Hybrid vehicle power generation and thermal management system using engine tail gas waste heat

Abstract

The invention belongs to the technical field of hybrid power vehicles, and particularly relates to a hybrid power vehicle power generation and heat management system utilizing engine tail gas waste heat, which is additionally provided with a heat management system for generating power by utilizing engine tail gas and managing a passenger compartment, a battery system and a motor system. According to the system, a power generation system, a passenger compartment thermal management system, a battery thermal management system and a motor thermal management system are integrated on the basis of a vehicle-mounted water tank, and the power generation system, the passenger compartment thermal management system, the battery thermal management system and the motor thermal management system can be monitored and controlled in real time in combination with a vehicle control system. The subsystems are integrated through the working medium water, mechanical water pumps in the original subsystems are reduced, the number of assemblies of the system and the weight of the assemblies are reduced, and energy loss caused by rotation of the mechanical water pumps is reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of hybrid vehicles, and particularly relates to a power generation and thermal management system for hybrid vehicles that utilizes the waste heat of engine exhaust gas. Background Art

[0002] The existing thermal management system solutions for hybrid vehicles are as Figure 1 shown. The existing thermal management system for hybrid vehicles mainly includes an engine thermal management system (label 103 - label 113 and label 115), a passenger compartment thermal management system (label 114 - label 121), a battery thermal management system (label 102, label 114 - label 124), and a motor thermal management system (label 101 and label 125 - label 128).

[0003] The existing components of the engine thermal management system mainly include a fan 103, an engine radiator 104, a cylinder block 105, a cylinder head 106, an engine water pump 107, a thermostat 108, a supercharger 109, an intercooler 110, an exhaust gas recirculation system EGR 111, an oil cooler for the lubrication system 112, and a transmission oil cooler 113. The liquid water in the water kettle 115, under the action of the engine water pump, flows through the cylinder block 105, the cylinder head 106, and the EGR 111 in sequence. After flowing through the cylinder block 105, the liquid water is divided into two branches. One branch flows into the engine radiator 104 and exchanges heat with the wind from the external environment through the fan 104, dissipating most of the heat to the external environment; the other branch flows into the supercharger 109, and the pressurized liquid water then flows into the intercooler 110 to cool the cylinder head 106. The liquid water flowing through the cylinder head 106 and the EGR 111 exchanges heat with the liquid water flowing out of the cylinder block 105 to cool the EGR 111 and reduce the emission of combustible substances in the exhaust gas. In addition, the liquid water flowing out of the engine radiator 104 after air cooling is mixed with the liquid water from the water kettle 115 in the thermostat 108, and then undergoes the next cycle process.

[0004] The existing components of the passenger compartment thermal management system include a refrigeration subsystem and a heating subsystem. Among them, the refrigeration subsystem adopts a traditional air - conditioning refrigeration system, and the traditional air - conditioning refrigeration system includes components such as a compressor, a condenser, an expansion valve, and an evaporator; the heating subsystem mainly utilizes a heat pump heating circulation system.

[0005] The existing components of the battery thermal management system include a condenser 102, a resistance heater PTC 117, an evaporator 120, a heat exchanger 121, a battery pack 122, a water kettle 123, and a battery water pump 124. In the battery thermal management system, under the action of the battery water pump 124, the liquid water in the water kettle 123 exchanges heat through the heat exchanger 121 to achieve the functions of pre - heating the battery in cold weather and cooling the battery when the battery temperature is too high.

[0006] The existing motor thermal management system components include a motor radiator 101, a motor and a controller (MCU) 128, an on-vehicle charger and a DC conversion unit (OBC&DCDC) 127, a water kettle 126, and a motor water pump 125. The liquid water in the water kettle 126 transfers the heat of the motor system to the external environment through the motor heat exchanger under the action of the motor water pump 125, realizing the cooling effect on the motor system.

[0007] In the existing hybrid vehicle thermal management system, each subsystem needs to rely on multiple water pump structures to drive the liquid water. This makes the weight of the existing vehicle thermal management system relatively large and requires more electrical energy to maintain the normal operation of the water pumps. However, most of the electrical energy of the existing hybrid vehicles is provided by the engine, resulting in relatively high energy consumption of the existing hybrid vehicle thermal management system. Summary of the Invention

[0008] (1) Technical problems to be solved

[0009] The technical problem to be solved by the present invention is: how to provide a hybrid vehicle power generation and thermal management system based on the recovery and utilization of engine exhaust waste heat, and solve the problems of energy waste in the engine exhaust of hybrid vehicles and the integrated comprehensive control of the occupant compartment thermal management system, battery thermal management system, and motor thermal management system.

[0010] (2) Technical solutions

[0011] To solve the above technical problems, the present invention provides a hybrid vehicle power generation and thermal management system that utilizes engine exhaust waste heat. The power generation and thermal management system has made innovative changes on the basis of the original hybrid vehicle integrated thermal management system, reducing the electric heating system and typical compression refrigeration system in the occupant compartment, reducing the mechanical water pump structure in the battery system, reducing the mechanical water pump, condenser and other structures in the motor system; adding an engine exhaust heat exchanger, a turbo power generation device and a steam injection device, and adopting a four-way steering valve to realize the thermal management functions of the same working medium in different states for the occupant compartment, battery system and motor system. The schematic diagram of the hybrid vehicle integrated thermal management system of the present invention is as Figure 2 shown.

