Four-wheel high-power direct-current charging thermal management system and method

Abstract

The invention discloses a four-wheel high-power direct-current charging thermal management system and method. The system comprises a charging pile module, a preheating module, a battery module and a thermal management module. The method comprises the following steps: step 1, initializing and detecting a system; 2, preheating the battery pack; step 3, starting charging and adjusting power; 4, performing high-power charging heat management; 5, monitoring and adjusting the temperature; 6, charging completion and safety check are carried out; the heat management system with a preheating function is designed, and the water tank is connected with the charging pile heat pump through a specific interface in a low-temperature environment, so that the system can utilize the heating capacity of the heat pump to preheat the cooling liquid in the water tank through the heat exchanger, and the cooling liquid reaches the most suitable temperature; and then the power battery is guided into a cold plate at the bottom of the battery, so that the temperature of the power battery is quickly increased, the power battery quickly reaches a state suitable for high-rate charging, and the charging duration of the power battery of the whole vehicle is remarkably shortened.

Description

Technical Field

[0001] The present invention relates to the technical field of charging thermal management, and particularly to a four-wheel high-power DC charging thermal management system and method. Background Art

[0002] The four-wheel high-power DC charging thermal management system is an important system for heat management during the high-power DC charging process of four-wheel electric vehicles, aiming to improve the charging efficiency of electric vehicles under high-power DC charging conditions and ensure the safety and stability of the battery. This system optimizes the charging performance by precisely controlling the heat generation and dissipation during the charging process, and is applicable to various four-wheel electric vehicle scenarios that require fast charging, such as electric vehicle charging stations, airport charging stations, etc. These scenarios usually require fast charging speed, high safety, and long-term stable operation.

[0003] The existing high-power DC charging thermal management methods have the following defects: First, in a low-temperature environment, the chemical reaction activity inside the battery decreases, resulting in a significant reduction in charging efficiency. The battery usually needs to be preheated to a suitable temperature range before it can smoothly enter the high-power charging state. Most of the existing thermal management systems lack effective integration with the preheating function, which means that in low-temperature conditions, the battery needs additional time to preheat, thus prolonging the overall charging cycle and reducing the charging efficiency. This defect not only affects the user experience but also limits the application potential of electric vehicles in cold regions. Second, although the traditional air-cooled heat dissipation method has advantages such as low cost and simple structure, its heat dissipation performance is difficult to meet the stringent requirements of the high-power DC charging system. Air-cooled heat dissipation mainly relies on convective heat transfer of air, and realizes heat transfer through fans and radiators. The thermal conductivity of air is relatively low, and its heat capacity is limited. This leads to the inability of air-cooled heat dissipation to effectively control the temperature of the battery and the charging system when facing a large amount of heat generated by high-power charging, increasing the risk of overheating and safety hazards. Third, although liquid-cooled heat dissipation improves the heat dissipation efficiency to a certain extent, its inherent complexity, high cost, and large volume have become the key factors restricting its widespread application. The liquid-cooled heat dissipation system uses liquid as the heat-absorbing medium and uses a pump to drive the liquid circulation to take away the heat from the heat source. This heat dissipation method requires complex pipeline layouts, high-precision sealing designs, and additional maintenance costs. For the battery and the charging module, liquid-cooled heat dissipation also poses higher sealing requirements to ensure that the liquid does not leak and damage electronic devices, increasing the complexity and cost of the system. Summary of the Invention

[0004] The purpose of the present invention is to provide a four-wheel high-power DC charging thermal management system and method to solve the problems raised in the above background art.

[0005] To achieve the above object, the present invention provides the following technical solutions: A four-wheel high-power DC charging thermal management system, including a charging pile module, the charging pile module includes a heat pump module, an interface module, a temperature monitoring module, a charging module, a remote control module, a charging management module, a safety protection module, and a data management module. The charging pile module is electrically connected to a battery module, and the battery module is electrically connected to the charging module. The charging pile module is fixedly connected with a preheating module and a thermal management module.

[0006] As a further technical solution of the present invention, the preheating module includes a water tank module, a heat exchanger module, a circulation pump module, and a cold plate module.

[0007] As a further technical solution of the present invention, the water tank module is fixedly connected to the interface module. The water tank module is conductively connected to a circulation pump module, and the circulation pump module is conductively connected to the cold plate module. The cold plate module is disposed on the battery module.

[0008] As a further technical solution of the present invention, the thermal management module includes a phase change material module, an air cooling module, a heat sink module, a phase change control module, and a coupling control module. The phase change material module is fixedly connected to the charging module.

