Electric loader heat management system and waste heat recovery control method

Abstract

The invention discloses an electric loader heat management system and a waste heat recovery control method, and belongs to the technical field of waste heat recovery. Comprising a motor water loop system, a hydraulic oil loop system, a battery water loop system, a water cooling loop system, a cab refrigerating loop and a temperature sensor group, through the multi-loop coupling design, repeated configuration of the radiator, the pump body and other components is reduced, the equipment repeatability and weight are reduced, and the problem of component redundancy of a traditional independent heat dissipation system is solved; the three-way valve is switched to be connected with the heat exchanger, waste heat of the motor and the hydraulic system is converted into an effective heat source for heating a power battery, dependence of battery heating in winter on a PTC heater is remarkably reduced, and the overall energy consumption of the system is reduced. Parameters of all loops are monitored in real time through the temperature sensor set, precise control over the opening degree of the three-way valve, the water pump rotating speed and the draught fan air speed is achieved, it is ensured that a motor, hydraulic pressure, a battery and other systems operate in the optimal temperature interval, and the energy utilization efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of waste heat recovery for electric loaders, and in particular to a thermal management system and a waste heat recovery control method for electric loaders. Background Art

[0002] As an environmentally friendly and efficient engineering machinery, electric loaders are increasingly used in mining, construction, logistics and other fields due to their low emissions, low noise, high energy utilization and convenient operation performance, becoming an important force in promoting the green and sustainable development of the engineering machinery industry.

[0003] The stable operation of electric loaders is highly dependent on temperature control of various core systems. Key components such as the power battery pack, electric drive system, electronic control system, hydraulic system, and cab environment must all operate within an appropriate temperature range. Specifically, the power battery pack must be maintained within a certain temperature range to ensure charge and discharge efficiency and cycle life, requiring cooling in summer and heating in winter. The electric drive and electronic control systems generate a large amount of heat when running at high speeds. If heat is not dissipated in time, it will lead to performance degradation or even damage. The hydraulic oil in the hydraulic system heats up during operation due to factors such as friction, and needs to be cooled to maintain its viscosity and working performance. The cab needs to be adjusted according to the ambient temperature to ensure the comfort of the operator.

[0004] At present, the thermal management of electric loaders mostly adopts a decentralized design: the cooling of the power battery pack and the cooling of the cab are achieved through independent refrigeration systems respectively, the cooling of the hydraulic oil and the heat dissipation of the electric drive system and the electronic control system also use independent cooling circuits, and the heating of the power battery pack in winter mainly relies on active heating devices such as PTC heaters or electric heating films.

[0005] However, the distributed thermal management system in the existing technology still has certain shortcomings: each subsystem is independently equipped with radiators, fans, pump bodies and other components, resulting in a complex structure and a large number of parts for the vehicle thermal management system, which not only increases the manufacturing cost, but also takes up a large amount of assembly space for the whole machine, which is not conducive to the compact design of the electric loader; the motor of the electric drive system and the hydraulic oil of the hydraulic system will generate a large amount of waste heat during operation. This waste heat is usually discharged directly into the environment through the radiator and is not effectively utilized; at the same time, in winter, the heating of the power battery pack relies entirely on energy-consuming devices such as PTC heaters, resulting in increased battery energy consumption, which may affect the cruising range and continuous working time of the electric loader. Summary of the Invention

[0006] The purpose of the present invention is to solve the problems raised in the above background technology and to propose a thermal management system and a waste heat recovery control method for an electric loader.

[0007] In order to achieve the above object, the present invention adopts the following technical solutions:

[0008] A thermal management system for an electric loader includes: a motor water circuit system, a hydraulic oil circuit system, a battery water circuit system, a water cooling circuit system, a cab cooling circuit, and a temperature sensor group; the motor water circuit system and the hydraulic oil circuit system are both connected to the battery water circuit system;

[0009] The motor water circuit system includes a six-in-one combined motor controller, a drive motor, a working motor, a first expansion kettle, a motor water radiator, a three-way valve on the motor water radiator side, a first three-way valve, a motor water pump, and a motor waste heat recovery heat exchanger connected in sequence;

