New energy vehicle waste heat recovery device and recovery method

Abstract

The present invention provides a waste heat recovery device and method for new energy vehicles, relating to the technical field of vehicle power motor cooling devices. The device comprises a hydrogen-helium heat exchanger housing, wherein two partitions divide the housing into a first heat exchange chamber and a second heat exchange chamber. A tube sheet is disposed between the partitions. A hydrogen heat exchange tube passes through the first heat exchange chamber and exits the tube sheet to form a circuit. A helium heat exchange tube is introduced from the tube sheet and passes through the second heat exchange chamber to form a circuit. The hydrogen and helium heat exchange tubes are staggered, with a straight length on the tube sheet of 30 mm to 50 mm. The first heat exchange chamber is connected to the motor assembly, and the second heat exchange chamber is connected to the air conditioning heating assembly. A three-way solenoid valve is provided on the pipe of the air conditioning heating assembly, and the heat dissipation assembly is connected in parallel with the air conditioning heating assembly via the three-way solenoid valve. This device solves the problems of poor heat dissipation and waste heat energy in the prior art, achieving the technical effect of rapidly cooling the power motor, efficiently exchanging heat, and recovering waste heat into the air conditioning system for energy reuse.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle power motor cooling devices, and in particular to a waste heat recovery device and a recovery method for a new energy vehicle. Background Art

[0002] In new energy vehicles, the power motor will generate a lot of heat during operation. If it cannot be cooled effectively and in a timely manner, the motor temperature will continue to rise, which will not only lead to a decline in motor performance and shorten its service life, but may also cause safety hazards.

[0003] Currently, most new energy vehicle power motor cooling systems utilize conventional tubular aluminum alloy radiators. The cooling medium flows through the tubular radiator, exchanging heat with the outside air through the tube walls, removing heat generated by the motor and discharging it directly, leaving the waste heat unused. Furthermore, the heat source for new energy vehicle air conditioning systems is relatively simple, relying solely on PTC heating. During vehicle operation, the heat exchanger and PTC heating operate independently, and therefore, there is no correlation between the two.

[0004] Therefore, the waste heat from the power motor and the heat source of the air conditioner in existing new energy vehicles have the following problems:

[0005] 1. In the cooling of the power motor, ordinary tubular aluminum alloy radiators are directly used to discharge heat out of the vehicle. The radiator has limited heat exchange efficiency and cannot quickly and stably dissipate the heat generated by the motor, and the waste heat is not recovered.

[0006] 2. Regarding heat recovery, new energy vehicles do not recycle waste heat generated by the motor heat exchanger into the air conditioning system. Instead, a large amount of waste heat is directly discharged to the outside world, resulting in energy waste. This not only increases the vehicle's energy consumption, but also causes the air conditioning system to rely entirely on PTC heating for heating, consuming excessive electricity and reducing the vehicle's range. Summary of the Invention

[0007] The purpose of the present invention is to provide a waste heat recovery device and a recovery method for new energy vehicles, so as to alleviate the technical problems in the prior art of directly using a radiator for heat dissipation, poor heat dissipation effect, and waste heat not being applied to the air-conditioning system, resulting in energy waste.

[0008] The present invention provides a waste heat recovery device for new energy vehicles, comprising: a hydrogen-helium heat exchanger, a motor assembly, an air conditioning heating assembly, a heat dissipation assembly, and a three-way solenoid valve;

[0009] The hydrogen-helium heat exchanger includes a shell, a partition, a first heat exchange cavity, a second heat exchange cavity, a tube sheet, a hydrogen heat exchange tube and a helium heat exchange tube;

[0010] The interior of the shell is separated into a first heat exchange chamber and a second heat exchange chamber by two partitions, with a tube sheet disposed between the two partitions. The hydrogen heat exchange tube passes through the first heat exchange chamber and is led out of the tube sheet to form a loop. The helium heat exchange tube is introduced from the tube sheet and passes through the second heat exchange chamber to form a loop. The hydrogen heat exchange tube and the helium heat exchange tube are staggered, and the straight length of the hydrogen heat exchange tube and the helium heat exchange tube on the tube sheet is 30 mm to 50 mm.

[0011] The first heat exchange chamber is connected to the motor assembly, and the second heat exchange chamber is connected to the air conditioning heating assembly. A three-way solenoid valve is also provided on the pipeline of the air conditioning heating assembly, and the heat dissipation assembly is connected in parallel with the air conditioning heating assembly through the three-way solenoid valve.

[0012] Furthermore, the hydrogen heat exchange tube passing through the first heat exchange cavity section and the helium heat exchange tube passing through the second heat exchange cavity section are both spiral.

[0013] Furthermore, the motor assembly includes a power motor and a first water pump; the first water pump is arranged in the water outlet pipe of the power motor, the first water pump is connected to the inlet end of the first heat exchange chamber, and the outlet end of the first heat exchange chamber is connected to the water inlet pipe of the power motor to form a loop.