[0012] The power generation and thermal management system includes: a fan device (201) for engine air cooling, an engine radiator (202), a thermostat (203) for the engine system, a water tank (204), a passenger compartment heat exchanger (205), a four-way steering valve (206) for the passenger compartment, a water pump (207) for the exhaust gas heat exchanger, a transmission oil cooler (208), an engine water pump (209), an engine (210), engine oil cooling for the lubrication system (211), an engine exhaust gas heat exchanger (212), the external environment (213), a steam ejector (214), a control valve (215) for the passenger compartment, a control valve (216) for the battery system, a control valve (217) for the motor system, a steam turbine (218), a generator (219), a 220 power system, a condenser (221), a four-way steering valve (222) for the motor system, a motor system (223), a four-way steering valve (224) for the battery system, and a battery system (225);

[0013] In the thermal management system corresponding to the engine (210), the liquid water in the water tank (204) flows through the thermostat (203) for the engine system and the engine water pump (209) under the action of the engine water pump (209). After flowing through the engine water pump (209), the liquid water is divided into two branches. One branch cools the engine (210) and then flows into the engine radiator (202), where it exchanges heat with the air in the external environment (213) through the fan device (201) for engine air cooling, and most of the heat is dissipated into the external environment (213);

[0014] The other branch flows into the engine oil cooling for the lubrication system (211). After cooling the engine oil in the lubrication system, it returns to the flow path of the engine water pump (209) between the thermostat (203) for the engine system;

[0015] In the thermal management system corresponding to the engine (210), an engine exhaust gas heat exchanger (212) is provided at the middle section of the engine exhaust gas pipeline. The exhaust gas flowing through the engine exhaust gas heat exchanger (212) exchanges heat with the liquid water led out from the water tank (204).

[0016] Among them, the engine exhaust gas heat exchanger (212) is made of high-quality stainless steel material with high temperature resistance and corrosion resistance, and a turbulator fin structure is designed in both the tube side and the shell side to increase the turbulence degree of the exhaust gas in the engine exhaust gas heat exchanger (212) and enhance the heat exchange effect.

[0017] Among them, after the liquid water absorbs the heat carried by the exhaust gas in the engine exhaust gas heat exchanger (212), it becomes superheated steam, and the cooled exhaust gas is dissipated into the external environment;

[0018] The superheated steam enters the steam ejector (214). The front end of the structure of the steam ejector (214) is a converging-diverging structure, which is conducive to increasing the speed of the superheated steam entering the steam ejector (214). The outlet of the converging-diverging structure is connected to a straight pipe with a smaller diameter size, aiming to reduce the speed loss of the superheated steam;

[0019] The superheated steam flowing through the steam ejector (214) is divided into four branches, namely the occupant compartment thermal management system, the battery thermal management system, the motor thermal management system, and the power generation system. Control valves are provided in the occupant compartment thermal management system, the battery thermal management system, and the motor thermal management system among the four branches, namely the control valve (215) for the occupant compartment, the control valve (216) for the battery system, and the control valve (217) for the motor system;

[0020] A precise water level sensor is provided in the water tank (204). The water level sensor accurately monitors the water level in the water tank in real time. When the water level is lower than the preset minimum value, an alarm signal is immediately sent to the vehicle control system to remind the driver or the control system to perform the water replenishment operation in time;

[0021] In addition, the outlet of the engine exhaust gas heat exchanger (212) is closely connected to the steam generator. Its function is to reliably convert the heated water into steam; it is equipped with high-precision pressure sensors and temperature sensors inside to accurately monitor the pressure and temperature status of the steam in real time to ensure that the steam parameters meet the system requirements; at the same time, to ensure system safety, a reliable safety valve is also set. When the pressure in the system exceeds the set safety pressure, the safety valve will automatically open quickly in time to release the excess steam, effectively preventing potential safety accidents caused by excessive pressure in the system.

[0022] Among them, most of the superheated steam flowing through the steam ejector (214) is used for the power generation system. The specific process is as follows: The superheated steam flows through the steam turbine (218). The energy of the exhaust gas drives the steam turbine (218) to rotate at a high speed, converting thermal energy into the mechanical energy of the steam turbine (218). The steam turbine (218) is connected to the rotor of the generator (219) through a strong shaft, efficiently converting mechanical energy into electrical energy to drive the rotation of the generator (219), converting mechanical energy into electrical energy. The electrical energy generated by the generator (219) is transmitted to the power system (220) for powering on-board equipment and charging the battery. The steam flowing through the steam turbine (218) exchanges heat with the condenser (221) and becomes subcooled water and then flows back to the water tank (204);

[0023] The power generation system includes a rectifier, an intelligent inverter, and a battery;

[0024] The alternating current generated by the generator (219) is accurately converted into direct current by a rectifier, providing a stable DC power supply for subsequent power storage and use; an inverter is used to flexibly convert the direct current into appropriate alternating current according to the needs of vehicle electrical equipment, ensuring the effective supply and use of power; a battery is used to store the excess electrical energy generated by the power generation device and can supply power to various electrical equipment of the vehicle in a timely manner when needed, playing a role in energy buffering and regulation.

[0025] Among them, when the occupant compartment thermal management system needs to be heated in cold weather, the superheated steam enters the occupant compartment through the control valve (215) used for the occupant compartment and the four-way steering valve (206) for the occupant compartment, and exchanges heat with the occupant compartment heat exchanger (205) in the occupant compartment. The steam end of the occupant compartment heat exchanger (205) adopts a converging-diverging structure, increasing the contact area with the indoor air while also slowing down the steam velocity, raising the air temperature in the occupant compartment and realizing the heating function of the occupant compartment.