[0010] The hydraulic oil circuit system includes a hydraulic working motor pump, a hydraulic working device, a hydraulic oil flow control tee, a hydraulic oil radiator, a hydraulic oil radiator side tee valve, a hydraulic oil waste heat recovery heat exchanger, a second tee, a third tee, and a hydraulic oil tank in sequence;

[0011] The battery water circuit system includes, in sequence, a battery water pump, a second expansion kettle, a PTC heater, a power battery pack, a three-way valve on the motor waste heat recovery heat exchanger side, a fourth three-way valve, a three-way valve on the hydraulic oil waste heat recovery heat exchanger side, and a fifth three-way valve;

[0012] The water cooling circuit system includes a compressor, a condenser, an expansion valve, and a battery pack cooling heat exchanger in sequence;

[0013] The cab refrigeration circuit includes a compressor, a condenser, an expansion valve, an evaporator, and a blower in sequence.

[0014] Preferably, the temperature sensor group includes a first temperature sensor, a second temperature sensor, a third temperature sensor, a fourth temperature sensor, a fifth temperature sensor, a sixth temperature sensor, a seventh temperature sensor, an eighth temperature sensor, and a ninth temperature sensor.

[0015] A waste heat recovery control method for thermal management of an electric loader includes the following control steps:

[0016] The first temperature sensor is used to monitor the water inlet temperature of the six-in-one combination motor controller in real time. When the water inlet temperature is higher than the first preset temperature of the motor, the six-in-one combination motor controller controls the three-way valve on the motor water radiator side to open, and at the same time controls the opening of the three-way valve on the motor water radiator side and the speed of the fan according to the outlet temperature monitored in real time by the eighth temperature sensor and the second temperature sensor, so that the water inlet temperature monitored in real time by the first temperature sensor is higher than the second preset temperature of the motor and lower than the first preset temperature of the motor; when the temperature is lower than the second preset temperature of the motor, the six-in-one combination motor controller controls the three-way valve on the motor water radiator side to close, and at the same time controls the speed of the fan to make the water inlet temperature between the second preset temperature of the motor and the first preset temperature of the motor; the third temperature sensor is used to monitor the water outlet temperature on the battery side of the motor waste heat recovery heat exchanger in real time. When the water outlet temperature is lower than the third preset temperature of the battery, the six-in-one combination motor controller controls the three-way valve on the motor water radiator side to close;

[0017] A first temperature sensor is used to monitor the water inlet temperature of the six-in-one combination motor controller in real time. When the water inlet temperature is lower than the second preset temperature of the motor, the six-in-one combination motor controller controls the three-way valve on the motor waste heat recovery heat exchanger side to close; a fourth temperature sensor is used to monitor the water outlet temperature of the fourth three-way valve in real time. When the water outlet temperature is higher than the fifth preset temperature of the battery, the six-in-one combination motor controller controls the three-way valve on the motor waste heat recovery heat exchanger side to close; when the temperature is lower than the fourth preset temperature of the battery, the three-way valve is controlled to open; a third temperature sensor is used to monitor the water outlet temperature of the battery side of the motor waste heat recovery heat exchanger in real time. When the water outlet temperature is lower than the third preset temperature of the battery, the six-in-one combination motor controller controls the three-way valve on the motor waste heat recovery heat exchanger side to close;

[0018] The ninth temperature sensor is used to monitor the hydraulic oil temperature at the oil inlet of the hydraulic oil tank in real time. When the hydraulic oil temperature there is higher than the first preset temperature of the hydraulic oil, the six-in-one combined motor controller controls the three-way valve on the hydraulic oil radiator side to open, and at the same time controls the opening of the three-way valve on the hydraulic oil radiator side, the hydraulic oil flow control three-way and the speed of the fan according to the outlet temperature monitored in real time by the eighth temperature sensor and the second temperature sensor, so that the hydraulic oil temperature is between the second preset temperature of the hydraulic oil and the first preset temperature of the hydraulic oil; when the temperature is lower than the second preset temperature of the hydraulic oil, the six-in-one combined motor controller controls the three-way valve on the hydraulic oil radiator side to close, and at the same time controls the speed of the fan, so that the hydraulic oil temperature is in the above range; the fourth temperature sensor is used to monitor the outlet water temperature of the fourth three-way in real time. When the outlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combined motor controller controls the three-way valve on the hydraulic oil radiator side to close; the fifth temperature sensor is used to monitor the outlet water temperature on the battery side of the hydraulic oil waste heat recovery heat exchanger in real time. When the outlet water temperature is lower than the third preset temperature of the battery, the six-in-one combined motor controller controls the three-way valve on the hydraulic oil radiator side to close;

