Full liquid cooling charging pile current sharing system

Abstract

The invention relates to the technical field of current sharing, in particular to a full liquid cooling charging pile current sharing system. Comprising a cooling liquid pipeline used for conveying cooling liquid to a plurality of power modules, the cooling liquid pipeline comprises a liquid inlet branch and a liquid outlet branch, each liquid inlet and each liquid outlet are communicated with the corresponding power module, and in the flowing process of the cooling liquid, the cooling liquid enters the corresponding power module through the liquid inlet of the liquid inlet branch and then enters the corresponding power module through the liquid outlet of the liquid outlet branch; after heat dissipation, the cooling liquid flows out from a liquid outlet corresponding to the power module, and the position of the liquid outlet in the liquid outlet branch enables the cooling liquid to flow out of the cooling liquid pipeline relatively late; and the pump assembly is arranged at the liquid outlet of the power module, connected with the controller and used for adjusting the pump speed according to the balance control strategy. According to the full-liquid-cooling charging pile flow equalizing system provided by the invention, each power module in the system can be uniformly cooled by the cooling liquid, and the system can optimize the distribution of the cooling liquid according to the actual thermal load and heat dissipation requirements.

Description

Technical Field

[0001] The present invention relates to the field of current balancing technology, and in particular to a full liquid-cooled charging stack current balancing system. Background Art

[0002] With the rapid development of new energy vehicles and power electronics technology, all-liquid-cooled charging stacks have been widely used as efficient heat dissipation solutions in key areas such as charging piles and power stacks. However, in the all-liquid-cooled charging stack system, due to factors such as differences in flow resistance of each branch and improper pipeline layout, the coolant flow is often unevenly distributed, affecting the heat dissipation effect and stability of the system. In the prior art, the flow equalization strategy is mainly implemented through hardware design, such as adjusting the pipe diameter. This method can improve the problem of uneven flow to a certain extent, but it has certain limitations: the hardware design is complex and requires parts of multiple models, which increases the cost and difficulty of production and assembly; the flow equalization effect is limited, and it is difficult to achieve precise control of the flow; there is a lack of real-time monitoring and adjustment mechanism, and it is impossible to dynamically adjust the coolant distribution according to the real-time status and needs of the system.

[0003] For example, in the patent publication number CN117320385A, entitled "A method for equalizing flow in a liquid cooling system", the first flow resistance of each first pipeline of the liquid cooling system in actual operation is obtained, and the second flow resistance of each first pipeline of the liquid cooling system when the flow rate of each first pipeline is the same is obtained. The initial flow resistance value of the first flow blocker is determined according to the difference between the first flow resistance and the second flow resistance, so that the flow resistance of each first pipeline tends to be consistent before the heating groups are connected in parallel. Since the flow resistance of the heating groups is basically consistent, the flow resistance of each first pipeline also tends to be consistent, and the flow rate of each first pipeline is basically close to the first flow value, thereby achieving equal flow of each heating group. The disadvantages are: it depends on accurate flow resistance measurement and calculation, and there may be errors in actual operation; there is a lack of real-time monitoring and adjustment mechanism, and it is impossible to dynamically adjust the coolant distribution according to the real-time status and needs of the system. Summary of the invention

[0004] In response to the problems in the prior art, the present invention provides a full liquid-cooled charging stack current balancing system to ensure that each power module in the system can be evenly cooled by the coolant. The system can optimize the distribution of the coolant according to the actual heat load and heat dissipation requirements.

[0005] In order to achieve the above technical objectives, the present invention provides a technical solution, which is a full liquid-cooled charging stack current balancing system, comprising:

[0006] A coolant pipeline, used for conveying coolant to a plurality of power modules, the coolant pipeline comprising a liquid inlet branch and a liquid outlet branch, the liquid inlet branch is provided with a plurality of liquid inlets, the liquid outlet branch is provided with a plurality of liquid outlets, each liquid inlet and liquid outlet are respectively connected with a corresponding power module, during the flow of the coolant, the coolant first enters the corresponding power module through the liquid inlet of the liquid inlet branch, and after the power module dissipates heat, flows out from the liquid outlet corresponding to the power module, and the position of the liquid outlet on the liquid outlet branch makes the coolant flow out of the coolant pipeline relatively late;

[0007] Sensors for real-time monitoring of coolant temperature, flow rate and pressure;

[0008] A controller connected to the sensor, for receiving sensor data and generating a balancing control strategy;

[0009] The pump assembly is arranged at the liquid outlet of the power module and is connected to the controller to adjust the pump speed according to the balanced control strategy.