[0026] When the temperature in the occupant compartment is relatively high in a hot weather environment and the occupant compartment thermal management system needs to be cooled, the control valve (215) used for the occupant compartment is closed, and the subcooled water flowing through the condenser (221) flows into the occupant compartment through the four-way steering valve (206) for the occupant compartment and exchanges heat with the occupant compartment heat exchanger (205), reducing the air temperature in the occupant compartment and realizing the cooling function of the occupant compartment.

[0027] A plurality of high-precision temperature sensors are arranged in the occupant compartment thermal management system to accurately monitor the temperature changes at different positions in real time and feed back the temperature signals to the vehicle control system; the vehicle control system intelligently adjusts the steam flow rate and pressure of the steam injector (214) and the working state of the condenser (221) according to these feedback signals, so as to keep the temperature in the occupant compartment within the set comfortable range.

[0028] Among them, when the loss of the battery system (225) is relatively large in cold weather and the battery system (225) needs to be heated, the superheated steam flowing through the steam injector (214) enters the battery system (225) through the control valve (216) used for the battery system and the four-way steering valve (224) for the battery system, and exchanges heat with the heat pipes in the battery module to ensure that the battery temperature is within the appropriate working temperature range, thereby improving the charge and discharge efficiency and performance of the battery.

[0029] When the battery temperature is too high and needs to be cooled, the control valve (216) used for the battery system is closed, and the subcooled water flowing through the condenser (221) flows into the battery system (225) through the four-way steering valve (224) and exchanges heat with the heat pipes in the battery to absorb the heat of the battery, quickly reducing the battery temperature to within the safe range.

[0030] A temperature sensor is provided inside the battery system (225) to monitor the temperature inside the battery system (225) in real time and transmit the data to the vehicle control system. The control system precisely adjusts the flow rate and temperature of the steam and cooling water according to the real-time change of the battery temperature, realizes precise control of the battery temperature, and effectively extends the service life and reliability of the battery.

[0031] Among them, before the motor starts or when operating in a low-temperature and cold environment, at this time the motor temperature is relatively low, and the motor system (223) needs to be heated;

[0032] The superheated steam flowing through the steam injector (214) enters the motor system (223) through the control valve (217) used by the motor system and the four-way steering valve (222) of the motor system. The heat of the superheated steam is transferred to the motor through the heat exchanger inside the motor system (223) to preheat the motor and improve the working efficiency and reliability of the motor;

[0033] When the temperature of the motor system (223) rises above the set threshold during operation, the control valve (217) used by the motor system is closed, and the subcooled water flowing through the condenser (221) enters the motor system (223) and exchanges heat with the heat exchanger inside the motor system (223) to absorb the heat of the motor system (223) to ensure that the motor temperature is always within the normal operating range;

[0034] At the same time, a temperature sensor is equipped inside the motor system (223) to monitor the temperature of the motor system (223) in real time and feedback the temperature information to the vehicle control system. The control system flexibly adjusts the supply amounts of the superheated steam and subcooled water according to the actual temperature of the motor system (223), realizes precise management of the temperature of the motor system (223), and ensures the stable operation and performance of the motor system (223).

[0035] Among them, the hybrid vehicle power generation and thermal management system proposes corresponding control strategies according to different vehicle states;

[0036] During the startup phase of the vehicle, the thermal management system, the power generation device, and the condenser control system start the initialization program simultaneously. First, the vehicle control system quickly detects the operating state and exhaust gas temperature of the engine (210). When the exhaust gas temperature reaches the preset startup threshold, the water pump is started to stably supply water to the engine exhaust gas heat exchanger (212) to start the heating process. At the same time, the temperatures of the battery system (225), the motor system (223), and various state parameters of the generator (219) are comprehensively monitored. If the temperature of the battery system (225) or the motor system (223) is too low and the conditions in the steam generator meet the requirements, the vehicle control system intelligently activates the corresponding steam heating circuit to preheat the battery system (225) and the motor system (223) to ensure that they can quickly reach the optimal operating temperature range after startup. For the power generation device, after checking that all components are normal, the steam turbine (218) regulating valve is gradually and finely adjusted according to the exhaust gas temperature and pressure, so that the steam turbine (218) generator starts smoothly at a lower power to avoid excessive impact on the system during startup.

[0037] Among them, when the engine (210) is in a high-load operating state and the exhaust gas temperature is relatively high, the control system will increase the water flow rate and steam output to provide sufficient heating heat for the passenger compartment. At the same time, according to the real-time temperature requirements of the battery system (225) and the motor system (223), the heating or cooling is precisely adjusted.

[0038] If the battery power in the battery system (225) is low and the temperature is suitable for charging, the system will preferentially use the exhaust gas waste heat for battery heating to improve the battery charging efficiency. If the temperature of the motor in the motor system (223) rises, the vehicle control system appropriately adjusts the supply of subcooled water to effectively dissipate heat for it.

[0039] Among them, according to the feedback information of multiple temperature sensors in the passenger compartment, the steam and subcooled water amounts are precisely adjusted in real time to ensure that the temperature of the passenger compartment always remains within a comfortable range. In cold weather, the vehicle control system increases the steam heating amount in advance to ensure that the passenger compartment quickly warms up and remains warm. In hot weather, the vehicle control system strengthens ventilation and heat dissipation, and at the same time increases the subcooled water amount in the condenser (221) as needed to moderately cool the passenger compartment to keep the interior cool and comfortable.