[0009] As a further technical solution of the present invention, the safety protection module includes an overcurrent protection module, an overvoltage protection module, an undervoltage protection module, an overtemperature protection module, a short-circuit protection module, and a grounding protection module.

[0010] A four-wheel high-power DC charging thermal management method, including Step 1, system initialization and detection; Step 2, battery pack preheating; Step 3, charging start and power adjustment; Step 4, high-power charging thermal management; Step 5, temperature monitoring and adjustment; Step 6, charging completion and safety inspection;

[0011] Among them, in the above Step 1, before starting charging, the system first initializes and checks the status and connection of each module;

[0012] Among them, in the above Step 2, in a low-temperature environment, the preheating module starts to work to raise the temperature of the battery module to a suitable charging range;

[0013] Among them, in the above Step 3, after the preheating is completed, the system starts charging, and according to the current state of the battery module, the system adjusts the charging power to optimize the charging efficiency and safety;

[0014] Among them, in the above Step 4, the thermal management module starts to work to control the temperature of the charging module;

[0015] Among them, in the above Step 5, the system continuously monitors the temperature changes of the battery module and the charging module, and adjusts the working states of the preheating module and the thermal management module as needed;

[0016] In step six above, when the battery module is fully charged, the system stops charging and shuts down each module, and conducts a safety check to ensure that all devices are working properly and there are no abnormal conditions.

[0017] As a further technical solution of the present invention, in step two, the water tank module in the vehicle preheating module is connected to the heat pump module through the interface module in the charging pile module and exchanges heat with the heat pump module through the heat exchanger module. The heat pump module preheats the coolant in the water tank module to a predetermined temperature. The water tank module passes the preheated coolant into the cold plate module at the bottom of the battery module through the circulation pump module, thereby realizing rapid preheating of the battery module to reach the appropriate temperature for high-power DC charging, improving the charging efficiency, and shortening the charging time.

[0018] As a further technical solution of the present invention, in step four, during the charging process, the temperature of the charging module is controlled by the thermal management module. The phase change material module covers the heating surface of the charging module, initially absorbs the heat generated during the charging process and undergoes a phase change. During the phase change process from solid to liquid, the phase change material module will absorb a large amount of heat and at the same time maintain a relatively stable temperature.

[0019] As a further technical solution of the present invention, in step four, when the phase change material module reaches a certain temperature or degree of phase change, it will start to release heat and undergo the reverse phase change. During this process, the phase change material module will gradually release the heat stored in it into the environment. At the same time, the air cooling module starts to take away the heat released by the phase change material module and dissipate it into the environment.

[0020] As a further technical solution of the present invention, in step five, the system monitors the temperature change in real time through the temperature monitoring module, controls the phase change temperature parameters of the phase change material module through the phase change control module, and controls the rotation speed of the air cooling module and the heat dissipation area of the heat sink module through the coupling control module to achieve the best heat dissipation effect, and switches the connection state between the water tank module and the heat pump module according to the temperature state of the battery module to ensure that the battery module always maintains the best charging temperature.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention is designed with a thermal management system having a preheating function. In a low-temperature environment, the water tank is connected to the charging pile heat pump through a specific interface, enabling the system to utilize the heating capacity of the heat pump to preheat the coolant in the water tank through a heat exchanger, so that the coolant reaches an optimal temperature and is then introduced into the cold plate at the bottom of the battery, rapidly increasing the temperature of the power battery and enabling it to quickly reach a state suitable for high-rate charging, thereby significantly shortening the charging duration of the vehicle's power battery and improving the charging efficiency. In addition, a phase change material and air-cooled coupled thermal control system is designed. When the charging system generates heat, the phase change material first absorbs this heat and undergoes a phase change. The phase change material can absorb a large amount of heat while maintaining its temperature relatively stable, thus effectively avoiding overheating of the system. As the phase change material absorbs more heat, when it reaches a certain temperature or phase change degree, the phase change material begins to release heat. At this time, the air-cooled heat dissipation module is activated to efficiently take away the heat released by the phase change material and dissipate it into the environment. During this process, the control system will intelligently adjust the rotation speed of the fan and the heat dissipation area of the heat sink according to the real-time changes in the temperature of the phase change material and the ambient temperature to achieve the best heat dissipation effect. This intelligent adjustment mechanism not only ensures the heat dissipation efficiency of the system but also makes the entire thermal management system more concise and easy to maintain in structure. Compared with traditional air-cooled and liquid-cooled systems, this system performs excellently in heat dissipation efficiency and has the advantages of simple structure and easy maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is the system structure diagram of the present invention;

[0023] Figure 2 is the module architecture diagram of the charging pile module of the present invention;

[0024] Figure 3 is the module architecture diagram of the safety protection module of the present invention;

[0025] Figure 4 is the method flow chart of the present invention;

[0026] Figure 5 is the system flow chart of the present invention.