[0010] In the present technical scheme, during the flow of the coolant, the coolant first enters the corresponding power module through the inlet of the inlet branch, and after completing the effective heat exchange here, it flows out from the outlet corresponding to the power module. The position of the outlet on the outlet branch is designed to be relatively late, so that the flow resistance of the branch corresponding to each power module tends to be consistent, which provides a strong guarantee for the system to achieve the purpose of equal flow. The system is also equipped with sensors to monitor the temperature, flow and pressure of the coolant in real time to ensure that these data can accurately reflect the actual operating state of the system. The controller is closely connected with the sensor, receives the data from the sensor, and generates a balanced control strategy based on this, aiming to optimize the distribution of the coolant to meet the actual heat load and heat dissipation requirements of the system. The pump components arranged at the inlet and outlet are the key to the system to achieve equal flow control. These pump components are connected to the controller, and the pump speed is flexibly adjusted according to the balanced control strategy to ensure that the coolant can be optimized according to the actual heat load and heat dissipation requirements. Distribution between each power module is ensured, and each power module in the system can be evenly cooled by the coolant. The system can optimize the distribution of the coolant according to the actual heat load and heat dissipation requirements.

[0011] The present invention is further configured as follows: the pump assembly includes a plurality of pump groups, the number of the liquid outlet branches is multiple, and each pump group is respectively arranged on a different liquid outlet branch.

[0012] In this technical solution, a refined pump assembly layout is adopted, which includes multiple pump groups, and multiple liquid outlet branches are set accordingly. In order to achieve more accurate flow control, the system effectively manages the power modules in groups. Similar to the way the modules are arranged in two or three rows (usually more rows are rarely used), the system introduces coolant from a common pipeline into the module for heat dissipation. After heat dissipation, the coolant flows out according to pre-set groups, and each group of modules corresponds to an independent pump group. Specifically, the coolant flowing out of the first group of modules passes through pump group one, the second group of modules passes through pump group two, and so on, forming a clear and orderly correspondence between module groupings and pump groups, thereby optimizing the flow control effect.

[0013] The present invention is further configured as follows: the generating balance control strategy comprises:

[0014] Receive and analyze sensor monitoring data in real time;

[0015] Detect abnormal conditions of flow, temperature and pressure according to preset thresholds and generate abnormal detection results;

[0016] Generate a thermal management model based on historical data, current environmental conditions and system configuration, predict the system's thermal load and cooling requirements, evaluate the coolant requirements of each power module, and generate a demand assessment report;

[0017] Based on the abnormal detection results and demand assessment reports, dynamic instructions for adjusting the pump speed are generated.

[0018] In this technical solution, the data monitored by the sensor is received and analyzed in real time to ensure accurate grasp of key parameters such as coolant temperature, flow rate and pressure. On this basis, the system detects anomalies in flow rate, temperature and pressure according to preset thresholds, and generates anomaly detection results in a timely manner, providing a strong guarantee for the safe operation of the system. At the same time, the system also combines historical data, current environmental conditions and system configuration to generate a thermal management model that can accurately predict the system's thermal load and heat dissipation requirements, and evaluate the coolant requirements of each power module to generate a detailed demand assessment report. Finally, the system dynamically generates adjustment instructions for the pump speed based on the anomaly detection results and demand assessment report, realizes the optimal distribution of coolant, and improves the heat dissipation efficiency and stability of the system.

[0019] The present invention is further configured as follows: generating a thermal management model according to historical data, current environmental conditions and system configuration includes:

[0020] Collecting the operating data of the system under different working conditions, the operating data including the temperature, flow rate, pressure of the coolant, the temperature of the power module, the heat dissipation efficiency and the pump speed;

[0021] Standardize the collected operational data;

[0022] According to the thermophysical parameters of the coolant, the flow resistance characteristics of the pipeline, the thermal resistance and heat transfer coefficient of the power module, a physical model of the flow of the coolant in the pipeline and the heat dissipation process of the power module is established.

[0023] In this technical solution, by collecting the operating data of the system under different working conditions, including the temperature, flow rate, pressure of the coolant, and the temperature, heat dissipation efficiency and pump speed of the power module, a wealth of basic data is provided for the establishment of the thermal management model. Subsequently, the collected operating data is standardized to ensure the accuracy and consistency of the data. On this basis, combined with the thermophysical parameters of the coolant, the flow resistance characteristics of the pipeline, the thermal resistance and heat transfer coefficient of the power module and other physical properties, a physical model of the coolant flow in the pipeline and the heat dissipation process of the power module is established.