[0040] (III) Beneficial effects

[0041] Compared with the prior art, the key points and protection points of the present invention are:

[0042] A heat management system for generating electricity using engine exhaust gas and for the occupant compartment, battery system, and motor system is added. This system integrates the power generation system, occupant compartment heat management system, battery heat management system, and motor heat management system based on an on-vehicle water tank. Combined with the vehicle control system, it can achieve real-time monitoring and control of the power generation system, occupant compartment heat management system, battery heat management system, and motor heat management system.

[0043] The advantages of the present invention are as follows:

[0044] The present invention proposes an integrated heat management system based on waste heat power generation from engine exhaust gas, and integrates each subsystem through working medium water, reducing the mechanical water pumps in the original subsystems, reducing the number and weight of system components, and reducing the energy loss caused by the rotation of the mechanical water pumps. In addition, the present invention generates electricity based on waste heat from engine exhaust gas, reducing energy dissipation and storing more electrical energy for the vehicle; at the same time, the superheated steam generated by the exhaust gas can meet the preheating and heating of systems such as the occupant compartment and battery in low-temperature and cold weather, saving more energy; in addition, the liquid water after power generation is used to cool systems such as the occupant compartment and battery, realizing the recycling of the heating and cooling function working medium, and the heating and cooling working medium used is a pollution-free substance, reducing pollution to the external environment. Description of the Drawings

[0045] Figure 1 It is a schematic diagram of the prior art.

[0046] Figure 2 It is a schematic diagram of the technology of the present invention. Detailed Embodiments

[0047] To make the objectives, content, and advantages of the present invention clearer, the following further describes in detail the specific embodiments of the present invention with reference to the drawings and embodiments.

[0048] To solve the above technical problems, the present invention provides a power generation and heat management system for a hybrid vehicle using waste heat from engine exhaust gas. The power generation and heat management system has made innovative changes on the basis of the original integrated heat management system of the hybrid vehicle, reducing the electric heating system and typical compression refrigeration system in the occupant compartment, reducing the mechanical water pump structure in the battery system, and reducing the mechanical water pumps, condensers, etc. in the motor system; adding an engine exhaust gas heat exchanger, a turbine power generation device, and a steam injection device, and using a four-way steering valve to achieve the heat management function of the same working medium in different states for the occupant compartment, battery system, and motor system. The schematic diagram of the integrated heat management system of the hybrid vehicle of the present invention is as Figure 2 shown.

[0049] The power generation and thermal management system includes: a fan device (201) for engine air cooling, an engine radiator (202), a thermostat (203) for the engine system, a water tank (204), a passenger compartment heat exchanger (205), a four-way steering valve (206) for the passenger compartment, a water pump (207) for the exhaust gas heat exchanger, a transmission oil cooler (208), an engine water pump (209), an engine (210), engine oil cooling for the lubrication system (211), an engine exhaust gas heat exchanger (212), the external environment (213), a steam injector (214), a control valve (215) for the passenger compartment, a control valve (216) for the battery system, a control valve (217) for the motor system, a steam turbine (218), a generator (219), a 220 power system, a condenser (221), a four-way steering valve (222) for the motor system, a motor system (223), a four-way steering valve (224) for the battery system, and a battery system (225);

[0050] In the thermal management system corresponding to the engine (210), the liquid water in the water tank (204) flows through the thermostat (203) for the engine system and the engine water pump (209) under the action of the engine water pump (209). After flowing through the engine water pump (209), the liquid water is divided into two branches. One branch cools the engine (210) and then flows into the engine radiator (202), where it exchanges heat with the air in the external environment (213) through the fan device (201) for engine air cooling, and most of the heat is dissipated into the external environment (213);

[0051] The other branch flows into the engine oil cooling for the lubrication system (211). After cooling the engine oil in the lubrication system, it returns to the flow path of the engine water pump (209) between the thermostat (203) for the engine system;

[0052] In the thermal management system corresponding to the engine (210), an engine exhaust gas heat exchanger (212) is provided at the middle section of the engine exhaust gas pipeline. The exhaust gas flowing through the engine exhaust gas heat exchanger (212) exchanges heat with the liquid water led out from the water tank (204).

[0053] Among them, the engine exhaust gas heat exchanger (212) is made of high-quality stainless steel materials with high temperature resistance and corrosion resistance, and a turbulator fin structure is designed in both the tube side and the shell side to increase the turbulence degree of the exhaust gas in the engine exhaust gas heat exchanger (212) and enhance the heat exchange effect.

[0054] Among them, after the liquid water absorbs the heat carried by the exhaust gas in the engine exhaust gas heat exchanger (212), it becomes superheated steam, and the cooled exhaust gas is dissipated into the external environment;

[0055] The superheated steam enters the steam ejector (214). The front end of the structure of the steam ejector (214) is a converging-diverging structure, which is conducive to increasing the speed of the superheated steam entering the steam ejector (214). The outlet of the converging-diverging structure is connected to a straight pipe with a smaller diameter size, aiming to reduce the speed loss of the superheated steam;

[0056] The superheated steam flowing through the steam ejector (214) is divided into four branches, namely the occupant compartment thermal management system, the battery thermal management system, the motor thermal management system, and the power generation system. Control valves are provided in the occupant compartment thermal management system, the battery thermal management system, and the motor thermal management system among the four branches, which are the control valve for the occupant compartment (215), the control valve for the battery system (216), and the control valve for the motor system (217);