[0019] The ninth temperature sensor is used to monitor the hydraulic oil temperature at the oil inlet of the hydraulic oil tank in real time. When the hydraulic oil temperature there is lower than the second preset temperature of the hydraulic oil, the six-in-one combination motor controller controls the three-way valve on the hydraulic oil waste heat recovery heat exchanger side to close; the fourth temperature sensor is used to monitor the outlet water temperature of the fourth three-way valve in real time. When the outlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combination motor controller controls the three-way valve on the hydraulic oil waste heat recovery heat exchanger side to close; the temperature sensor is used to monitor the inlet water temperature of the battery water pump in real time. When the inlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combination motor controller controls the three-way valve on the hydraulic oil waste heat recovery heat exchanger side to close, and when the temperature is lower than the fourth preset temperature of the battery, the three-way valve is controlled to open; the fifth temperature sensor is used to monitor the outlet water temperature of the battery side of the hydraulic oil waste heat recovery heat exchanger in real time. When the outlet water temperature is lower than the third preset temperature of the battery, the six-in-one combination motor controller controls the three-way valve on the hydraulic oil waste heat recovery heat exchanger side to close;

[0020] When the three-way valve on the motor waste heat recovery heat exchanger side and the three-way valve on the hydraulic oil waste heat recovery heat exchanger side are both in the closed state, the seventh temperature sensor is used to monitor the water inlet temperature of the power battery pack in real time. When the water inlet temperature is higher than the third preset temperature of the battery, the six-in-one combination motor controller controls the heating power of the PTC heater to be the fifth preset power. When the temperature is lower than the first preset temperature of the battery, the heating power is controlled to be the fourth preset power. The sixth temperature sensor is used to monitor the water inlet temperature of the power battery pack in real time. When the water inlet temperature is higher than the fourth preset temperature of the battery and lower than the fifth preset temperature of the battery, the heating power is controlled to be the first preset power. When the temperature is higher than the third preset temperature of the battery and lower than the fourth preset temperature of the battery, the heating power is controlled to be the second preset power. When the temperature is higher than the second preset temperature of the battery and lower than the third preset temperature of the battery, the heating power is controlled to be the third preset power. When the temperature is higher than the first preset temperature of the battery and lower than the second preset temperature of the battery, the heating power is controlled to be the fifth preset power. When the temperature is lower than the first preset temperature of the battery, the heating power is controlled to be the fourth preset power. When the water inlet temperature is higher than the fifth preset temperature of the battery, the PTC heater is controlled to stop heating.

[0021] The fan speed requirements of the motor water circuit system, hydraulic oil circuit system, battery water circuit system, chilled water circuit system, and cab refrigeration circuit are fed back to the six-in-one combination motor controller. After comparison, the six-in-one combination motor controller selects the maximum wind speed as the output wind speed to control the fan speed.

[0022] Preferably, the first preset temperature of the motor is 65°C, and the second preset temperature of the motor is 25°C.

[0023] Furthermore, the first preset temperature of the hydraulic oil is 75°C, and the second preset temperature of the hydraulic oil is 25°C.

[0024] Furthermore, the first preset power is 25% of the full power, the second preset power is 50% of the full power, the third preset power is 75% of the full power, the fourth preset power is full power, and the fifth preset power is 60% of the full power.