[0014] Furthermore, the air conditioning heating component includes a warm air water pump, a water heating PTC, and an air conditioning warm air core; the warm air water pump, the water heating PTC and the air conditioning warm air core are arranged in sequence along the water flow direction on the outlet end pipeline of the second heat exchange chamber; the outlet end of the air conditioning warm air core is connected to the inlet end of the second heat exchange chamber to form a loop; the three-way solenoid valve is arranged in the upstream pipeline of the warm air water pump.

[0015] Furthermore, the heat dissipation component includes a radiator, a fan, and a second water pump; one side of the radiator's inlet end is connected to a three-way solenoid valve, and one side of the radiator's outlet end is connected to an upstream pipeline of the second water pump; the air outlet of the fan faces the radiator.

[0016] Furthermore, a plurality of temperature sensors are provided on the pipeline connecting the second heat exchange chamber and the air-conditioning heating component.

[0017] Furthermore, the radiator is a tubular radiator or an evaporative radiator.

[0018] The present invention also provides a method for recovering waste heat from a new energy vehicle, which uses the above-mentioned waste heat recovery device for a new energy vehicle and comprises the following steps:

[0019] Step 1: The hot water flowing out of the motor assembly flows through the first heat exchange chamber to transfer the waste heat to the hydrogen in the hydrogen heat exchange tube, and then cools down and flows back to the motor assembly;

[0020] Step 2: The hydrogen in the hydrogen heat exchange tube conducts heat with the helium in the helium heat exchange tube to exchange heat energy; the helium in the helium heat exchange tube then flows through the cold water at the outlet end of the adjusted heating component to be heated;

[0021] Step 3: When the heated water flows through the three-way solenoid valve, the three-way solenoid valve compares the heat Q1 generated by the motor component and the heat Q2 required by the air conditioning heating component, determines the switch side of the three-way solenoid valve, and transmits the waste heat to the air conditioning heating component to complete the waste heat recovery of the new energy vehicle.

[0022] Furthermore, the judgment method of the switch side of the three-way solenoid valve in step 3 is:

[0023] When the heat of Q1 is less than the heat of Q2 and the speed of the motor assembly is greater than 0, the air conditioning heating assembly heats itself, closes the valve on one side of the air conditioning heating assembly, and opens the heat dissipation assembly side to dissipate heat;

[0024] When the heat of Q1 is greater than or equal to the heat of Q2, the solenoid valve PID control method is used to determine whether Q2 has excess heat. When heat is not needed, the valve on one side of the heat dissipation component is opened;

[0025] When heat is needed, the valve on one side of the heat dissipation component is closed, and the valve opening on the side of the air conditioning heating component is opened and controlled, and the water after heat conduction is used to heat the air conditioning heating component 3 to complete the waste heat recovery of the new energy vehicle.

[0026] Furthermore, the solenoid valve PID control method uses the position PID and incremental PID in parallel as the outer loop to calculate the target opening of the solenoid valve, and then connects the outer loop and the inner loop incremental PID in series to calculate the final opening of the solenoid valve;

[0027] The position PID calculation formula in the outer loop is:

[0028] (1);

[0029] Where u(k) is the control output at the kth moment; Kp is the proportional coefficient; e(k) is the error value (Q1-Q2) at the kth moment; Ki is the integral coefficient; Ki×∑e(k) is the cumulative sum of all errors from the beginning to the kth moment, and Kd is the differential coefficient;

[0030] The incremental PID calculation formula in the outer loop or inner loop is:

[0031] (2);

[0032] Where Δu(k) is the increment of the controlled variable at the kth moment; Kp, Ki, Kd, ​​and e(k) are the same as those in the position PID; e(k-1) is the error value at the k-1th moment, and e(k-2) is the error value at the k-2th moment.

[0033] Beneficial effects:

[0034] The present invention provides a waste heat recovery device for new energy vehicles and a recovery method thereof, comprising a hydrogen-helium heat exchanger, wherein the interior of the hydrogen-helium heat exchanger shell is separated into a first heat exchange chamber and a second heat exchange chamber by two partitions, and a tube sheet is arranged between the two partitions; the hydrogen heat exchange tubes and the helium heat exchange tubes are staggered, and the straight lengths of the hydrogen heat exchange tubes and the helium heat exchange tubes on the tube sheet are 30 mm to 50 mm. The hydrogen heat exchange tubes pass through the first heat exchange chamber and are led out from the tube sheet to form a loop; the helium heat exchange tubes are introduced from the tube sheet and pass through the second heat exchange chamber to form a loop; the first heat exchange chamber is connected to a motor assembly, and the second heat exchange chamber is connected to an air-conditioning heating assembly. A three-way solenoid valve is also arranged on the pipeline of the air-conditioning heating assembly, and the heat dissipation assembly is connected in parallel with the air-conditioning heating assembly through the three-way solenoid valve.