[0024] The present invention is further configured as follows: the different working conditions include environmental conditions and system configurations, the environmental conditions include temperature, humidity and altitude, and the system configuration includes the number of power modules and the type of coolant. In this technical solution, not only the changes in environmental conditions, such as natural factors such as temperature, humidity and altitude, are taken into account, which directly affect the heat dissipation effect of the coolant and the operating status of the system; at the same time, the system also fully considers the differences in system configurations, such as the number of power modules and the type of coolant, etc. These factors directly determine the heat dissipation capacity and efficiency of the system. By incorporating these different working conditions into the consideration scope of the thermal management model, the system can more accurately simulate and predict the heat load and heat dissipation requirements under different environmental conditions and system configurations. Not only does it improve the accuracy and reliability of the model, it also provides strong support for the optimal design of the system and the flexible response to various working conditions.

[0025] The present invention is further configured as follows: the generation of the balance control strategy further includes:

[0026] Establish a flow resistance simulation model for the coolant pipeline;

[0027] According to the actual working conditions of the system, the coolant inlet flow, pressure and temperature boundary conditions are set; according to the structure and material characteristics of the power module, the thermal resistance and heat transfer coefficient are set;

[0028] Run a flow resistance simulation model to calculate the flow of coolant in the pipes;

[0029] The flow resistance simulation results are compared with the actual flow data. Based on the comparison results, the pump speed that needs to be adjusted is calculated, and the adjustment instructions for the pump speed are dynamically generated.

[0030] In the present technical solution, the accuracy and practicality of the simulation model are ensured by setting the coolant inlet flow, pressure and temperature boundary conditions according to the actual working conditions of the system. At the same time, the thermal resistance and heat transfer coefficient are set in combination with the structure and material properties of the power module, so that the simulation model can more realistically reflect the heat dissipation performance of the power module. After running the flow resistance simulation model, the flow of the coolant in the pipeline can be calculated, including key indicators such as flow rate and pressure distribution. By comparing the flow resistance simulation results with the actual flow data, the differences between the simulation model and the actual system can be discovered and corrected in time to ensure the accuracy of the control strategy. Finally, the pump speed that needs to be adjusted is calculated based on the comparison results, and an adjustment instruction for the pump speed is dynamically generated, thereby achieving precise control of the coolant and improving the heat dissipation efficiency and stability of the system. The present invention is further configured as follows: the dynamic generation of the adjustment instruction for the pump speed includes:

[0031] Determine the total coolant flow required for the system based on the needs assessment report;

[0032] Adjust the pump speed according to the coolant demand ratio of each power module.

[0033] In this technical solution, when dynamically generating the adjustment instructions for the pump speed, the overall coolant flow required by the system is first accurately determined based on the demand assessment report, providing a clear overall goal for the adjustment of the pump speed. Then, based on the coolant demand ratio of each power module, the pump speed is finely adjusted to ensure that each power module can obtain an appropriate amount of coolant to meet its heat dissipation needs. This adjustment process takes into account both the overall needs of the system and the individual differences of each power module, achieving optimal distribution of coolant and improving the heat dissipation efficiency and stability of the system.

[0034] The present invention is further configured as follows: the system also includes a deviation correction strategy:

[0035] Use standard sources to compare the output of the sensor, identify and record the systematic deviation and random deviation of the sensor, monitor the changing trend of the sensor data in real time, and identify abnormal fluctuations in the data based on standard deviation analysis statistical methods as input for deviation correction;

[0036] Predict the temperature, flow rate and pressure of the coolant according to the thermal management model, compare the model prediction value with the actual measurement value of the sensor, and calculate the deviation;

[0037] Regularly run the flow resistance simulation model of the coolant pipeline, calculate the flow of coolant in the pipeline, compare and analyze the simulation results with the actual flow data, and adjust the pipeline flow resistance parameters and power module thermal resistance parameters in the flow resistance simulation model according to the deviation analysis results.

[0038] In this technical solution, the system further introduces a deviation correction strategy on the basis of ensuring the accuracy of the balanced control strategy to improve the stability and reliability of the system. By comparing the output of the sensor with a standard source, the system can accurately identify and record the system deviation and random deviation of the sensor, and monitor the changing trend of the sensor data in real time. Using the statistical method of standard deviation analysis, the system can effectively identify abnormal fluctuations in the data and use it as an important basis for deviation correction. In addition, the system also predicts the temperature, flow rate and pressure of the coolant according to the thermal management model, and compares these predicted values ​​with the actual measured values ​​of the sensor to calculate the deviation, thereby further correcting and optimizing the prediction ability of the system. By comparing and analyzing the simulation results with the actual flow data, the system can flexibly adjust the pipeline flow resistance parameters and power module thermal resistance parameters in the flow resistance simulation model according to the deviation analysis results to ensure the accuracy and practicality of the simulation model.