[0025] Compared with the prior art, the present invention provides a thermal management system and waste heat recovery control method for an electric loader, which has the following beneficial effects:

[0026] 1. The present invention uses a multi-circuit coupling design to reduce the duplication of components such as radiators and pump bodies, reduce equipment duplication and weight, and solve the component redundancy problem of traditional independent cooling systems. By switching the three-way valve to connect with the heat exchanger, the waste heat of the motor and hydraulic system is converted into an effective heat source for heating the power battery, significantly reducing the dependence of battery heating on PTC heaters in winter and reducing the overall energy consumption of the system.

[0027] 2. The present invention monitors the parameters of each circuit in real time through a temperature sensor group to achieve precise coordinated control of the three-way valve opening, water pump speed, and fan speed, ensuring that the motor, hydraulic, battery and other systems operate in the optimal temperature range, improving energy utilization efficiency and reducing ineffective power consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a structural schematic diagram of a thermal management system for an electric loader proposed by the present invention.

[0029] In the figure: 101, six-in-one combined motor controller; 102, drive motor; 103, working motor; 104, first expansion kettle; 105, three-way valve on the motor water radiator side; 106, fan; 107, motor water radiator; 108, first three-way valve; 109, motor water pump; 110, motor waste heat recovery heat exchanger; 201, hydraulic working motor pump; 202, hydraulic working device; 203, hydraulic oil flow control three-way valve; 204, hydraulic oil radiator side three-way valve; 205, hydraulic oil waste heat recovery heat exchanger; 206, second three-way valve; 207, third three-way valve; 208, hydraulic oil tank; 209, hydraulic oil radiator; 301, compressor; 302, condenser; 303, expansion valve; 304, battery pack cooling heat exchanger; 30 5. Evaporator; 306. Blower; 401. Battery water pump; 402. Second expansion kettle; 403. PTC heater; 404. Power battery pack; 405. Three-way valve on the motor waste heat recovery heat exchanger side; 406. Fourth three-way valve; 407. Three-way valve on the hydraulic oil waste heat recovery heat exchanger side; 408. Fifth three-way valve; 501. First temperature sensor; 502. Second temperature sensor; 503. Tenth temperature sensor; 504. Eleventh temperature sensor; 505. Third temperature sensor; 506. Fourth temperature sensor; 507. Fifth temperature sensor; 508. Sixth temperature sensor; 509. Seventh temperature sensor; 510. Eighth temperature sensor; 511. Ninth temperature sensor; 512. Twelfth temperature sensor. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0031] Example:

[0032] Reference Figure 1 , a thermal management system for an electric loader, including a motor water circuit system, a hydraulic oil circuit system, a battery water circuit system, a water cooling circuit system, a cab cooling circuit and a temperature sensor group; the motor water circuit system and the hydraulic oil circuit system are both connected to the battery water circuit system;

[0033] The motor water circuit system sequentially includes a six-in-one combined motor controller 101, a drive motor 102, a working motor 103, a first expansion kettle 104, a motor water radiator 107, a three-way valve 105 on the motor water radiator side, a first three-way valve 108, a motor water pump 109, and a motor waste heat recovery heat exchanger 110;

[0034] In the motor water circuit system, the water outlet of the six-in-one combination motor controller 101 is connected to the water inlet of the drive motor 102, the water outlet of the drive motor 102 is connected to the water inlet of the working motor 103, the water outlet of the working motor 103 is connected to the water inlet of the first expansion kettle 104, and the water outlet of the first expansion kettle 104 is divided into two paths, one path is connected to the water inlet of the motor water radiator 107, and the other path is connected to the first interface of the first three-way valve 108 through the motor water radiator side three-way valve 105; the water outlet of the motor water radiator 107 is connected to the other interface of the motor water radiator side three-way valve 105, the second interface of the first three-way valve 108 is connected to the water inlet of the motor water pump 109, the water outlet of the motor water pump 109 is connected to the water inlet of the motor waste heat recovery heat exchanger 110, and the water outlet of the motor waste heat recovery heat exchanger 110 is connected to the water inlet of the six-in-one combination motor controller 101, forming a closed loop;

[0035] The hydraulic oil circuit system includes, in sequence, a hydraulic working motor pump 201, a hydraulic working device 202, a hydraulic oil flow control tee 203, a hydraulic oil radiator 209, a hydraulic oil radiator side tee valve 204, a hydraulic oil waste heat recovery heat exchanger 205, a second tee 206, a third tee 207, and a hydraulic oil tank 208;