[0027] In the figure: 1. Charging pile module; 11. Heat pump module; 12. Interface module; 13. Temperature monitoring module; 14. Charging module; 15. Remote control module; 16. Charging management module; 17. Safety protection module; 171. Overcurrent protection module; 172. Overvoltage protection module; 173. Undervoltage protection module; 174. Over-temperature protection module; 175. Short-circuit protection module; 176. Grounding protection module; 18. Data management module; 2. Preheating module; 21. Water tank module; 22. Heat exchanger module; 23. Circulation pump module; 24. Cold plate module; 3. Battery module; 4. Thermal management module; 41. Phase change material module; 42. Air-cooling module; 43. Heat sink module; 44. Phase change control module; 45. Coupling control module. Detailed implementation manners

[0028] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0029] Please refer to the attached Figure 1 - attached Figure 3, an embodiment provided by the present invention: a four-wheel high-power DC charging thermal management system, including a charging pile module 1, the charging pile module 1 includes a heat pump module 11, an interface module 12, a temperature monitoring module 13, a charging module 14, a remote control module 15, a charging management module 16, a safety protection module 17 and a data management module 18. A battery module 3 is electrically connected to the charging pile module 1, and the battery module 3 is electrically connected to the charging module 14. A preheating module 2 and a thermal management module 4 are fixedly connected to the charging pile module 1; the preheating module 2 includes a water tank module 21, a heat exchanger module 22, a circulation pump module 23 and a cold plate module 24. The water tank module 21 exchanges heat with the heat pump module 11 through the heat exchanger module 22 to preheat the coolant therein, and is introduced into the cold plate module 24 at the bottom of the battery module 3 through the circulation pump module 23 to preheat the battery module 3; the water tank module 21 is fixedly connected to the interface module 12, the water tank module 21 is conductively connected to the circulation pump module 23, and the circulation pump module 23 is conductively connected to the cold plate module 24. The cold plate module 24 is arranged on the battery module 3; the thermal management module 4 includes a phase change material module 41, an air cooling module 42, a heat sink module 43, a phase change control module 44 and a coupling control module 45. The phase change material module 41 is fixedly connected to the charging module 14, and the heat sink module 43 is used to increase the heat dissipation area to improve the heat dissipation effect of the air cooling module 42; the safety protection module 17 includes an overcurrent protection module 171, an overvoltage protection module 172, an undervoltage protection module 173, an overtemperature protection module 174, a short-circuit protection module 175 and a grounding protection module 176. The overcurrent protection module 171, the overvoltage protection module 172, the undervoltage protection module 173, the overtemperature protection module 174, the short-circuit protection module 175 and the grounding protection module 176 are used to protect the equipment in case of abnormal current, abnormal voltage, abnormal temperature and short-circuit abnormalities.

[0030] Please refer to the appendix Figure 4 - appendix Figure 5 , an embodiment provided by the present invention: a four-wheel high-power DC charging thermal management method, including Step 1, system initialization and detection; Step 2, battery pack preheating; Step 3, charging start and power adjustment; Step 4, high-power charging thermal management; Step 5, temperature monitoring and adjustment; Step 6, charging completion and safety inspection;

[0031] Among them, in the above Step 1, before starting charging, the system first initializes and checks the status and connection of each module;

[0032] Among them, in the above step two, in a low-temperature environment, the preheating module 2 starts to work to raise the temperature of the battery module 3 to an appropriate charging range. The water tank module 21 in the vehicle preheating module 2 is connected to the heat pump module 11 through the interface module 12 in the charging pile module 1 and exchanges heat with the heat pump module 11 through the heat exchanger module 22. The heat pump module 11 is used to preheat the coolant in the water tank module 21 to a predetermined temperature. The water tank module 21 passes the preheated coolant into the cold plate module 24 at the bottom of the battery module 3 through the circulation pump module 23, thereby realizing the rapid preheating of the battery module 3 to reach the appropriate temperature for high-power DC charging, improving the charging efficiency, and shortening the charging time;

[0033] Among them, in the above step three, after the preheating is completed, the system starts to charge. According to the current state of the battery module 3, the system adjusts the charging power to optimize the charging efficiency and safety;