[0035] The hydrogen-helium heat exchanger utilizes the heat conduction effect between hydrogen and helium to achieve efficient heat exchange from high-temperature hydrogen to low-temperature helium, rapidly reducing the power motor temperature and improving motor performance while transferring waste heat to the helium. The helium side is connected to the air conditioning heating component, which can recover waste heat to the air conditioning system, reducing vehicle energy consumption and enabling waste heat reuse in new energy vehicles. Furthermore, a three-way solenoid valve is installed on the air conditioning heating component pipeline, with the heat dissipation component connected in parallel. This allows for flexible control of waste heat flow based on actual heat demand. When the air conditioning does not require heat, the heat dissipation component can be used to discharge waste heat outside the vehicle. When the air conditioning does require heat, the heat dissipation component is closed, transferring the heat to the air conditioning system, improving energy efficiency.

[0036] In summary, the present invention can not only improve the heat dissipation effect of new energy vehicles, but also recycle the waste heat originally directly discharged into the air-conditioning system; and stably transport it according to the opening of the solenoid valve in the method. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0038] Figure 1 A schematic structural diagram of a waste heat recovery device for a new energy vehicle provided by an embodiment of the present invention;

[0039] Figure 2 A schematic structural diagram of a hydrogen-helium heat exchanger in a waste heat recovery device for a new energy vehicle provided by an embodiment of the present invention;

[0040] Figure 3 A flow chart of a method for recovering waste heat from a new energy vehicle provided by an embodiment of the present invention;

[0041] Figure 4 A switching logic diagram of a three-way solenoid valve in a waste heat recovery method for new energy vehicles provided by an embodiment of the present invention;

[0042] Figure 5 This is a flow chart of the solenoid valve PID control method in the new energy vehicle waste heat recovery method provided by an embodiment of the present invention.

[0043] Icons: 1-Hydrogen-helium heat exchanger; 101-shell; 102-partition; 103-first heat exchange chamber; 104-second heat exchange chamber; 105-tube sheet; 106-hydrogen heat exchange tube; 107-helium heat exchange tube; 2-motor assembly; 201-power motor; 202-first water pump; 3-air conditioning heating assembly; 301-warm air water pump; 302-water heating PTC; 303-air conditioning warm air core; 4-heating assembly; 401-radiator; 402-fan; 403-second water pump; 5-three-way solenoid valve; 6-temperature sensor. DETAILED DESCRIPTION

[0044] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0045] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort shall fall within the scope of protection of the present invention.

[0046] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0047] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" and the like indicate positions or locations based on the positions shown in the accompanying drawings, or the positions or locations in which the inventive product is typically placed when in use. These terms are intended solely to facilitate the description of the present invention and to simplify the description, and are not intended to indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third," etc., are used solely to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0048] Furthermore, terms such as "horizontal," "vertical," and "overhanging" do not necessarily imply that a component must be absolutely horizontal or overhanging, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but rather that it can be slightly tilted.

[0049] In the description of the present invention, it should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to mechanical connections or electrical connections; they may refer to direct connections or indirect connections through an intermediate medium; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0050] The following embodiments of the present invention are described in detail with reference to the accompanying drawings. In the absence of conflict, the following embodiments and features in the embodiments may be combined with each other.

[0051] like Figure 1 、 Figure 2 As shown, the present invention provides a waste heat recovery device for new energy vehicles, comprising: a hydrogen-helium heat exchanger 1, a motor assembly 2, an air conditioning heating assembly 3, a heat dissipation assembly 4 and a three-way solenoid valve 5;

[0052] The hydrogen-helium heat exchanger 1 includes a shell 101, a partition 102, a first heat exchange cavity 103, a second heat exchange cavity 104, a tube sheet 105, a hydrogen heat exchange tube 106 and a helium heat exchange tube 107;

[0053] The interior of the shell 101 is separated into a first heat exchange chamber 103 and a second heat exchange chamber 104 by two partitions 102. The tube sheet 105 is provided between the two partitions 102. The hydrogen heat exchange tubes and the helium heat exchange tubes are staggered. The straight lengths of the hydrogen heat exchange tubes and the helium heat exchange tubes on the tube sheet are 30 mm to 50 mm. The hydrogen heat exchange tube 106 passes through the first heat exchange chamber 103 and is led out from the tube sheet 105 to form a loop. The helium heat exchange tube 107 is introduced from the tube sheet 105 and passes through the second heat exchange chamber 104 to form a loop.

[0054] The first heat exchange chamber 103 is connected to the motor assembly 2, and the second heat exchange chamber 104 is connected to the air conditioning heating assembly 3. A three-way solenoid valve 5 is also provided on the pipeline of the air conditioning heating assembly 3, and the heat dissipation assembly 4 is connected in parallel with the air conditioning heating assembly 3 through the three-way solenoid valve 5.