[0036] In the hydraulic oil circuit system, the oil outlet of the hydraulic working motor pump 201 is connected to the oil inlet of the hydraulic working device 202, the oil outlet of the hydraulic working device 202 is connected to the first interface of the hydraulic oil flow control tee 203, the second interface of the hydraulic oil flow control tee 203 is connected to the water inlet of the hydraulic oil radiator 209, the third interface of the hydraulic oil flow control tee 203 is connected to the first interface of the hydraulic oil radiator side three-way valve 204; the water outlet of the hydraulic oil radiator 209 is connected to the hydraulic oil radiator side three-way valve 204. 04, the third interface of the three-way valve 204 on the hydraulic oil radiator side is connected to the oil inlet of the hydraulic oil waste heat recovery heat exchanger 205, the oil outlet of the hydraulic oil waste heat recovery heat exchanger 205 is connected to the first interface of the second three-way valve 206, the second interface of the second three-way valve 206 is connected to the first interface of the third three-way valve 207, the second interface of the third three-way valve 207 is connected to the oil return port of the hydraulic oil tank 208, and the oil outlet of the hydraulic oil tank 208 is connected to the oil inlet of the hydraulic working motor pump 201, forming a closed loop;

[0037] The battery water circuit system includes, in sequence, a battery water pump 401, a second expansion kettle 402, a PTC heater 403, a power battery pack 404, a three-way valve 405 on the motor waste heat recovery heat exchanger side, a fourth three-way valve 406, a three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side, and a fifth three-way valve 408;

[0038] In the battery water circuit system, the water outlet of the battery water pump 401 is connected to the water inlet of the second expansion kettle 402, the water outlet of the second expansion kettle 402 is connected to the water inlet of the PTC heater 403, the water outlet of the PTC heater 403 is connected to the water inlet of the power battery pack 404, the water outlet of the power battery pack 404 is connected to the first interface of the three-way valve 405 on the side of the motor waste heat recovery heat exchanger, the second interface of the three-way valve 405 on the side of the motor waste heat recovery heat exchanger is connected to the battery side water inlet of the motor waste heat recovery heat exchanger 110, the battery side water outlet of the motor waste heat recovery heat exchanger 110 is connected to the first interface of the fourth three-way valve 406; The third interface of the three-way valve 405 on the heat recovery side is connected to the second interface of the fourth three-way valve 406, the third interface of the fourth three-way valve 406 is connected to the first interface of the three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side, the second interface of the three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side is connected to the water inlet of the hydraulic oil waste heat recovery heat exchanger 205, and the water outlet of the hydraulic oil waste heat recovery heat exchanger 205 is connected to the first interface of the fifth three-way valve 408; the third interface of the three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side is connected to the second interface of the fifth three-way valve 408, and the third interface of the fifth three-way valve 408 is connected to the water inlet of the battery water pump 401, forming a closed loop;

[0039] The water cooling circuit system includes a compressor 301, a condenser 302, an expansion valve 303, and a battery pack cooling heat exchanger 304 in sequence;

[0040] In the water cooling circuit system, the exhaust port of the compressor 301 is connected to the air inlet of the condenser 302, the air outlet of the condenser 302 is connected to the inlet of the expansion valve 303, the outlet of the expansion valve 303 is connected to the inlet of the battery pack cooling heat exchanger 304, and the outlet of the battery pack cooling heat exchanger 304 is connected to the air intake of the compressor 301, forming a closed circuit.

[0041] The cab refrigeration circuit includes a compressor 301 , a condenser 302 , an expansion valve 303 , an evaporator 305 , and a blower 306 in sequence.

[0042] In the cab refrigeration circuit, the exhaust port of the compressor 301 is connected to the air inlet of the condenser 302, the air outlet of the condenser 302 is connected to the inlet of the expansion valve 303, the outlet of the expansion valve 303 is connected to the inlet of the evaporator 305, the outlet of the evaporator 305 is connected to the air intake of the compressor 301, and the blower 306 is set corresponding to the evaporator 305.

