Thermal management system and method for a motor vehicle
By designing a thermal management system in a motor vehicle fluid heater, and using the control unit to monitor the housing temperature to determine the existence or absence of the heat exchange fluid, the problem of difficulty in detecting liquid levels in the prior art is solved, and safe and reliable thermal management is achieved.
Patent Information
- Application Number
- CN202380072561.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-10-14
- Filing Date
- 2023-10-12
- Publication Date
- 2025-05-13
AI Technical Summary
The prior art is difficult to effectively detect the liquid level of heat exchange fluid in the fluid heater of a motor vehicle, and there are safety hazards.
A thermal management system is designed, including a fluid heater and a control unit communicating with the heater. The control unit determines the presence or absence of the heat exchange fluid by monitoring the housing temperature, and determines the liquid level based on the temperature and time period.
Effective detection and determination of the heat exchange fluid level is achieved, safety hazards caused by overheating of the heater are avoided, and additional components are not required to be added to the heater.
Smart Images
Figure CN119998599A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a thermal management system and method for a motor vehicle. In particular, the present invention relates to a thermal management system and method for detecting and measuring the level of a heat exchange fluid in a fluid heater of a motor vehicle. Background Art
[0002] Motor vehicles, such as plug-in hybrid electric vehicles and electric vehicles with internal combustion engines, often employ a rechargeable energy storage system (RESS), such as a battery pack or other rechargeable energy storage device, to store large amounts of energy for the electric propulsion system. Typically, these types of vehicles may include a heater, such as a high-pressure coolant heater, to regulate the temperature of the battery pack in order to maximize the charge capacity and life of the battery pack or to heat the vehicle interior.
[0003] The heater includes a housing having an inlet and an outlet for the flow of a heat exchange fluid. A heating element is positioned within the housing in a heat transfer relationship with a coolant, the coolant being used to transfer heat to the heating element. The heating element may be controlled, for example, by a control circuit. The heater also includes a flow sensor for detecting the coolant level of the heater and a temperature sensor for detecting a temperature rise in the heater. In the absence of liquid in the heater, its temperature will rise rapidly, posing a risk of causing a fire in the surrounding area. Therefore, it is necessary to be able to easily detect the absence of a heat exchange fluid. Although the sensor detects the level of the coolant, it cannot effectively determine the absence of the coolant.
[0004] Therefore, there is a need for a thermal management system for a motor vehicle to detect and measure the level of a heat exchange fluid in a fluid heater of the motor vehicle. Summary of the invention
[0005] In this specification, some elements or parameters may be indexed, such as first element and second element. In this case, unless otherwise specified, such indexing is only used to distinguish and name similar but not identical elements. The concept of priority should not be inferred from such indexing, as these terms can be interchanged without departing from the present invention. In addition, such indexing does not imply any order in the installation or use of the elements of the present invention.
[0006] In view of the above situation, the present invention discloses a thermal management system for a motor vehicle. The system includes a fluid heater having: a housing having an inlet and an outlet for the flow of a heat exchange fluid; a heating module positioned in the housing and having a heat transfer relationship with the heat exchange fluid; and at least one temperature sensor positioned at the housing to generate a signal indicating the temperature of the housing. The system also includes a control unit in communication with the sensor, the control unit being configured to control the heating module. The control unit is configured to operate the heating module at at least one predetermined power level. The control unit is also configured to monitor the temperature of the housing to detect whether the temperature of the housing exceeds a predetermined temperature within a predetermined time. The control unit is also configured to detect the presence of a heat exchange fluid when the temperature of the housing is below a predetermined temperature within a predetermined time. The control unit is also configured to determine the liquid level of the heat exchange fluid based on the temperature of the housing and the time period for reaching the temperature of the housing.
[0007] The control unit is further configured to determine that the heat exchange fluid is absent when the temperature of the housing exceeds a predetermined temperature within a predetermined time.
[0008] The control unit is also configured to determine a range of power levels for operating the heating module. The predetermined power levels are less than a nominal power level of the heating module. The control unit is also configured to transmit data related to the heat exchange fluid to one or more control units of the vehicle.
[0009] The present invention also discloses a method for detecting and measuring the level of a heat exchange fluid in a fluid heater of a thermal management system of a motor vehicle. The system includes a heater having a housing having an inlet and an outlet for the flow of a heat exchange fluid. The heater also includes a heating module positioned in the housing and in heat exchange relationship with the heat exchange fluid, a sensor positioned at the housing to generate a signal indicating the temperature of the housing, and a control unit for operating the heater. In one step, the control unit operates the heating module at at least one predetermined power level.