[0055] Specifically, the hydrogen-helium heat exchanger 1 serves as a heat exchange part connecting the two ends of the loop, such as Figure 2As shown, a set of water inlets and outlets are provided at each end, and two partitions 102 separate the interior of the housing 101 into a first heat exchange chamber 103 and a second heat exchange chamber 104. Hot water discharged from the motor assembly 2 enters the first heat exchange chamber 103 and is absorbed by the hydrogen heat exchange tube 106 before being discharged. Similarly, the helium heat exchange tube 107 absorbs heat from the hydrogen heat exchange tube 106 and heats the fluid flowing back from the air conditioning heating assembly 3 at the other end. The cavity between the two partitions 102 is provided with a tube sheet 105. Two holes are provided between the two partitions 102 for the hydrogen heat exchange tube 106 and the helium heat exchange tube 107 to pass through and be arranged on the tube sheet 105. The tube sheet 105 is typically made of high-strength, corrosion-resistant carbon steel or aluminum alloy, and is covered with holes for the hydrogen heat exchange tube 106 and the helium heat exchange tube 107. The hydrogen heat exchange tubes 106 and the helium heat exchange tubes 107 are arranged in a staggered manner on the tube sheet 105, thereby maximizing the contact area and time between the two gases during the heat exchange process.

[0056] The tube wall of the hydrogen heat exchange tube 106 has good thermal conductivity and can absorb the heat in the first heat exchange cavity 103. After passing through the first heat exchange cavity 103, the hydrogen heat exchange tube 106 is led out from the other side of the tube sheet 105 and forms a closed loop. In this loop, hydrogen absorbs heat, realizing the effective transfer of heat from the first heat exchange cavity 103 of the high-temperature water discharged from the motor assembly 2. The layout of the helium heat exchange tube 107 cooperates with the hydrogen heat exchange tube 106, is introduced from the tube sheet 105, and then passes through the second heat exchange cavity 104. The helium heat exchange tube 107 also has excellent thermal conductivity and can transfer the absorbed heat to the second heat exchange cavity 104. After passing through the second heat exchange cavity 104, the helium heat exchange tube 107 also forms an independent closed loop, in which helium circulates and continuously exchanges heat.

[0057] It should be noted that the staggered shape of the hydrogen heat exchange tubes 106 and the helium heat exchange tubes 107 on the tube sheet 105 can be a broken line staggered shape (such as Figure 2 The heat exchange tubes 106 and 107 are shaped like a spiral (DNA) or other shapes to maximize contact between the two heat exchange tubes, promoting heat transfer from hydrogen to helium. Each straight-line fold on the tube sheet 105 is 30mm to 50mm long, maximizing contact length within the vehicle. This significantly increases the length and surface area of ​​the hydrogen and helium heat exchange tubes 106 and 107 within the limited space, allowing for more contact time between the hydrogen and helium gases, thereby improving heat exchange efficiency and ensuring more efficient heat transfer.

[0058] Optionally, the straight length of each folded-back section is 30 mm, 45 mm or 50 mm.

[0059] It should be noted that the surfaces of the hydrogen heat exchange tube 106 and the helium heat exchange tube 107 are also provided with regularly arranged hemispherical bumps, with a height of 0.3 mm to 0.5 mm. Since the operating pressure in the hydrogen heat exchange tube 106 is 0.3 MPa to 0.5 MPa higher than that in the helium heat exchange tube 107, the density of the bumps on the surface of the hydrogen heat exchange tube 106 should be 30% to 40% higher than that on the surface of the helium heat exchange tube 107.

[0060] By adding bumps, hydrogen and helium can form a more intense turbulent flow effect when flowing through the tube, thereby improving heat transfer efficiency. The high density of bumps in the hydrogen heat exchange tube 106 is due to the more intense movement of hydrogen molecules under high pressure, and the dense bumps can achieve more efficient heat transfer.

[0061] It should be noted that hydrogen and helium have relatively high thermal conductivity among common gases. In hydrogen-helium heat exchanger 1, this high thermal conductivity enables hydrogen and helium to quickly transfer heat, significantly improving heat exchange efficiency. The two gases in hydrogen heat exchange tube 106 and helium heat exchange tube 107 circulate in their respective loops, continuously and efficiently exchanging heat. Compared to traditional heat exchange methods, this significantly improves heat exchange efficiency and rapidly reduces the temperature of motor assembly 2.