[0043] The condenser 302, the motor water radiator 107, the hydraulic oil radiator 209 and the fan 106 are assembled as one body, and the condenser of the cab cooling system and the condenser and compressor of the battery cooling system are shared, and the fans of the motor electronic control cooling system, the hydraulic oil cooling system, the cab cooling system and the battery cooling system are shared.

[0044] Loop coupling reduces the duplication of components such as radiators and pump bodies. Existing technologies do not achieve cross-system utilization of waste heat. This solution uses a three-way valve to switch and connect to a heat exchanger, converting the waste heat from the motor and hydraulic system into an effective heat source for battery heating. Conventional designs require separate cab cooling and battery cooling systems. This solution reduces equipment complexity by sharing refrigerant circuits. Distributed temperature control systems find it difficult to achieve comprehensive energy utilization. This solution improves overall energy efficiency through multi-circuit collaborative control.

[0045] The temperature sensor group includes a first temperature sensor 501 , a second temperature sensor 502 , a third temperature sensor 505 , a fourth temperature sensor 506 , a fifth temperature sensor 507 , a sixth temperature sensor 508 , a seventh temperature sensor 509 , an eighth temperature sensor 510 , and a ninth temperature sensor 511 .

[0046] The temperature sensor group further includes a tenth temperature sensor 503 , an eleventh temperature sensor 504 , and a twelfth temperature sensor 512 .

[0047] The first temperature sensor 501 is a temperature detection device located at the water inlet of the six-in-one combined motor controller 101. Specifically, it can be implemented as a thermistor or thermocouple. It is used to monitor the inlet water temperature of the motor water circuit system in real time, providing reference data for the opening and closing of the three-way valve 105 on the motor water radiator side. The second temperature sensor 502 is a temperature detection device located at the outlet of the motor water radiator 107. Specifically, it can be implemented as a platinum resistance temperature sensor. It is used to coordinate with the eighth temperature sensor 510 to monitor the outlet temperature of the motor water radiator 107 and provide feedback signals for adjusting the speed of the fan 106. The third temperature sensor 505 is a temperature detection device located at the battery-side outlet of the motor waste heat recovery heat exchanger 110. Specifically, it can be implemented as a digital temperature sensor. It is used to determine whether the waste heat recovery meets the battery heating requirements. The fourth temperature sensor 506 is a temperature detection device located at the outlet of the fourth three-way valve 406. Specifically, it can be implemented as an infrared temperature sensor. It is used to control the matching status of the hydraulic system waste heat recovery and battery heating. The fifth temperature sensor 507 refers to a temperature detection device provided at the water outlet on the battery side of the hydraulic oil waste heat recovery heat exchanger 205. Specifically, it can be implemented by an optical fiber temperature sensor and is used to monitor the heat status of the waste heat of the hydraulic system transferred to the battery circuit. The sixth temperature sensor 508 and the seventh temperature sensor 509 refer to temperature detection devices provided at the water inlet and water outlet of the power battery pack 404, respectively. Specifically, they can be implemented by a bimetallic temperature sensor and are used to construct the basic parameters for closed-loop control of the battery pack temperature. The eighth temperature sensor 510 refers to a temperature detection device provided at the outlet on the other side of the motor water radiator 107. Specifically, it can be implemented by a semiconductor temperature sensor and is used to form a cross-verification of the heat dissipation efficiency with the second temperature sensor 502. The ninth temperature sensor 511 refers to a temperature detection device provided at the oil inlet of the hydraulic oil tank 208. Specifically, it can be implemented by a pressure temperature sensor and is used to obtain the core temperature reference value of the hydraulic system.

[0048] Through the spatial distribution of multiple sensors, comprehensive perception of the temperature fields of the three major systems of motor, hydraulics and battery is achieved, solving problems such as errors in the judgment of waste heat recovery timing and delayed coordination of thermal management of multiple systems caused by insufficient monitoring nodes in existing technologies.