[0010] In another step, the control unit monitors the temperature of the housing to detect whether the temperature of the housing exceeds a predetermined temperature within a predetermined time. In another step, the control unit detects the presence of the heat exchange fluid when the temperature of the housing is below a predetermined temperature within a predetermined time. In yet another step, the control unit determines the level of the heat exchange fluid based on the temperature of the housing and the time period to reach the temperature of the housing.
[0011] In a further step, the control unit determines that the heat exchange fluid is not present when the temperature of the housing exceeds a predetermined temperature within a predetermined time. The control unit is further configured to determine a range of power levels for operating the heating module. The predetermined power level is less than a nominal power level of the heating module. In a further step, the control unit transmits data related to the heat exchange fluid to one or more control units of the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other features, details and advantages of the present invention can be inferred from the following description of the invention. A more complete understanding of the present invention and its many attendant advantages will be readily obtained and will become better understood by referring to the following detailed description when considered in conjunction with the accompanying drawings, in which:
[0013] Figure 1 is a simplified partial schematic diagram of a thermal management system for a motor vehicle controlling a fluid heater according to an embodiment of the present invention;
[0014] Figure 2 yes Figure 1 A perspective view of a coolant heater;
[0015] Figure 3 yes Figure 1 A cross-sectional view of a coolant heater, and
[0016] Figure 4 is a flow chart of a method for detecting and measuring the level of a heat exchange fluid in a fluid heater. DETAILED DESCRIPTION
[0017] It must be noted that the drawings disclose the invention in sufficient detail to help better define the invention if necessary. However, the invention should not be limited to the embodiments disclosed in the description.
[0018] The present invention discloses a thermal management system and method for a motor vehicle. The system includes a fluid heater and a control unit in communication with the heater. The heater includes a housing having an inlet and an outlet for a heat exchange fluid to flow, a heating module positioned within the housing and having a heat transfer relationship with the heat exchange fluid, and at least one temperature sensor disposed at the housing to generate a signal indicating the temperature of the housing. The control unit is configured to operate the heating module at at least one predetermined power level.
[0019] The control unit is further configured to monitor the temperature of the housing to detect whether the temperature of the housing exceeds a predetermined temperature within a predetermined time. The control unit is further configured to detect the presence of a heat exchange fluid when the temperature of the housing is below a predetermined temperature within a predetermined time. The control unit is configured to determine the level of the heat exchange fluid based on the temperature of the housing and the time period for reaching the temperature of the housing. Therefore, the system and method of the present invention can effectively determine the absence of a heat exchange fluid level and the level of the heat exchange fluid without adding any components to the fluid heater.
[0020] refer to Figure 1 , the thermal management system 100 includes a fluid heater 102 and a control unit 104 in communication with the heater 102. The circuit for controlling the heater 102 includes a microcontroller 106 and a transistor 108. The microcontroller 106 receives input data from the control unit 104 to operate the fluid heater 102. In one example, the heater 102 can be used to heat a heat exchange fluid to be introduced into a heater core of a heating ventilation and air conditioning unit. In another example, the heater 102 can be used to heat a heat exchange fluid to be circulated through a battery pack of a vehicle, such as a hybrid vehicle or an electric vehicle. The heater 102 receives power 122 from an external power source.
[0021] refer to Figure 2 and Figure 3 The heater 102 includes a shell 110 having an inlet port 112 for introducing a heat exchange fluid into the shell 110 and an outlet port 114 for discharging the heat exchange fluid from the shell 110. In this document, the inlet port 112 and the outlet port 114 are also referred to as the inlet 112 and the outlet 114, respectively. The shell 110 also includes an internal space. Depending on the required conditions and design specifications, the shell 110 can have various structures and shapes, and the present disclosure does not restrict or limit the structure and shape of the shell 110. The internal space can be divided into a first part 116 and a second part 118. In one example, the internal space may include a partition plate that divides the internal space into the first part 116 and the second part 118.
[0022] The inlet port 112 is configured to be in fluid communication with a first portion 116 of the housing 110, and the outlet port 114 is configured to be in fluid communication with a second portion 118 of the housing 110. The first portion 116 defines a first flow path, and the second portion 118 defines a second flow path. A heat exchange fluid flows in from the inlet port 112 and flows through the first flow path in a first direction. In addition, the fluid is guided to flow through the second flow path in a second direction. The first direction is different from the second direction. At least one heating module 120A, 120B has a heat exchange relationship with the heat exchange fluid.
