above a set threshold as active high. Combining this with the n pulses per revolution determined by the fan's mechanical characteristics, the current actual fan speed is calculated using the following formula: Current fan speed = (number of pulses ÷ counting time) × 60 ÷ (number of pulses per revolution).

3. The intelligent thermal management control method as described in claim 2, characterized in that, Based on PID control, the PWM frequency signal of the fan request duty cycle is dynamically adjusted to make the actual fan speed closer to the target fan speed; including: The intelligent thermal management control system selects P / I / D control parameters based on the hysteresis of the difference between the fan's final target speed and the current actual fan speed. When the speed difference is greater than the set speed, proportional P adjustment is performed; when the speed difference is less than the set speed, integral I and derivative D adjustment are performed. The P / I / D control adjusts the PWM frequency signal of the fan request duty cycle, so that the actual fan speed quickly and smoothly approaches the target speed. The P / I / D adjustment value is configured and flashed according to different models of retarder systems, air conditioning systems, and engine control system ECMs, automatically selecting different control values.

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