[0039] The present invention is further configured as follows: the deviation correction strategy also includes:

[0040] Establish a sensor deviation database to store the system deviation, random deviation and historical deviation correction records of each sensor;

[0041] According to the information in the sensor deviation database, the real-time measurement data of the sensor is compensated for the deviation; a deviation threshold is set, and when the deviation of the sensor exceeds the threshold, an alarm mechanism is triggered and the sensor is adjusted or replaced.

[0042] In this technical solution, by establishing a sensor deviation database, comprehensive management and utilization of sensor deviation information is achieved. The database not only stores the system deviation and random deviation of each sensor, but also records the details of historical deviation corrections, providing rich data support for the system's deviation correction. Based on the information in the sensor deviation database, the system can compensate for the deviation of the real-time measurement data of the sensor, effectively improving the accuracy and reliability of the measurement data. This step ensures that the system can make correct control decisions based on accurate sensor data, further improving the control accuracy of the system. At the same time, the system also sets a deviation threshold. When the deviation of the sensor exceeds the threshold, an alarm mechanism will be triggered. This mechanism can promptly detect abnormal problems with the sensor and remind the operator to adjust or replace the sensor, effectively avoiding system control errors or performance degradation caused by sensor failure.

[0043] The present invention is further configured as follows: the system also includes an adaptive learning module, which is connected to the controller and is used to automatically learn and optimize the parameters of the thermal management model and the flow resistance simulation model according to the long-term operation data and deviation correction records of the system. The system realizes the automatic learning and optimization of the parameters of the thermal management model and the flow resistance simulation model by introducing the adaptive learning module, and further improves the intelligence level of the system. The adaptive learning module is closely connected with the controller and can make full use of the long-term operation data and deviation correction records of the system. These valuable data resources provide a solid foundation for the optimization of the model. Under the action of the adaptive learning module, the system can continuously analyze and summarize the experience and rules in the operation process, automatically adjust the parameters of the thermal management model and the flow resistance simulation model, and make the model more in line with the actual operation state of the system. This automatic learning and optimization capability not only improves the accuracy and reliability of the model, but also enhances the system's adaptability to different working conditions and changes.

[0044] The beneficial effects of the present invention are as follows: (1) It ensures that each power module in the system can be evenly cooled by the coolant, and the system can optimize the distribution of the coolant according to the actual heat load and heat dissipation requirements; (2) During the flow of the coolant, the coolant first enters the corresponding power module through the liquid inlet of the liquid inlet branch, completes the effective heat exchange here, and then flows out from the liquid outlet corresponding to the power module. The position of the liquid outlet on the liquid outlet branch is designed to be relatively late, so that the flow resistance of the branch corresponding to each power module tends to be consistent, providing a strong guarantee for achieving the purpose of equal flow. The system is also equipped with sensors to monitor the temperature, flow rate and pressure of the coolant in real time to ensure that these data can accurately reflect the actual operating status of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 This is a structural schematic diagram of a full liquid-cooled charging stack current balancing system of the present invention;

[0046] Figure 2 This is an axonometric diagram of a full liquid-cooled charging stack current balancing system of the present invention;

[0047] Figure 3 It is a schematic diagram of the structure of the coolant pipeline.

[0048] In the figure: 1. coolant pipeline; 11. liquid inlet branch; 111. liquid inlet; 12. liquid outlet branch; 121. liquid outlet; 2. power module. DETAILED DESCRIPTION

[0049] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific implementation method described herein is only an optimal embodiment of the present invention, which is only used to explain the present invention and does not limit the scope of protection of the present invention. All other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0050] like Figure 1-Figure 2 As shown, as the first embodiment of the present invention, a full liquid-cooled charging stack flow balancing system includes: a coolant pipeline 1, which is used to transport coolant to multiple power modules 2, the coolant pipeline 1 includes a liquid inlet branch 11 and a liquid outlet branch 12, the liquid inlet branch 11 is provided with a plurality of liquid inlets 111, the liquid outlet branch 12 is provided with a plurality of liquid outlets 121, each of the liquid inlet 111 and the liquid outlet 121 are respectively connected to the corresponding power module 2, in the flow process of the coolant, the coolant first enters the corresponding power module 2 through the liquid inlet 111 of the liquid inlet branch 11, and after the power module 2 dissipates heat, it flows out from the liquid outlet 121 corresponding to the power module 2, and the position of the liquid outlet 121 on the liquid outlet branch 12 makes the coolant flow out of the coolant pipeline 1 relatively late;

[0051] Sensors for real-time monitoring of coolant temperature, flow rate and pressure;

[0052] A controller connected to the sensor, for receiving sensor data and generating a balancing control strategy;

[0053] The pump assembly is disposed at the liquid outlet 121 of the power module 2 and is connected to the controller for adjusting the pump speed according to the balanced control strategy.