[0062] A three-way solenoid valve 5 is installed in the piping of the air conditioning heating assembly 3. The three-way solenoid valve comprises a valve body, a valve core, and a control unit (not shown). Under the precise control of the control unit, the valve core can rapidly switch between different operating modes. The heat dissipation assembly 4 is connected in parallel with the air conditioning heating assembly 3 via the three-way solenoid valve 5. When the three-way solenoid valve 5 is switched to a specific position, the thermal fluid from the hydrogen-helium heat exchanger 1 flows to the heat dissipation assembly 4, where it dissipates heat to the outside environment through its cooling fins. When the three-way solenoid valve 5 is switched to another position, the heat dissipation assembly 4 is disconnected from the system, and the thermal fluid flows to the air conditioning heating assembly 3, meeting the heating needs of the air conditioner. This not only reduces vehicle energy waste but also improves the overall energy utilization rate, aligning with the energy-saving and environmentally friendly development philosophy of new energy vehicles and reducing vehicle operating costs.

[0063] In an embodiment of the present invention, the motor assembly 2 includes a power motor 201 and a first water pump 202;

[0064] The first water pump 202 is arranged on the water outlet pipeline of the power motor 201 , and the first water pump 202 is connected to the inlet end of the first heat exchange chamber 103 , and the outlet end of the first heat exchange chamber 103 is connected to the water inlet pipeline of the power motor 201 to form a loop.

[0065] The section of the hydrogen heat exchange tube 106 passing through the first heat exchange cavity 103 and the section of the helium heat exchange tube 107 passing through the second heat exchange cavity 104 are both spiral.

[0066] Specifically, the first water pump 202 is installed on the water outlet pipe of the power motor 201, promoting fluid circulation. One end of the first water pump 202 is connected to the water outlet pipe of the power motor 201, ensuring that the heat-laden fluid flowing out of the power motor 201 can smoothly enter the first water pump 202. The other end of the first water pump 202 is connected to the inlet of the first heat exchange chamber 103. Through its pumping capacity, the first heat exchange chamber 103 continuously injects high-temperature fluid into the first heat exchange chamber 103. The first heat exchange chamber 103 serves as a heat exchange site and then returns the cooled fluid to the power motor 201 for use.

[0067] like Figure 2 As shown, the portion of hydrogen heat exchange tube 106 passing through first heat exchange chamber 103, and the portion of helium heat exchange tube 107 passing through second heat exchange chamber 104, are both spiral. This spiral shape significantly increases the contact area between hydrogen heat exchange tube 106 and the fluid in first heat exchange chamber 103, utilizing the space within the chambers. This allows heat from the fluid to be more fully transferred to the hydrogen within hydrogen heat exchange tube 106. Similarly, the spiral portion of helium heat exchange tube 107 within second heat exchange chamber 104 also expands its contact area with the fluid within the chamber, allowing it to transfer waste heat to the fluid within second heat exchange chamber 104.

[0068] In an embodiment of the present invention, the air conditioning heating component 3 includes a warm air water pump 301, a water heating PTC 302, and an air conditioning warm air core 303; the warm air water pump 301, the water heating PTC 302 and the air conditioning warm air core 303 are arranged in sequence along the water flow direction on the outlet end pipeline of the second heat exchange chamber 104; the outlet end of the air conditioning warm air core 303 is connected to the inlet end of the second heat exchange chamber 104 to form a loop; the three-way solenoid valve 5 is arranged in the upstream pipeline of the warm air water pump 301.

[0069] The heat dissipation component 4 includes a radiator 401, a fan 402, and a second water pump 403; one side of the inlet end of the radiator 401 is connected to the three-way solenoid valve 5, and one side of the outlet end of the radiator 401 is connected to the upstream pipeline of the second water pump 403; the air outlet of the fan 402 faces the radiator 401.

[0070] Several temperature sensors 6 are also provided on the pipeline connecting the second heat exchange cavity 104 and the air conditioning heating component 3 .

[0071] The radiator 401 is a tubular radiator or an evaporative radiator.

[0072] Specifically, the air conditioning heating assembly 3 is used for heating the interior of the vehicle and is composed of a heater water pump 301, a water heating PTC 302, and an air conditioning heater core 303. In the pipeline connected to the second heat exchange chamber 104, the various components are arranged in sequence along the direction of water flow. The heater water pump 301 is located at the upstream end and generates power through mechanical operation to promote the circulation flow, ensuring that the fluid heated by waste heat can continuously and stably enter the water heating PTC 302. When the fluid heated once flows through the water heating PTC 302, the temperature is further increased and heated again. After being heated by the water heating PTC 302, it enters the air conditioning heater core 303 and delivers heat into the vehicle from inside the core. The outlet end of the air conditioning heater core 303 is connected to the inlet end of the second heat exchange chamber 104 through a pipeline, forming a circulation loop. In this loop, the fluid whose heat is absorbed by the air conditioning heater core 303 returns to the second heat exchange chamber 104 and is heated by helium. The three-way solenoid valve 5, located upstream of the heater pump 301, controls the flow of fluid according to actual needs. When heating is required, the three-way solenoid valve 5 directs the fluid to the air conditioning heating assembly 3 for heating. When heating is not required, the three-way solenoid valve 5 redirects the fluid to the heat dissipation assembly 4 for normal heat dissipation.