[0057] A precise water level sensor is provided in the water tank (204). The water level sensor accurately monitors the water level in the water tank in real time. When the water level is lower than the preset minimum value, an alarm signal is immediately sent to the vehicle control system to remind the driver or the control system to perform the water replenishment operation in time;

[0058] In addition, the outlet of the engine exhaust gas heat exchanger (212) is closely connected to the steam generator. Its function is to reliably convert the heated water into steam; it is internally equipped with high-precision pressure sensors and temperature sensors to accurately monitor the pressure and temperature status of the steam in real time to ensure that the steam parameters meet the system requirements; at the same time, to ensure system safety, a reliable safety valve is also provided. When the pressure in the system exceeds the set safety pressure, the safety valve will automatically open quickly in time to release the excess steam, effectively preventing potential safety accidents caused by excessive pressure in the system.

[0059] Among them, most of the superheated steam flowing through the steam ejector (214) is used for the power generation system. The specific process is as follows: The superheated steam flows through the steam turbine (218). The energy of the exhaust gas drives the steam turbine (218) to rotate at a high speed, converting thermal energy into the mechanical energy of the steam turbine (218). The steam turbine (218) is connected to the rotor of the generator (219) through a sturdy shaft, efficiently converting mechanical energy into electrical energy to drive the rotation of the generator (219), converting mechanical energy into electrical energy. The electrical energy generated by the generator (219) is transmitted to the power system (220) for powering on-board equipment and charging the battery. The steam flowing through the steam turbine (218) exchanges heat with the condenser (221) and becomes subcooled water and then flows back to the water tank (204);

[0060] The power generation system includes a rectifier, an intelligent inverter, and a battery;

[0061] The alternating current generated by the generator (219) is accurately converted into direct current by a rectifier, providing a stable DC power supply for subsequent power storage and use; an inverter is used to flexibly convert the direct current into appropriate alternating current according to the needs of vehicle electrical equipment, ensuring the effective supply and use of power; a battery is used to store the excess electrical energy generated by the power generation device and can supply power to various electrical equipment of the vehicle in a timely manner when needed, playing a role in energy buffering and regulation.

[0062] Among them, when the occupant compartment thermal management system needs to be heated in cold weather, the superheated steam enters the occupant compartment through the control valve (215) used for the occupant compartment and the four-way steering valve (206) for the occupant compartment, and exchanges heat with the occupant compartment heat exchanger (205) in the occupant compartment. The steam end of the occupant compartment heat exchanger (205) adopts a converging-diverging structure, increasing the contact area with the indoor air and slowing down the steam velocity at the same time, raising the air temperature in the occupant compartment and realizing the heating function of the occupant compartment.

[0063] When the temperature in the occupant compartment is relatively high in hot weather and the occupant compartment thermal management system needs to be cooled, the control valve (215) used for the occupant compartment is closed, and the subcooled water flowing through the condenser (221) flows into the occupant compartment through the four-way steering valve (206) for the occupant compartment and exchanges heat with the occupant compartment heat exchanger (205), reducing the air temperature in the occupant compartment and realizing the cooling function of the occupant compartment.

[0064] A plurality of high-precision temperature sensors are arranged in the occupant compartment thermal management system to accurately monitor the temperature changes at different positions in real time and feed the temperature signals back to the vehicle control system; the vehicle control system intelligently adjusts the steam flow rate and pressure of the steam injector (214) and the working state of the condenser (221) according to these feedback signals, so as to keep the temperature of the occupant compartment within the set comfortable range.

[0065] Among them, when the loss of the battery system (225) is relatively large in cold weather and the battery system (225) needs to be heated, the superheated steam flowing through the steam injector (214) enters the battery system (225) through the control valve (216) used for the battery system and the four-way steering valve (224) for the battery system, and exchanges heat with the heat pipes in the battery module to ensure that the battery temperature is within the appropriate operating temperature range, thereby improving the charging and discharging efficiency and performance of the battery.

[0066] When the battery temperature is too high and needs to be cooled, the control valve (216) used for the battery system is closed, and the subcooled water flowing through the condenser (221) flows into the battery system (225) through the four-way steering valve (224) for the battery system and exchanges heat with the heat pipes in the battery to absorb the heat of the battery and quickly reduce the battery temperature to the safe range.

[0067] A temperature sensor is provided inside the battery system (225) to monitor the temperature inside the battery system (225) in real time and transmit the data to the vehicle control system. The control system precisely adjusts the flow rate and temperature of the steam and cooling water according to the real-time change of the battery temperature, realizes precise control of the battery temperature, and effectively extends the service life and reliability of the battery.

[0068] Among them, before the motor starts or when operating in a low-temperature and cold environment, at this time the motor temperature is relatively low, and the motor system (223) needs to be heated;

[0069] The superheated steam flowing through the steam injector (214) enters the motor system (223) through the control valve (217) used by the motor system and the four-way steering valve (222) of the motor system. The heat of the superheated steam is transferred to the motor through the heat exchanger inside the motor system (223) to preheat the motor and improve the working efficiency and reliability of the motor;

[0070] When the temperature of the motor system (223) rises above the set threshold during operation, the control valve (217) used by the motor system is closed, and the subcooled water flowing through the condenser (221) enters the motor system (223) and exchanges heat with the heat exchanger inside the motor system (223) to absorb the heat of the motor system (223) to ensure that the motor temperature is always within the normal working range;

[0071] At the same time, a temperature sensor is equipped inside the motor system (223) to monitor the temperature of the motor system (223) in real time and feedback the temperature information to the vehicle control system. The control system flexibly adjusts the supply amount of superheated steam and subcooled water according to the actual temperature of the motor system (223) to realize precise management of the temperature of the motor system (223) and ensure the stable operation and performance of the motor system (223).