[0054] In this embodiment, during the flow of the coolant, the coolant first enters the corresponding power module 2 through the liquid inlet 111 of the liquid inlet branch 11, and after completing the effective heat exchange here, it flows out from the liquid outlet 121 corresponding to the power module 2. The position of the liquid outlet 121 on the liquid outlet branch 12 is designed to be relatively late, so that the flow resistance of the branch corresponding to each power module 2 tends to be consistent, which provides a strong guarantee for the system to achieve the purpose of equal flow. The system is also equipped with sensors to monitor the temperature, flow rate and pressure of the coolant in real time to ensure that these data can accurately reflect the actual operating status of the system. The controller is closely connected to the sensor, receives the data from the sensor, and generates a balanced control strategy based on this, aiming to optimize the distribution of the coolant to meet the actual heat load and heat dissipation requirements of the system. The pump components arranged at the liquid inlet 111 and the liquid outlet 121 are the key to realizing the equal flow control of the system. These pump components are connected to the controller, and the pump speed is flexibly adjusted according to the balanced control strategy to ensure that the coolant can be optimally distributed among the power modules 2 according to the actual heat load and heat dissipation requirements, and ensure that each power module 2 in the system can be evenly cooled by the coolant. The system can optimize the distribution of the coolant according to the actual heat load and heat dissipation requirements. In one embodiment of the present invention, the pump component includes a plurality of pump groups, and the number of the liquid outlet branches 12 is multiple, and each pump group is respectively arranged on a different liquid outlet branch 12.

[0055] In the present technical solution, a refined pump component layout is adopted, which includes multiple pump groups, and multiple liquid outlet branches 12 are correspondingly arranged. In order to achieve more precise flow balancing control, the system effectively groups the power modules 2. Similar to the way of arranging the modules into two or three rows (usually more rows are rarely used), the system introduces coolant from a common pipeline into the module for heat dissipation. After heat dissipation, the coolant flows out according to pre-set groups, and each group of modules corresponds to an independent pump group. Specifically, the coolant flowing out of the first group of modules passes through pump group one, the second group of modules passes through pump group two, and so on, forming a clear and orderly correspondence between module groupings and pump groups, thereby optimizing the flow balancing control effect. As Figure 3 As shown, Ro1, Ro2...RoN are flow resistances between adjacent liquid outlet branches, and Ri1, Ri2...RiN are flow resistances between adjacent liquid inlet branches.

[0056] In one embodiment of the present invention, generating a balancing control strategy includes:

[0057] Receive and analyze sensor monitoring data in real time;

[0058] Detect abnormal conditions of flow, temperature and pressure according to preset thresholds and generate abnormal detection results;

[0059] Generate a thermal management model based on historical data, current environmental conditions and system configuration, predict the system's thermal load and cooling requirements, evaluate the coolant requirements of each power module 2, and generate a demand assessment report;

[0060] Based on the abnormal detection results and demand assessment reports, adjustment instructions for the pump speed are dynamically generated.

[0061] In this technical solution, the data monitored by the sensor is received and analyzed in real time to ensure accurate grasp of key parameters such as coolant temperature, flow rate and pressure. On this basis, the system detects abnormalities in flow rate, temperature and pressure according to preset thresholds, and generates abnormal detection results in a timely manner, providing a strong guarantee for the safe operation of the system. At the same time, the system also combines historical data, current environmental conditions and system configuration to generate a thermal management model that can accurately predict the thermal load and heat dissipation requirements of the system, and evaluate the coolant requirements of each power module 2 to generate a detailed demand assessment report. Finally, the system dynamically generates adjustment instructions for the pump speed based on the abnormal detection results and demand assessment report, realizes the optimal distribution of coolant, and improves the heat dissipation efficiency and stability of the system.

[0062] In one embodiment of the present invention, generating a thermal management model according to historical data, current environmental conditions and system configuration includes:

[0063] Collecting the operating data of the system under different working conditions, the operating data including the temperature, flow rate, pressure of the coolant, the temperature of the power module 2, the heat dissipation efficiency and the pump speed;

[0064] Standardize the collected operational data;

[0065] According to the thermophysical parameters of the coolant, the flow resistance characteristics of the pipeline, the thermal resistance and heat transfer coefficient of the power module 2, a physical model of the flow of the coolant in the pipeline and the heat dissipation process of the power module 2 is established.

[0066] In this technical solution, by collecting the operating data of the system under different working conditions, including the temperature, flow rate, pressure of the coolant, and the temperature, heat dissipation efficiency and pump speed of the power module 2, a wealth of basic data is provided for the establishment of the thermal management model. Subsequently, the collected operating data are standardized to ensure the accuracy and consistency of the data. On this basis, combined with the thermophysical parameters of the coolant, the flow resistance characteristics of the pipeline, the thermal resistance and heat transfer coefficient of the power module 2 and other physical properties, a physical model of the flow of the coolant in the pipeline and the heat dissipation process of the power module 2 is established.