[0073] The heat dissipation component 4 includes a radiator 401, a fan 402 and a second water pump 403. One side of the inlet end of the radiator 401 is connected to the three-way solenoid valve 5. The radiator 401 adopts different heat dissipation methods according to different types. If it is a tubular radiator, the fluid flows in the tube and transfers heat to the surrounding air through the tube wall; if it is an evaporative radiator, the fluid evaporates inside the radiator, and a large amount of heat is taken away by the latent heat of evaporation to achieve efficient heat dissipation. The air outlet of the fan 402 faces the radiator 401, accelerating the air flow. When the fan 402 is running, a large amount of air flows quickly through the surface of the radiator 401, taking away the heat emitted by the radiator 401 and dissipating it outside the vehicle. The second water pump 403 is located in the downstream pipeline on the outlet side of the radiator 401. Its function is similar to that of the warm air water pump 301, providing power for the fluid so that it can smoothly flow back to the second heating chamber to maintain circulation.

[0074] Several temperature sensors 6 are also installed on the pipeline connecting the second heat exchange chamber 104 and the air conditioning heating assembly 3. These temperature sensors 6 are distributed at different locations to monitor the temperature changes of the fluid in real time. They transmit the collected temperature data to the three-way solenoid valve 5 for control.

[0075] The embodiment of the present invention also provides a new energy vehicle waste heat recovery method, which uses the new energy vehicle waste heat recovery device in the above embodiment, such as Figure 3 As shown, the following steps are included:

[0076] Step 1: The hot water flowing out of the motor assembly 2 flows through the first heat exchange chamber 103 to transfer the waste heat to the hydrogen in the hydrogen heat exchange pipe 106, and then cools down and flows back to the motor assembly 2;

[0077] Specifically, the motor assembly 2 generates a large amount of heat during continuous operation, causing the temperature of the fluid in contact with it to rise sharply, forming high-temperature water. The hot water flows out of the power motor 201 along the pipeline, enters the first water pump 202, and flows into the first heat exchange chamber 103. Inside the first heat exchange chamber 103, the hydrogen heat exchange tube 106 is distributed in a spiral shape. When the hot water flows in the first heat exchange chamber 103, the waste heat it carries is transferred to the hydrogen in the hydrogen heat exchange tube 106. The hydrogen quickly absorbs heat, causing the temperature of the hot water to gradually decrease. After the heat exchange is completed, the cooled fluid flows back to the power motor 201 through the pipeline through the outlet end of the first heat exchange chamber 103, forming a continuous and stable cooling cycle. The operating temperature of the power motor 201 is controlled to ensure that it operates efficiently within an appropriate temperature range, avoiding performance degradation and failures caused by overheating.

[0078] Step 2: The hydrogen in the hydrogen heat exchange tube 106 and the helium in the helium heat exchange tube 107 conduct heat to exchange heat energy; the helium in the helium heat exchange tube 107 then flows through the cold water at the outlet end of the air conditioning heating component 3 to be heated;

[0079] Specifically, the hydrogen in hydrogen heat exchange tube 106 absorbs heat from the hot water, raising its temperature. At this point, the hydrogen and the helium in the adjacent helium heat exchange tube 107 conduct heat transfer through the tube wall. Because of the temperature difference between the two gases, heat is transferred from the high-temperature hydrogen to the low-temperature helium, achieving a heat exchange between the two gases. After this heat exchange, the helium's temperature rises significantly, carrying a significant amount of heat energy. Meanwhile, in the air conditioning heating assembly 3, there is heated cold water at a lower temperature. The heated helium in the helium heat exchange tube 107 contacts the cold water in the second heat exchange chamber 104, transferring its heat to the cold water. After absorbing the heat, the cold water is ready for subsequent heating applications. This achieves efficient heat transfer from the waste heat of motor assembly 2 to the cold water in the air conditioning heating assembly 3, improving energy utilization.

[0080] Step 3: When the heated water flows through the three-way solenoid valve 5, the three-way solenoid valve 5 compares the heat Q1 generated by the motor component 2 with the heat Q2 required by the air-conditioning heating component 3, determines the switch side of the three-way solenoid valve 5, and transmits the waste heat to the air-conditioning heating component 3 to complete the waste heat recovery of the new energy vehicle.

[0081] Specifically, if Figure 4 As shown, the judgment method of the switch side of the three-way solenoid valve 5 is: there are four cases in total;

[0082] The first is when the heat of Q1 is less than the heat of Q2 and the speed of the motor assembly 2 is greater than 0 (the speed of the power motor 201 is not 0 at this time, indicating that it is working), the air conditioning heating assembly 3 is heated by its own heat, the valve on the air conditioning heating assembly 3 is closed, and the heat dissipation assembly 4 is opened to dissipate heat. In addition, there is another situation:

[0083] The second type is when the heat of Q1 is less than the heat of Q2 and the speed of motor component 2 is 0, it means that none of them are working and they can be turned off.