[0034] Among them, in the above step four, during the charging process, the temperature of the charging module 14 is controlled by the thermal management module 4. The phase change material module 41 covers the heating surface of the charging module 14 and initially absorbs the heat generated during the charging process and undergoes a phase change. During the phase change process from solid to liquid, the phase change material module 41 will absorb a large amount of heat while maintaining a relatively stable temperature. When the phase change material module 41 reaches a certain temperature or phase change degree, it will start to release heat and undergo the reverse phase change. During this process, the phase change material module 41 will gradually release the heat it stores into the environment. At the same time, the air-cooling module 42 is started to take away the heat released by the phase change material module 41 and dissipate it into the environment;

[0035] Among them, in the above step five, the system continuously monitors the temperature changes of the battery module 3 and the charging module 14 and adjusts the working states of the preheating module 2 and the thermal management module 4 as needed. The system monitors the temperature changes in real time through the temperature monitoring module 13, controls the phase change temperature parameters of the phase change material module 41 through the phase change control module 44, controls the rotation speed of the air-cooling module 42 and the heat dissipation area of the heat sink module 43 through the coupling control module 45 to achieve the best heat dissipation effect, and switches the connection state between the water tank module 21 and the heat pump module 11 according to the temperature state of the battery module 3 to ensure that the battery module 3 always maintains the best charging temperature;

[0036] Among them, in the above step six, when the battery module 3 is fully charged, the system stops charging and shuts down each module for safety inspection to ensure that all devices are working properly and there are no abnormal situations.

[0037] Based on the above, the advantages of the present invention are as follows: When using the present invention for four-wheel high-power DC charging thermal management, first, before starting charging, the system first initializes and checks the status and connection of each module. In a low-temperature environment, the preheating module 2 starts to work to raise the temperature of the battery module 3 to an appropriate charging range. The water tank module 21 in the vehicle preheating module 2 is connected to the heat pump module 11 through the interface module 12 in the charging pile module 1 and exchanges heat with the heat pump module 11 through the heat exchanger module 22. The heat pump module 11 preheats the coolant in the water tank module 21 to a predetermined temperature. The water tank module 21 passes the preheated coolant into the cold plate module 24 at the bottom of the battery module 3 through the circulation pump module 23, thereby achieving rapid preheating of the battery module 3 to reach the appropriate temperature for high-power DC charging, improving the charging efficiency and shortening the charging time. After the preheating is completed, the system starts charging. According to the current state of the battery module 3, the charging power is adjusted by the charging management module 16 to optimize the charging efficiency and safety. During the charging process, the temperature of the charging module 14 is controlled by the thermal management module 4. The phase change material module 41 covers the heating surface of the charging module 14, initially absorbs the heat generated during the charging process and undergoes a phase change. During the phase change from solid to liquid, the phase change material module 41 absorbs a large amount of heat and maintains a relatively stable temperature. When the phase change material module 41 reaches a certain temperature or phase change degree, it starts to release heat and undergoes the opposite phase change. During this process, the phase change material module 41 gradually releases the heat it stores into the environment. At the same time, the air-cooling module 42 starts to take away the heat released by the phase change material module 41 and dissipate it into the environment. The system continuously monitors the temperature changes of the battery module 3 and the charging module 14, and adjusts the working states of the preheating module 2 and the thermal management module 4 as needed. The system monitors the temperature changes in real time through the temperature monitoring module 13, controls the phase change temperature parameters of the phase change material module 41 through the phase change control module 44, and controls the rotation speed of the air-cooling module 42 and the heat dissipation area of the heat sink module 43 through the coupling control module 45 to achieve the best heat dissipation effect. The connection state between the water tank module 21 and the heat pump module 11 is switched according to the temperature state of the battery module 3 to ensure that the battery module 3 always maintains the best charging temperature. When the battery module 3 is fully charged, the system stops charging and shuts down each module, and conducts a safety check to ensure that all devices are working properly and there are no abnormal situations; among them, the overcurrent protection module 171, overvoltage protection module 172, undervoltage protection module 173, overtemperature protection module 174, short-circuit protection module 175, and grounding protection module 176 in the safety protection module 17 are used to protect the equipment in case of abnormal current, voltage, temperature, and short circuit. The remote control module 15 is used to remotely control the system operation, and the data management module 18 is used to store and manage the charging and thermal management data.

[0038] It is obvious to those skilled in the art that the present invention is not limited to the details of the above-described exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, in all respects, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the appended claims rather than the above description. Accordingly, all changes that fall within the meaning and scope of the equivalent elements of the claims are intended to be embraced within the present invention. Any reference signs in the claims should not be construed as limiting the claims concerned.