[0067] Furthermore, the different operating conditions include environmental conditions and system configurations, the environmental conditions include temperature, humidity and altitude, and the system configuration includes the number of power modules 2 and the type of coolant.

[0068] In this technical solution, not only the changes in environmental conditions, such as temperature, humidity and altitude, are taken into account, which directly affect the heat dissipation effect of the coolant and the operating status of the system; at the same time, the system also fully considers the differences in system configuration, such as the number of power modules 2 and the type of coolant, etc. These factors directly determine the heat dissipation capacity and efficiency of the system. By incorporating these different working conditions into the consideration scope of the thermal management model, the system can more accurately simulate and predict the heat load and heat dissipation requirements under different environmental conditions and system configurations. Not only does it improve the accuracy and reliability of the model, but it also provides strong support for the optimal design of the system and the flexible response to various working conditions.

[0069] In one embodiment of the present invention, the generating balance control strategy further comprises:

[0070] Establish a flow resistance simulation model of the coolant pipeline 1;

[0071] According to the actual working conditions of the system, the flow rate, pressure and temperature boundary conditions of the coolant inlet 111 are set;

[0072] According to the structure and material characteristics of the power module 2, the thermal resistance and heat transfer coefficient are set;

[0073] Run a flow resistance simulation model to calculate the flow of coolant in the pipes;

[0074] The flow resistance simulation results are compared with the actual flow data. Based on the comparison results, the pump speed that needs to be adjusted is calculated, and the adjustment instructions for the pump speed are dynamically generated.

[0075] In this technical solution, the accuracy and practicality of the simulation model are ensured by setting the flow rate, pressure and temperature boundary conditions of the coolant inlet 111 according to the actual working conditions of the system. At the same time, the thermal resistance and heat transfer coefficient are set in combination with the structure and material properties of the power module 2, so that the simulation model can more realistically reflect the heat dissipation performance of the power module 2. After running the flow resistance simulation model, the flow of the coolant in the pipeline can be calculated, including key indicators such as flow rate and pressure distribution. By comparing the flow resistance simulation results with the actual flow data, the differences between the simulation model and the actual system can be discovered and corrected in time to ensure the accuracy of the control strategy. Finally, the pump speed that needs to be adjusted is calculated based on the comparison results, and the adjustment instructions for the pump speed are dynamically generated, so as to achieve precise control of the coolant and improve the heat dissipation efficiency and stability of the system.

[0076] It can be understood that the calculation formula of the flow resistance is:

[0077]

[0078] Where ΔP is the flow resistance, f is the friction coefficient, L is the pipe length, D is the pipe diameter, ρ is the coolant density, and v is the flow velocity.

[0079] The heat calculation formula is:

[0080] Q = h·A·ΔT;

[0081] Among them, Q is the heat, h is the heat transfer coefficient, A is the heat transfer area, and ΔT is the temperature difference.

[0082] It can be understood that the model includes the liquid inlet branch 11, the liquid outlet branch 12, the power module 2, and the pipes and pumps connecting them.

[0083] It will be appreciated that flow conditions include flow distribution and pressure loss.

[0084] The dynamically generating the adjustment instruction for the pump speed comprises:

[0085] Determine the total coolant flow required for the system based on the needs assessment report;

[0086] The pump speed is adjusted according to the cooling liquid demand ratio of each power module 2.

[0087] In this technical solution, when dynamically generating the adjustment instructions for the pump speed, the overall coolant flow required by the system is first accurately determined based on the demand assessment report, providing a clear overall goal for the adjustment of the pump speed. Then, based on the coolant demand ratio of each power module 2, the pump speed is finely adjusted to ensure that each power module 2 can obtain an appropriate amount of coolant to meet its heat dissipation needs. This adjustment process takes into account both the overall needs of the system and the individual differences of each power module 2, achieving optimal distribution of coolant and improving the heat dissipation efficiency and stability of the system.

[0088] It is understood that the system also includes a deviation correction strategy:

[0089] Use standard sources to compare the output of the sensor, identify and record the systematic deviation and random deviation of the sensor, monitor the changing trend of the sensor data in real time, and identify abnormal fluctuations in the data based on standard deviation analysis statistical methods as input for deviation correction;

[0090] Predict the temperature, flow rate and pressure of the coolant according to the thermal management model, compare the model prediction value with the actual measurement value of the sensor, and calculate the deviation;

[0091] Run the flow resistance simulation model of coolant pipeline 1 regularly, calculate the flow of coolant in the pipeline, compare and analyze the simulation results with the actual flow data, and adjust the pipeline flow resistance parameters and thermal resistance parameters of power module 2 in the flow resistance simulation model according to the deviation analysis results.