[0023] In another example, the heater 102 may include at least two heating modules 120A, 120B. The two heating modules 120A, 120B are identical and are arranged side by side substantially in parallel. The side-by-side arrangement makes it possible to reduce the size of the heater 102 in the longitudinal direction. This arrangement has low thermal inertia and low pressure drop. However, alternatively, it is conceivable to include an arrangement of heating modules 120A, 120B having different arrangements. Alternatively, the heater 102 may include one or more heating modules 120A, 120B. In one example, the heating modules 120A, 120B may be resistive heating elements electrically connected to a vehicle power supply (for supplying electrical energy to the heater 102). During operation of the heater 102, the heating modules 120A, 120B may increase the temperature of the housing 110.
[0024] The heater 102 also includes a first temperature sensor and a second temperature sensor. The heater 102 is also in communication with a control unit 104 of the vehicle. The first temperature sensor is configured to transmit a signal indicating the temperature of the heat exchange fluid to the control unit 104. The second temperature sensor is configured to transmit a signal indicating the temperature of the housing 110 to the control unit 104. In one example, the heat exchange fluid can be a coolant. In one embodiment, the control unit 104 can be part of the heater 102.
[0025] The control unit 104 includes one or more processors and one or more memory units. The memory unit includes a set of modules. Each of these modules can be formed by an executable code that can be executed by a processor. The memory unit also includes a series of power levels, the temperature of the housing 110 at a given power level when a heat exchange fluid is present (also referred to as a predetermined temperature), the temperature of the housing 110 at a given power level when there is no heat exchange fluid, information related to a set of predetermined times to reach the set of predetermined temperatures when there is no heat exchange fluid, and information related to a set of predetermined times to reach the set of predetermined temperatures when there is a heat exchange fluid.
[0026] During operation of the heater 102, the control unit 104 is configured to supply power 122 from a power source to the heating modules 120A, 120B. A heat exchange fluid flows in from the inlet port 112 and then flows into the interior space of the annular space of the heating modules 120A, 120B. The heating modules 120A, 120B increase the temperature of the heat exchange fluid before the heat exchange fluid is discharged through the outlet port 114. The temperature sensor is used to measure the temperature of the heat exchange fluid and transmit a signal indicating the temperature of the heat exchange fluid to the control unit 104.
[0027] In addition, the temperature sensor also measures the temperature of the housing 110 and transmits a signal indicating the temperature of the housing 110 to the control unit 104. Heat from the heat exchange fluid, or from the heating modules 120A, 120B when the heat exchange fluid is not present, is transferred to the housing 110. In the absence of the heat exchange fluid, the temperature of the housing 110 rises rapidly, which is used to determine that the heat exchange fluid is not present in the heater 102. In addition, the temperature of the housing 110 is used to determine the liquid level of the heat exchange fluid.
[0028] The control unit 104 may determine a range of power levels for operating the heating modules 120A, 120B. Alternatively, the control unit 104 uses information stored in a memory to operate the heating modules 120A, 120B. The control unit 104 is configured to operate the heating modules 120A, 120B at at least one predetermined power level and monitor the temperature of the housing 110 using a temperature sensor. If the temperature of the housing 110 is below a predetermined temperature within a predetermined time, the control unit 104 determines that coolant is present. If the temperature of the housing 110 exceeds a predetermined temperature within a predetermined time, the control unit 104 determines that coolant is not present. The control unit 104 is also configured to transmit data related to the coolant to the vehicle control unit 104. The control unit 104 is also configured to determine the level of the heat exchange fluid based on the temperature of the housing 110 and the time to reach the temperature of the housing 110.
[0029] See also Figure 4 , a method for detecting and measuring the level of a heat exchange fluid in a fluid heater 102 of a thermal management system 100 for a motor vehicle is disclosed. The system 100 includes the fluid heater 102 and a control unit 104 in communication with the fluid heater 102. The heater 102 includes a housing 110 having an inlet port 112 and an outlet port 114 for flow of a heat exchange fluid, heating modules 120A and 120B positioned within the housing 110 and in heat transfer relationship with the heat exchange fluid, and at least one temperature sensor positioned at the housing 110 to generate a signal indicative of a temperature of the housing 110. The control unit 104 is configured to operate the heater 102.
[0030] The control unit 104 includes one or more processors and one or more memory units. The memory unit includes a set of modules. Each of these modules can be formed by an executable code, which can be executed by a processor. The memory unit also includes a series of power levels, the temperature of the housing 110 at a given power level when a heat exchange fluid is present (also referred to as a predetermined temperature), the temperature of the housing 110 at a given power level when there is no heat exchange fluid, information related to a set of predetermined times to reach the set of predetermined temperatures when there is no coolant, and information related to a set of predetermined times to reach the set of predetermined temperatures when there is a coolant.
[0031] In step 202, the control unit 104 transmits an input to the heater 102 to operate the heating modules 120A, 120B at at least one predetermined power level. The predetermined power level is less than the nominal power level. The control unit 104 operates the heater 102 at the predetermined power level. The temperature sensor periodically transmits a signal indicating the temperature of the housing 110 to the control unit 104.