[0072] Among them, the hybrid vehicle power generation and thermal management system proposes corresponding control strategies according to different vehicle states;

[0073] During the startup phase of the vehicle, the thermal management system, the power generation device, and the condenser control system simultaneously start the initialization program. First, the vehicle control system quickly detects the operating state and exhaust gas temperature of the engine (210). When the exhaust gas temperature reaches the preset startup threshold, the water pump is started to stably supply water to the engine exhaust gas heat exchanger (212) to start the heating process. At the same time, the temperatures of the battery system (225), the motor system (223), and the various state parameters of the generator (219) are comprehensively monitored. If the temperature of the battery system (225) or the motor system (223) is too low and the conditions in the steam generator are met, the vehicle control system intelligently activates the corresponding steam heating circuit to preheat the battery system (225) and the motor system (223) to ensure that they can quickly reach the optimal operating temperature range after startup. For the power generation device, after checking that all components are normal, the regulating valve of the steam turbine (218) is gradually and finely adjusted according to the exhaust gas temperature and pressure, so that the steam turbine (218) generator starts smoothly with a low power to avoid excessive impact on the system during startup.

[0074] Among them, when the engine (210) is in a high-load operating state and the exhaust gas temperature is high, the control system will increase the water flow rate and steam output to provide sufficient heating heat for the passenger compartment. At the same time, according to the real-time temperature requirements of the battery system (225) and the motor system (223), precise heating or cooling regulation is carried out.

[0075] If the battery charge in the battery system (225) is low and the temperature is suitable for charging, the system will preferentially use the exhaust gas waste heat for battery heating to improve the battery charging efficiency. If the temperature of the motor in the motor system (223) rises, the vehicle control system appropriately adjusts the supply of subcooled water to effectively dissipate heat for it.

[0076] Among them, according to the feedback information of multiple temperature sensors in the passenger compartment, the steam and subcooled water volumes are precisely adjusted in real time to ensure that the temperature of the passenger compartment always remains within a comfortable range. In cold weather, the vehicle control system increases the steam heating volume in advance to ensure that the passenger compartment quickly warms up and remains warm. In hot weather, the vehicle control system strengthens ventilation and heat dissipation, and at the same time increases the subcooled water volume in the condenser (221) as needed to moderately cool the passenger compartment to keep the interior cool and comfortable.

[0077] In summary, the present invention proposes a comprehensive thermal management system based on waste heat power generation and waste heat reuse from engine exhaust. Since the temperature of the engine exhaust is relatively high and it carries a large amount of heat, the present invention adds an exhaust gas heat exchanger at the middle section of the engine exhaust pipeline. The exhaust gas heat exchanger adopts a shell-and-tube structure design, with the exhaust gas flowing inside the tube and the liquid water in the shell side being heated into superheated steam; the superheated steam after heating enters the steam ejector. In the present invention, the steam enters the steam ejector from the expansion section and is ejected at the small cross-section. Such a design is beneficial to improving the ejection speed of the steam; the steam accelerated by the ejector is divided into four branches, namely the passenger compartment branch, the battery system branch, the motor system branch, and the power generation system branch. Control valves are provided in the passenger compartment branch, the battery system branch, and the motor system branch, and the corresponding amount of superheated steam can be supplied according to the temperature requirements of the branches. The superheated steam flowing through the power generation system is expanded by the turbine and its temperature decreases, converting thermal energy into mechanical energy. The mechanical energy drives the generator to rotate to generate electrical energy for the power generation system. The steam after expansion enters the condenser and becomes liquid subcooled water. The subcooled water flowing out of the condenser is respectively connected to the passenger compartment branch, the battery system branch, and the motor system branch through a four-way diversion valve. When the passenger compartment, the battery system, and the motor system need to provide heat, an appropriate amount of superheated steam flows into the passenger compartment, the battery system, and the motor system through the four-way diversion valve; when the temperatures of the passenger compartment, the battery system, and the motor system are relatively high and cooling is required, the liquid water flowing through the condenser flows into the passenger compartment, the battery system, and the motor system through the four-way diversion valve, thus realizing the comprehensive utilization of the waste heat in the engine exhaust of the hybrid vehicle, reducing the use of relevant mechanical pumps, and solving the problems of insufficient power and energy conservation of the vehicle in cold weather.

[0078] The above is only the preferred embodiment of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the technical principle of the present invention, several improvements and deformations can still be made, and these improvements and deformations should also be regarded as the protection scope of the present invention.