[0092] On the basis of ensuring the accuracy of the balanced control strategy, the system further introduces a deviation correction strategy to improve the stability and reliability of the system. By comparing the output of the sensor with a standard source, the system can accurately identify and record the system deviation and random deviation of the sensor, and monitor the changing trend of the sensor data in real time. Using the statistical method of standard deviation analysis, the system can effectively identify abnormal fluctuations in the data and use it as an important basis for deviation correction. In addition, the system also predicts the temperature, flow rate and pressure of the coolant according to the thermal management model, and compares these predicted values ​​with the actual measured values ​​of the sensor to calculate the deviation, so as to further correct and optimize the prediction ability of the system. By comparing and analyzing the simulation results with the actual flow data, the system can flexibly adjust the pipeline flow resistance parameters and the thermal resistance parameters of the power module 2 in the flow resistance simulation model according to the deviation analysis results to ensure the accuracy and practicality of the simulation model. It can be understood that the deviation correction strategy also includes:

[0093] Establish a sensor deviation database to store the system deviation, random deviation and historical deviation correction records of each sensor;

[0094] According to the information in the sensor deviation database, the real-time measurement data of the sensor is compensated for the deviation; a deviation threshold is set, and when the deviation of the sensor exceeds the threshold, an alarm mechanism is triggered and the sensor is adjusted or replaced.

[0095] In this technical solution, by establishing a sensor deviation database, comprehensive management and utilization of sensor deviation information is achieved. The database not only stores the system deviation and random deviation of each sensor, but also records the details of historical deviation corrections, providing rich data support for the system's deviation correction. Based on the information in the sensor deviation database, the system can compensate for the deviation of the real-time measurement data of the sensor, effectively improving the accuracy and reliability of the measurement data. This step ensures that the system can make correct control decisions based on accurate sensor data, further improving the control accuracy of the system. At the same time, the system also sets a deviation threshold. When the deviation of the sensor exceeds the threshold, an alarm mechanism will be triggered. This mechanism can promptly detect abnormal problems with the sensor and remind the operator to adjust or replace the sensor, effectively avoiding system control errors or performance degradation caused by sensor failure.

[0096] The system also includes an adaptive learning module, which is connected to the controller and is used to automatically learn and optimize the parameters of the thermal management model and the flow resistance simulation model according to the long-term operation data and deviation correction records of the system. By introducing the adaptive learning module, the system realizes the automatic learning and optimization of the parameters of the thermal management model and the flow resistance simulation model, and further improves the intelligence level of the system. The adaptive learning module is closely connected with the controller and can make full use of the long-term operation data and deviation correction records of the system. These valuable data resources provide a solid foundation for the optimization of the model. Under the action of the adaptive learning module, the system can continuously analyze and summarize the experience and rules in the operation process, automatically adjust the parameters of the thermal management model and the flow resistance simulation model, and make the model more in line with the actual operation state of the system. This automatic learning and optimization capability not only improves the accuracy and reliability of the model, but also enhances the system's adaptability to different working conditions and changes. In the adaptive learning module, the long-term operation data and deviation correction records of the system can be collected, and the data can be cleaned and feature extracted preprocessing steps can be performed; the machine learning algorithm is used to optimize the parameters of the thermal management model and the flow resistance simulation model. Specifically, the machine learning algorithm adopts a neural network algorithm, wherein the input layer receives the temperature, flow, and pressure operating data of the system, the hidden layer performs nonlinear transformation on the input data through multiple layers of neurons to extract features, and the output layer outputs the optimized thermal resistance, heat transfer coefficient, and flow resistance characteristic model parameters. The training process adopts a back propagation algorithm and adjusts the network weights according to the mean square error loss function to minimize the error between the model predicted value and the actual value; the adaptive learning module is closely connected with the controller, receives real-time feedback on the system's operating status, and automatically adjusts the model parameters according to the feedback information to achieve continuous optimization of the model. The optimized model parameters are updated to the thermal management model and the flow resistance simulation model to improve the accuracy and reliability of the model.

[0097] The specific description of the present invention in the above embodiments is only used to further illustrate the present invention and cannot be understood as limiting the scope of protection of the present invention. Technical engineers in this field may make some non-essential improvements and adjustments to the present invention based on the contents of the above invention, which fall within the scope of protection of the present invention.