[0032] In step 204, the control unit 104 monitors the temperature of the housing 110 to detect whether the temperature of the housing 110 exceeds a predetermined temperature within a predetermined time. In step 206, if the temperature of the housing 110 is below a predetermined temperature within a predetermined time, the control unit 104 detects the presence of coolant. In step 208, the control unit 104 may determine the level of the heat exchange fluid based on the temperature of the housing 110 and the time period for reaching the temperature of the housing 110. In step 210, if the temperature of the housing 110 is above a predetermined temperature within a predetermined time, the control unit 104 detects the absence of coolant. The control unit 104 may turn off the heater 102 in the absence of coolant. The control unit 104 may also warn the subsystems and the user of the vehicle that there is no coolant. The control unit 104 may also send data related to the insufficient level of the heat exchange fluid to the subsystems of the vehicle and the user of the vehicle.
[0033] Thus, the system 100 and method 200 of the present invention effectively determines the absence of fluid level and the level of heat exchange fluid within the heat exchanger without adding any components to the fluid heater 102. Detecting the presence or absence of heat exchange fluid allows the heater 102 to be operated safely without damaging the heater 102 or the environment in which the heater 102 is operating.
[0034] In any case, the present invention cannot and should not be limited to the embodiments specifically described herein, as other embodiments are possible. The present invention will extend to any equivalent means and any combination of technically operable means.
Claims
1. A method for detecting and measuring a heat exchange fluid level in a fluid heater (102) of a thermal management system (100) of a motor vehicle, the system (100) comprising the heater (102), the heater (102) having: a housing (110) having an inlet (112) and an outlet (114) for the flow of a heat exchange fluid; a heating module (120A, 120B) positioned in the housing (110) and in heat exchange relationship with the heat exchange fluid; a sensor positioned at the housing (110) to generate a signal indicative of a temperature of the housing (110); and a control unit (104) for operating the heater (102); the method comprising the following steps: Operating the heating modules (120A, 120B) at at least one predetermined power level; monitoring the temperature of the housing (110) at the control unit (104) to detect whether the temperature of the housing (110) exceeds a predetermined temperature within a predetermined time; When the temperature of the housing (110) is lower than the predetermined temperature within the predetermined time, the presence of the heat exchange fluid is detected at the control unit (104), and The liquid level of the heat exchange fluid is determined at the control unit (104) based on the temperature of the housing (110) and the time period for reaching the temperature of the housing (110).
2. The method according to claim 1, further comprising the steps of: When the temperature of the housing (110) exceeds the predetermined temperature within the predetermined time, it is determined at the control unit (104) that the heat exchange fluid is absent.
3. The method according to claim 1, further comprising the steps of: A series of power levels for operating the heating modules (120A, 120B) are determined at the control unit (104).
4. The method of claim 1, further comprising the step of transmitting data related to the heat exchange fluid to one or more control units of a vehicle.
5. The method according to claim 3, wherein: The predetermined power level is less than a nominal power level of the heating module (120A, 120B).
6. A thermal management system (100) for a motor vehicle, comprising: A fluid heater (102) having: a housing (110), the housing (110) having an inlet (112) and an outlet (114) for the flow of a heat exchange fluid, a heating module (120A, 120B) positioned within the housing (110) and in heat transfer relationship with the heat exchange fluid, and at least one temperature sensor positioned at the housing (110) to generate a signal indicative of a temperature of the housing (110), A control unit (104), the control unit (104) communicates with the sensor and is configured to control the heating modules (120A, 120B), the control unit (104) being configured to: Operating the heating modules (120A, 120B) at at least one predetermined power level; Monitoring the temperature of the housing (110) to detect whether the temperature of the housing (110) exceeds a predetermined temperature within a predetermined time; When the temperature of the housing (110) is lower than the predetermined temperature within the predetermined time, the presence of the heat exchange fluid is detected, and The liquid level of the heat exchange fluid is determined based on the temperature of the housing (110) and the time period for reaching the temperature of the housing (110).
7. The heater (102) according to claim 6, wherein: The control unit (104) is configured to determine that the heat exchange fluid is absent when the temperature of the housing (110) exceeds the predetermined temperature within the predetermined time.
8. The heater (102) according to claim 6, wherein: The control unit (104) is configured to determine a range of power levels for operating the heating modules (120A, 120B).
9. The heater (102) according to claim 8, wherein: The predetermined power level is less than a nominal power level of the heating module (120A, 120B).
10. The heater (102) according to claim 6, wherein: The control unit (104) is configured to transmit data related to the heat exchange fluid to one or more control units of the vehicle.