Claims

1. A hybrid vehicle power generation and thermal management system using engine exhaust waste heat, characterized in that The power generation and thermal management system includes: a fan device (201) for engine air cooling, an engine radiator (202), a thermostat (203) for the engine system, a water tank (204), a passenger compartment heat exchanger (205), a four-way steering valve (206) for the passenger compartment, an engine water pump (209), an engine (210), engine oil cooling for the lubrication system (211), an engine exhaust gas heat exchanger (212), the external environment (213), a steam injector (214), a control valve (215) for the passenger compartment, a control valve (216) for the battery system, a control valve (217) for the motor system, a steam turbine (218), a generator (219), a power system 220, a condenser (221), a four-way steering valve (222) for the motor system, a motor system (223), a four-way steering valve (224) for the battery system, and a battery system (225); In the thermal management system corresponding to the engine (210), the liquid water in the water tank (204) flows through the thermostat (203) for the engine system and the engine water pump (209) under the action of the engine water pump (209). After flowing through the engine water pump (209), the liquid water is divided into two branches. One branch cools the engine (210) and then flows into the engine radiator (202), where it exchanges heat with the air in the external environment (213) through the fan device (201) for engine air cooling, and most of the heat is dissipated into the external environment (213); The other branch flows into the engine oil cooling (211) for the lubrication system. After cooling the engine oil in the lubrication system, it returns to the flow path of the engine water pump (209) between the thermostat (203) for the engine system; In the thermal management system corresponding to the engine (210), an engine exhaust gas heat exchanger (212) is provided at the middle section of the engine exhaust gas pipeline. The exhaust gas flowing through the engine exhaust gas heat exchanger (212) exchanges heat with the liquid water led out from the water tank (204).

2. The hybrid vehicle power generation and thermal management system using engine exhaust waste heat according to claim 1, characterized in that, The engine exhaust gas heat exchanger (212) is made of high-quality stainless steel material with high temperature resistance and corrosion resistance, and a turbulator fin structure is designed in both the tube side and the shell side to increase the turbulence degree of the exhaust gas in the engine exhaust gas heat exchanger (212) and enhance the heat exchange effect.

3. The hybrid vehicle power generation and thermal management system using the waste heat of the engine exhaust gas according to claim 1, characterized in that, After the liquid water absorbs the heat carried by the exhaust gas in the engine exhaust gas heat exchanger (212), it becomes superheated steam, and the cooled exhaust gas is dissipated into the external environment; The superheated steam enters the steam injector (214). The front end of the structure of the steam injector (214) is a converging-diverging structure, which is beneficial to increasing the speed of the superheated steam entering the steam injector (214). The outlet of the converging-diverging structure is connected to a straight pipe with a smaller diameter size, aiming to reduce the speed loss of the superheated steam; The superheated steam flowing through the steam ejector (214) is divided into four branches, namely the occupant compartment thermal management system, the battery thermal management system, the motor thermal management system, and the power generation system. Control valves are provided in the occupant compartment thermal management system, the battery thermal management system, and the motor thermal management system among the four branches, which are the control valve for the occupant compartment (215), the control valve for the battery system (216), and the control valve for the motor system (217) respectively; A water level sensor is provided in the water tank (204). The water level sensor accurately monitors the water level in the water tank in real time. When the water level is lower than the preset minimum value, an alarm signal is immediately sent to the vehicle control system to remind the driver or the control system to perform the water replenishment operation in time; In addition, the outlet of the engine exhaust gas heat exchanger (212) is closely connected to the steam generator. Its function is to reliably convert the heated water into steam; a pressure sensor and a temperature sensor are equipped inside to accurately monitor the pressure and temperature status of the steam in real time to ensure that the steam parameters meet the system requirements; at the same time, in order to ensure system safety, a safety valve is also provided. When the pressure in the system exceeds the set safety pressure, the safety valve will automatically open quickly in time to release the excess steam, effectively preventing potential safety accidents caused by too high pressure in the system.

4. The hybrid vehicle power generation and thermal management system using engine exhaust waste heat according to claim 3, wherein Most of the superheated steam flowing through the steam ejector (214) is used for the power generation system. The specific process is as follows: The superheated steam flows through the steam turbine (218). The energy of the exhaust gas drives the steam turbine (218) to rotate at high speed, converting thermal energy into the mechanical energy of the steam turbine (218). The steam turbine (218) is connected to the rotor of the generator (219) through a shaft, efficiently converting mechanical energy into electrical energy to drive the rotation of the generator (219), converting mechanical energy into electrical energy. The electrical energy generated by the generator (219) is transmitted to the power system (220) for powering on-board equipment and charging the battery. The steam flowing through the steam turbine (218) exchanges heat with the condenser (221) and becomes subcooled water and then flows back to the water tank (204); The power generation system includes a rectifier, an intelligent inverter, and a battery; The alternating current generated by the generator (219) is accurately converted into direct current by the rectifier to provide a stable DC power source for subsequent power storage and use; the inverter is used to flexibly convert the direct current into appropriate alternating current according to the requirements of vehicle electrical equipment to ensure the effective supply and use of electricity; the battery is used to store the excess electrical energy generated by the power generation device and can supply power to various electrical equipment of the vehicle in time when needed, playing a role in energy buffering and regulation.

5. The hybrid vehicle power generation and thermal management system utilizing engine exhaust waste heat according to claim 4, wherein, When the occupant compartment thermal management system needs to be heated in cold weather, the superheated steam enters the occupant compartment through the control valve for the occupant compartment (215) and the occupant compartment four-way steering valve (206), and exchanges heat with the occupant compartment heat exchanger (205) in the occupant compartment. The steam end of the occupant compartment heat exchanger (205) adopts a convergent-divergent structure, which can increase the contact area with the indoor air and slow down the steam speed at the same time, raising the air temperature in the occupant compartment and realizing the heating function of the occupant compartment; When the temperature in the passenger compartment is relatively high in a hot weather environment, refrigeration of the passenger compartment thermal management system is required. Then, the control valve (215) used for the passenger compartment is closed, and the subcooled water flowing through the condenser (221) flows into the passenger compartment through the passenger compartment four-way steering valve (206), and exchanges heat with the passenger compartment heat exchanger (205) to reduce the air temperature in the passenger compartment, realizing the refrigeration function of the passenger compartment; A plurality of high-precision temperature sensors are arranged in the passenger compartment thermal management system to accurately monitor the temperature changes at different positions in real time and feed the temperature signals back to the vehicle control system; the vehicle control system intelligently adjusts the steam flow rate and pressure of the steam ejector (214) and the working state of the condenser (221) according to these feedback signals, so as to keep the temperature in the passenger compartment within the set comfortable range.