[0084] The third method is to determine whether Q2 has excess heat according to the solenoid valve PID control method when the heat of Q1 is greater than or equal to the heat of Q2. If heat is not needed, the valve on one side of the heat dissipation component 4 is opened to dissipate heat.

[0085] The fourth method is that when the heat of Q1 is greater than or equal to the heat of Q2, Q2 needs heat, close the valve on the side of the heat dissipation component 4, open and control the opening of the valve on the side of the air-conditioning heating component 3, and use the water after heat conduction to heat the air-conditioning heating component 3 to complete the waste heat recovery of the new energy vehicle.

[0086] It should be noted that the heat generated by the motor is Q1=CM(T1n-T1(n-1)), where T1n is the heat exchange temperature at the current moment, T1(n-1) is the heat exchange temperature at the previous moment, C is the specific heat capacity, and M is the mass; the heat required by the air conditioner is Q2=CM(target water temperature-T2), and T2 is the current water temperature.

[0087] like Figure 5 As shown in the figure, the solenoid valve PID control method uses the position PID and incremental PID in parallel as the outer loop to calculate the target opening of the solenoid valve, and then connects the outer loop and the inner loop incremental PID in series to calculate the final opening of the solenoid valve;

[0088] The calculation formula of the outer loop position PID is:

[0089] (1);

[0090] Where u(k) is the control output at the kth moment (the target opening of the solenoid valve); Kp is the proportional coefficient; e(k) is the error value at the kth moment (Q1-Q2); Ki is the integral coefficient; Ki×∑e(k) is the cumulative sum of all errors from the beginning to the kth moment, and Kd is the differential coefficient.

[0091] The incremental PID calculation formula for the outer loop or inner loop is:

[0092] (2);

[0093] Where Δu(k) is the increment of the control quantity at the kth moment (the change in the target opening of the solenoid valve); Kp, Ki, Kd, ​​and e(k) are the same as those in the position PID; e(k-1) is the error value at the k-1th moment, and e(k-2) is the error value at the k-2th moment.

[0094] It should be noted that if Figure 5 As shown, el(t) is Q1-Q2, ul(t) represents the target opening of the solenoid valve, e2(t) represents the target opening of the solenoid valve-the actual opening of the solenoid valve, and u2(t) represents the final output opening.

[0095] It should be noted that if the heat generated by the power motor 201 is not stable enough, the heat compensated to the air conditioning heating component 3 will also be unstable. If the heat delivered is lower or higher than required, it will cause unstable temperature control and affect comfort. Therefore, in order to stably compensate the heat of the power motor 201 to the air conditioner, it is necessary to quickly respond to the change of heat during the heat climbing stage, predict the peak heat in advance, and accurately calculate after the heat reaches the peak and stabilizes. Through analysis of the system, the calculation is performed by using a method of position PID and incremental PID in parallel and then in series with the inner loop. When the heat exchange is unstable, the incremental PID is used to calculate the target opening of the solenoid valve. When the heat is stable, the position PID is used to calculate the target opening of the solenoid valve. This can stably control the three-way solenoid valve 5 and stably deliver heat to the air conditioning heating component 3.

[0096] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A waste heat recovery device for new energy vehicles, characterized in that: include: A hydrogen-helium heat exchanger (1), a motor assembly (2), an air conditioning heating assembly (3), a heat dissipation assembly (4) and a three-way solenoid valve (5); The hydrogen-helium heat exchanger (1) comprises a shell (101), a partition (102), a first heat exchange cavity (103), a second heat exchange cavity (104), a tube sheet (105), a hydrogen heat exchange tube (106), and a helium heat exchange tube (107); The interior of the shell (101) is separated into the first heat exchange chamber (103) and the second heat exchange chamber (104) by two partitions (102), and the tube sheet (105) is provided between the two partitions (102); the hydrogen heat exchange tube (106) passes through the first heat exchange chamber (103) and is led out from the tube sheet (105) to form a loop; the helium heat exchange tube (107) is introduced from the tube sheet (105) and passes through the second heat exchange chamber (104) and form a loop, the hydrogen heat exchange tube (106) and the helium heat exchange tube (107) are staggered, and the straight length of each fold of the hydrogen heat exchange tube (106) and the helium heat exchange tube (107) on the tube plate (105) is 30 mm to 50 mm; on the surface of the hydrogen heat exchange tube (106) and the helium heat exchange tube (107), regularly arranged hemispherical protrusions are also provided, and the height of the protrusions is 0.3 mm to 0.5 mm; The first heat exchange chamber (103) is connected to the motor assembly (2), and the second heat exchange chamber (104) is connected to the air conditioning heating assembly (3). A three-way solenoid valve (5) is also provided on the pipeline of the air conditioning heating assembly (3), and the heat dissipation assembly (4) is connected in parallel with the air conditioning heating assembly (3) via the three-way solenoid valve (5).