Claims

1. A fully liquid-cooled charging stack current balancing system, characterized in that: include: A coolant pipeline, used for conveying coolant to a plurality of power modules, the coolant pipeline comprising a liquid inlet branch and a liquid outlet branch, the liquid inlet branch is provided with a plurality of liquid inlets, the liquid outlet branch is provided with a plurality of liquid outlets, each liquid inlet and liquid outlet are respectively connected with a corresponding power module, during the flow of the coolant, the coolant first enters the corresponding power module through the liquid inlet of the liquid inlet branch, and after the power module dissipates heat, flows out from the liquid outlet corresponding to the power module, and the position of the liquid outlet on the liquid outlet branch makes the coolant flow out of the coolant pipeline relatively late; Sensors for real-time monitoring of coolant temperature, flow rate and pressure; A controller connected to the sensor, for receiving sensor data and generating a balancing control strategy; The pump assembly is arranged at the liquid outlet of the power module and is connected to the controller to adjust the pump speed according to the balanced control strategy.

2. A full liquid-cooled charging stack current balancing system according to claim 1, characterized in that: The pump assembly comprises a plurality of pump groups, the number of the liquid outlet branches is multiple, and each pump group is respectively arranged on a different liquid outlet branch.

3. A full liquid-cooled charging stack current balancing system according to claim 2, characterized in that: The generation balance control strategy includes: Receive and analyze sensor monitoring data in real time; Detect abnormal conditions of flow, temperature and pressure according to preset thresholds and generate abnormal detection results; Generate a thermal management model based on historical data, current environmental conditions and system configuration, predict the system's thermal load and cooling requirements, evaluate the coolant requirements of each power module, and generate a demand assessment report; Based on the abnormal detection results and demand assessment reports, dynamic instructions for adjusting the pump speed are generated.

4. A full liquid-cooled charging stack current balancing system according to claim 3, characterized in that: Generating a thermal management model according to historical data, current environmental conditions and system configuration includes: Collecting the operating data of the system under different working conditions, the operating data including the temperature, flow rate, pressure of the coolant, the temperature of the power module, the heat dissipation efficiency and the pump speed; Standardize the collected operational data; According to the thermophysical parameters of the coolant, the flow resistance characteristics of the pipeline, the thermal resistance and heat transfer coefficient of the power module, a physical model of the flow of the coolant in the pipeline and the heat dissipation process of the power module is established.

5. A full liquid-cooled charging stack current balancing system according to claim 4, characterized in that: The different operating conditions include environmental conditions and system configurations. The environmental conditions include temperature, humidity and altitude. The system configuration includes the number of power modules and the type of coolant.

6. A full liquid-cooled charging stack current balancing system according to claim 5, characterized in that: The generation balance control strategy also includes: Establish a flow resistance simulation model for the coolant pipeline; According to the actual working conditions of the system, the coolant inlet flow, pressure and temperature boundary conditions are set; according to the structure and material characteristics of the power module, the thermal resistance and heat transfer coefficient are set; Run a flow resistance simulation model to calculate the flow of coolant in the pipes; The flow resistance simulation results are compared with the actual flow data. Based on the comparison results, the pump speed that needs to be adjusted is calculated, and the adjustment instructions for the pump speed are dynamically generated.

7. A full liquid-cooled charging stack current balancing system according to claim 3 or 6, characterized in that: The dynamically generating the adjustment instruction for the pump speed comprises: Determine the total coolant flow required for the system based on the needs assessment report; Adjust the pump speed according to the coolant demand ratio of each power module.

8. A full liquid-cooled charging stack current balancing system according to claim 7, characterized in that: The system also includes a deviation correction strategy: Use standard sources to compare the output of the sensor, identify and record the systematic deviation and random deviation of the sensor, monitor the changing trend of the sensor data in real time, and identify abnormal fluctuations in the data based on the statistical method of standard deviation analysis as input for deviation correction; Predict the temperature, flow rate and pressure of the coolant according to the thermal management model, compare the model prediction value with the actual measurement value of the sensor, and calculate the deviation; Regularly run the flow resistance simulation model of the coolant pipeline, calculate the flow of coolant in the pipeline, compare and analyze the simulation results with the actual flow data, and adjust the pipeline flow resistance parameters and power module thermal resistance parameters in the flow resistance simulation model according to the deviation analysis results.

9. A full liquid-cooled charging stack current balancing system according to claim 8, characterized in that: The deviation correction strategy also includes: Establish a sensor deviation database to store the system deviation, random deviation and historical deviation correction records of each sensor; According to the information in the sensor deviation database, the real-time measurement data of the sensor is compensated for the deviation; A deviation threshold is set. When the deviation of the sensor exceeds the deviation threshold, an alarm mechanism is triggered and the sensor is adjusted or replaced.

10. The full liquid-cooled charging stack current balancing system according to claim 1, characterized in that: The system also includes an adaptive learning module, which is connected to the controller and is used to automatically learn and optimize parameters of the thermal management model and the flow resistance simulation model based on the long-term operation data and deviation correction records of the system.

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