Claims

1. A four-wheel high-power DC charging thermal management system, comprising a charging pile module (1), characterized in that: The charging pile module (1) comprises a heat pump module (11), an interface module (12), a temperature monitoring module (13), a charging module (14), a remote control module (15), a charging management module (16), a safety protection module (17) and a data management module (18); the charging pile module (1) is electrically connected to a battery module (3), and the battery module (3) is electrically connected to the charging module (14); and the charging pile module (1) is fixedly connected to a preheating module (2) and a thermal management module (4).

2. A four-wheel high-power DC charging thermal management system according to claim 1, characterized in that: The preheating module (2) comprises a water tank module (21), a heat exchanger module (22), a circulation pump module (23) and a cold plate module (24).

3. A four-wheel high-power DC charging thermal management system according to claim 2, characterized in that: The water tank module (21) is fixedly connected to the interface module (12), the water tank module (21) is conductively connected to a circulation pump module (23), and the circulation pump module (23) is conductively connected to a cold plate module (24), and the cold plate module (24) is arranged on the battery module (3).

4. A four-wheel high-power DC charging thermal management system according to claim 1, characterized in that: The thermal management module (4) comprises a phase change material module (41), an air cooling module (42), a heat sink module (43), a phase change control module (44) and a coupling control module (45); the phase change material module (41) is fixedly connected to the charging module (14).

5. A four-wheel high-power DC charging thermal management system according to claim 1, characterized in that: The safety protection module (17) comprises an overcurrent protection module (171), an overvoltage protection module (172), an undervoltage protection module (173), an overtemperature protection module (174), a short circuit protection module (175) and a grounding protection module (176).

6. A four-wheel high-power DC charging thermal management method, comprising step 1, system initialization and detection; step 2, battery pack preheating; step 3, charging start and power adjustment; step 4, high-power charging thermal management; step 5, temperature monitoring and adjustment; step 6, charging completion and safety inspection; characterized in that: In the above step 1, before starting charging, the system first initializes and checks the status and connection of each module; In the above step 2, in a low temperature environment, the preheating module (2) starts to work to increase the temperature of the battery module (3) to a suitable charging range; In the above step 3, after preheating is completed, the system starts charging, and according to the current state of the battery module (3), the system adjusts the charging power to optimize the charging efficiency and safety; In the above step 4, the thermal management module (4) starts to work to control the temperature of the charging module (14); In the above step 5, the system continuously monitors the temperature changes of the battery module (3) and the charging module (14), and adjusts the working states of the preheating module (2) and the thermal management module (4) as needed; In the above step six, when the battery module (3) is fully charged, the system stops charging and shuts down each module, and performs a safety check to ensure that all devices are operating normally and no abnormalities occur.

7. A four-wheel high-power DC charging thermal management method according to claim 6, characterized in that: In the second step, the water tank module (21) in the vehicle preheating module (2) is connected to the heat pump module (11) via the interface module (12) in the charging pile module (1) and performs heat exchange with the heat pump module (11) via the heat exchanger module (22). The heat pump module (11) preheats the coolant in the water tank module (21) to a predetermined temperature. The water tank module (21) passes the preheated coolant into the cold plate module (24) at the bottom of the battery module (3) via the circulating pump module (23), thereby achieving rapid preheating of the battery module (3) to reach a suitable temperature for high-power DC charging, improving charging efficiency, and shortening charging time.

8. A four-wheel high-power DC charging thermal management method according to claim 6, characterized in that: In step 4, the temperature of the charging module (14) is controlled by the thermal management module (4) during the charging process, and the phase change material module (41) covers the heating surface of the charging module (14), initially absorbing the heat generated during the charging process and undergoing a phase change. During the phase change process from solid to liquid, the phase change material module (41) absorbs a large amount of heat while maintaining a relatively stable temperature.

9. A four-wheel high-power DC charging thermal management method according to claim 8, characterized in that: In step 4, when the phase change material module (41) reaches a certain temperature or phase change degree, it will start to release heat and undergo an opposite phase change. During this process, the phase change material module (41) will gradually release the stored heat into the environment. At the same time, the air cooling module (42) is started to take away the heat released by the phase change material module (41) and dissipate it into the environment.

10. A four-wheel high-power DC charging thermal management method according to claim 6, characterized in that: In the step 5, the system monitors the temperature change in real time through the temperature monitoring module (13), controls the phase change temperature parameter of the phase change material module (41) through the phase change control module (44), controls the rotation speed of the air cooling module (42) and the heat dissipation area of ​​the heat sink module (43) through the coupling control module (45) to achieve the best heat dissipation effect, and switches the connection state of the water tank module (21) and the heat pump module (11) according to the temperature state of the battery module (3), so as to ensure that the battery module (3) always maintains the best charging temperature.

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