2. The waste heat recovery device for new energy vehicles according to claim 1, characterized in that: The section of the hydrogen heat exchange tube (106) passing through the first heat exchange cavity (103) and the section of the helium heat exchange tube (107) passing through the second heat exchange cavity (104) are both spiral.

3. The waste heat recovery device for new energy vehicles according to claim 1, characterized in that: The motor assembly (2) comprises a power motor (201) and a first water pump (202); The first water pump (202) is arranged on the water outlet pipeline of the power motor (201), the first water pump (202) is connected to the inlet end of the first heat exchange chamber (103), and the outlet end of the first heat exchange chamber (103) is connected to the water inlet pipeline of the power motor (201) to form a loop.

4. The waste heat recovery device for new energy vehicles according to claim 1, characterized in that: The air conditioning heating component (3) comprises a warm air water pump (301), a water heating PTC (302), and an air conditioning warm air core (303); The warm air pump (301), the water heating PTC (302) and the air conditioning warm air core (303) are arranged in sequence along the water flow direction on the outlet pipe of the second heat exchange chamber (104); the outlet end of the air conditioning warm air core (303) is connected to the inlet end of the second heat exchange chamber (104) to form a loop; the three-way solenoid valve (5) is arranged in the upstream pipe of the warm air pump (301).

5. The waste heat recovery device for new energy vehicles according to claim 1, characterized in that: The heat dissipation component (4) includes a radiator (401), a fan (402), and a second water pump (403); One side of the inlet end of the radiator (401) is connected to the three-way solenoid valve (5), and one side of the outlet end of the radiator (401) is connected to the upstream pipeline of the second water pump (403); the air outlet of the fan (402) faces the radiator (401).

6. The waste heat recovery device for new energy vehicles according to claim 4, characterized in that: A plurality of temperature sensors (6) are also provided on the pipeline connecting the second heat exchange chamber (104) and the air-conditioning heating component (3).

7. The waste heat recovery device for new energy vehicles according to claim 5, characterized in that: The radiator (401) is a tubular radiator or an evaporative radiator.

8. A method for recovering waste heat from new energy vehicles, characterized in that: The method uses the new energy vehicle waste heat recovery device according to any one of claims 1 to 7, comprising the following steps: Step 1: The hot water flowing out of the motor assembly (2) flows through the first heat exchange chamber (103) to transfer waste heat to the hydrogen in the hydrogen heat exchange pipe (106), and then cools down and flows back to the motor assembly (2); Step 2: The hydrogen in the hydrogen heat exchange tube (106) and the helium in the helium heat exchange tube (107) conduct heat to exchange heat energy; the helium in the helium heat exchange tube (107) then flows through the cold water at the outlet end of the air conditioning heating component (3) to be heated; Step 3: When the heated water flows through the three-way solenoid valve (5), the three-way solenoid valve (5) compares the heat Q1 generated by the motor component (2) with the heat Q2 required by the air-conditioning heating component (3), determines the switch side of the three-way solenoid valve (5), and transmits the waste heat to the air-conditioning heating component (3), thereby completing the waste heat recovery of the new energy vehicle; The judgment method of the switch side of the three-way solenoid valve (5) in step 3 is: When the heat of Q1 is less than the heat of Q2 and the speed of the motor component (2) is greater than 0, the air conditioning heating component (3) is heated by its own heat, the valve on one side of the air conditioning heating component (3) is closed, and the heat dissipation component (4) is opened to dissipate heat; When the heat of Q1 is greater than or equal to the heat of Q2, it is determined whether Q2 has excess heat according to the solenoid valve PID control method, and when heat is not needed, the valve on one side of the heat dissipation component (4) is opened; When heat is needed, the valve on one side of the heat dissipation component (4) is closed, and the valve on one side of the air conditioning heating component (3) is opened and the opening is controlled, and the water after heat conduction is used to heat the air conditioning heating component (3), thereby completing the waste heat recovery of the new energy vehicle; The solenoid valve PID control method uses a position PID and an incremental PID in parallel as an outer loop to calculate the target opening of the solenoid valve, and then connects the outer loop and the inner loop incremental PID in series to calculate the final opening of the solenoid valve; The position PID calculation formula in the outer loop is: （1）； Where u(k) is the control output at the kth moment; Kp is the proportional coefficient; e(k) is the error value (Q1-Q2) at the kth moment; Ki is the integral coefficient; Ki×∑e(k) is the cumulative sum of all errors from the beginning to the kth moment, and Kd is the differential coefficient; The incremental PID calculation formula in the outer loop or inner loop is: （2）； Where Δu(k) is the increment of the controlled variable at the kth moment; Kp, Ki, Kd, ​​and e(k) are the same as those in the position PID; e(k-1) is the error value at the k-1th moment, and e(k-2) is the error value at the k-2th moment.

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