6. The hybrid vehicle power generation and thermal management system using the waste heat of the engine exhaust gas according to claim 5, characterized in that, When it is cold, the loss of the battery system (225) is relatively large, and heating of the battery system (225) is required. The superheated steam flowing through the steam ejector (214) enters the battery system (225) through the control valve (216) used for the battery system and the battery system four-way steering valve (224), and exchanges heat with the heat pipes in the battery module to ensure that the battery temperature is within the appropriate operating temperature range, thereby improving the charge and discharge efficiency and performance of the battery; When the battery temperature is too high and cooling is required, the control valve (216) used for the battery system is closed, and the subcooled water flowing through the condenser (221) flows into the battery system (225) through the battery system four-way steering valve (224), and exchanges heat with the heat pipes in the battery to absorb the heat of the battery and quickly reduce the battery temperature to the safe range; Temperature sensors are arranged in the battery system (225) to monitor the temperature in the battery system (225) in real time and transmit the data to the vehicle control system. The control system accurately adjusts the flow rate and temperature of steam and cooling water according to the real-time change of the battery temperature, realizes precise control of the battery temperature, and effectively extends the service life and reliability of the battery.

7. The hybrid vehicle power generation and thermal management system using the waste heat of the engine exhaust gas according to claim 6, characterized in that, Before the motor starts or when it operates in a low-temperature cold environment, the motor temperature is relatively low at this time, and heating of the motor system (223) is required; The superheated steam flowing through the steam ejector (214) enters the motor system (223) through the control valve (217) used for the motor system and the motor system four-way steering valve (222), and transfers the heat of the superheated steam to the motor through the heat exchanger in the motor system (223) to preheat the motor and improve the working efficiency and reliability of the motor; When the temperature of the motor system (223) rises above the set threshold during operation, the control valve (217) used for the motor system is closed, and the subcooled water flowing through the condenser (221) enters the motor system (223) and exchanges heat with the heat exchanger in the motor system (223) to absorb the heat of the motor system (223) to ensure that the motor temperature is always within the normal operating range; Meanwhile, a temperature sensor is equipped in the motor system (223) to monitor the temperature of the motor system (223) in real time and feed back the temperature information to the vehicle control system. The control system flexibly adjusts the supply amounts of superheated steam and subcooled water according to the actual temperature of the motor system (223), realizes precise management of the temperature of the motor system (223), and ensures the stable operation and performance of the motor system (223).

8. The hybrid vehicle power generation and thermal management system using engine exhaust waste heat according to claim 7, characterized in that, The hybrid vehicle power generation and thermal management system proposes corresponding control strategies according to different vehicle states; During the vehicle startup phase, the thermal management system, the power generation device, and the condenser control system start the initialization program simultaneously. First, the vehicle control system quickly detects the operating state and exhaust gas temperature of the engine (210). When the exhaust gas temperature reaches the preset startup threshold, the water pump is started to stably supply water to the engine exhaust gas heat exchanger (212) to start the heating process. At the same time, the temperatures of the battery system (225) and the motor system (223) and various state parameters of the generator (219) are comprehensively monitored. If the temperature of the battery system (225) or the motor system (223) is too low and the conditions in the steam generator are met, the vehicle control system intelligently activates the corresponding steam heating circuit to preheat the battery system (225) and the motor system (223) to ensure that they can quickly reach the optimal operating temperature range after startup. For the power generation device, after checking that all components are normal, the steam turbine (218) regulating valve is gradually and finely adjusted according to the exhaust gas temperature and pressure, so that the steam turbine (218) generator starts smoothly at a lower power, avoiding excessive impact on the system during startup.

9. The hybrid vehicle power generation and thermal management system using the waste heat of the engine exhaust gas according to claim 8, wherein, When the engine (210) is in a high-load operating state and the exhaust gas temperature is high, the control system will increase the water flow rate and steam output to provide sufficient heating heat for the passenger compartment. At the same time, according to the real-time temperature requirements of the battery system (225) and the motor system (223), precise heating or cooling adjustments are made; If the battery power in the battery system (225) is low and the temperature is suitable for charging, the system will preferentially use the exhaust gas waste heat for battery heating to improve the battery charging efficiency. If the motor temperature of the motor system (223) rises, the vehicle control system appropriately adjusts the supply of subcooled water for effective heat dissipation.

10. The hybrid vehicle power generation and thermal management system using engine exhaust waste heat according to claim 9, wherein According to the feedback information of multiple temperature sensors in the passenger compartment, the steam and subcooled water amounts are precisely adjusted in real time to ensure that the temperature of the passenger compartment always remains within a comfortable range. In cold weather, the vehicle control system increases the steam heating amount in advance to ensure that the passenger compartment warms up quickly and remains warm. In hot weather, the vehicle control system strengthens ventilation and heat dissipation, and at the same time increases the subcooled water amount in the condenser (221) as needed to moderately cool the passenger compartment and keep the interior cool and comfortable.

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