[0049] A waste heat recovery control method for thermal management of an electric loader includes the following control steps:

[0050] The first temperature sensor 501 is used to monitor the water temperature at the water inlet of the six-in-one combination motor controller 101 in real time. When the water temperature is higher than the first preset temperature of the motor, the six-in-one combination motor controller 101 controls the three-way valve 105 on the motor water radiator side to open. At the same time, the opening degree of the three-way valve 105 on the motor water radiator side and the speed of the fan 106 are controlled according to the outlet temperature monitored in real time by the eighth temperature sensor 510 and the second temperature sensor 502, so that the water temperature monitored in real time by the first temperature sensor 501 is higher than the second preset temperature of the motor and lower than the second preset temperature of the motor. at the first preset temperature of the motor; when the temperature is lower than the second preset temperature of the motor, the six-in-one combined motor controller 101 controls the three-way valve 105 on the motor water radiator side to close, and at the same time controls the speed of the fan 106 to make the inlet water temperature between the second preset temperature of the motor and the first preset temperature of the motor; uses the third temperature sensor 505 to monitor the outlet water temperature on the battery side of the motor waste heat recovery heat exchanger 110 in real time, and when the outlet water temperature is lower than the third predetermined temperature of the battery, the six-in-one combined motor controller 101 controls the three-way valve 105 on the motor water radiator side to close;

[0051] The first temperature sensor 501 is used to monitor the water inlet temperature of the six-in-one combination motor controller 101 in real time. When the water inlet temperature is lower than the second preset temperature of the motor, the six-in-one combination motor controller 101 controls the three-way valve 405 on the motor waste heat recovery heat exchanger side to close; the fourth temperature sensor 506 is used to monitor the water outlet temperature of the fourth three-way valve 406 in real time. When the water outlet temperature is higher than the fifth preset temperature of the battery, the six-in-one combination motor controller 101 controls the three-way valve 405 on the motor waste heat recovery heat exchanger side to close; when the temperature is lower than the fourth preset temperature of the battery, the three-way valve is controlled to open; the third temperature sensor 505 is used to monitor the water outlet temperature on the battery side of the motor waste heat recovery heat exchanger 110 in real time. When the water outlet temperature is lower than the third preset temperature of the battery, the six-in-one combination motor controller 101 controls the three-way valve 405 on the motor waste heat recovery heat exchanger side to close;

[0052] The ninth temperature sensor 511 is used to monitor the hydraulic oil temperature at the oil inlet of the hydraulic oil tank 208 in real time. When the hydraulic oil temperature at the inlet is higher than the first preset temperature of the hydraulic oil, the six-in-one combined motor controller 101 controls the three-way valve 204 on the hydraulic oil radiator side to open. At the same time, according to the outlet temperature monitored in real time by the eighth temperature sensor 510 and the second temperature sensor 502, the opening of the three-way valve 204 on the hydraulic oil radiator side and the hydraulic oil flow control three-way valve 203 and the speed of the fan 106 are controlled to make the hydraulic oil temperature between the second preset temperature of the hydraulic oil and the first preset temperature of the hydraulic oil; when the temperature is lower than the second preset temperature of the hydraulic oil, the six-in-one combined motor controller 101 controls the three-way valve 204 on the hydraulic oil radiator side and the opening of the hydraulic oil flow control three-way valve 203 and the speed of the fan 106. The controller 101 controls the three-way valve 204 on the hydraulic oil radiator side to close, and at the same time controls the speed of the fan 106 to keep the hydraulic oil temperature within the above-mentioned range; uses the fourth temperature sensor 506 to monitor the outlet water temperature of the fourth three-way valve 406 in real time. When the outlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combination motor controller 101 controls the three-way valve 204 on the hydraulic oil radiator side to close; uses the fifth temperature sensor 507 to monitor the outlet water temperature on the battery side of the hydraulic oil waste heat recovery heat exchanger 205 in real time. When the outlet water temperature is lower than the third preset temperature of the battery, the six-in-one combination motor controller 101 controls the three-way valve 204 on the hydraulic oil radiator side to close;

[0053] The ninth temperature sensor 511 is used to monitor the hydraulic oil temperature at the oil inlet of the hydraulic oil tank 208 in real time. When the hydraulic oil temperature therein is lower than the second preset temperature of the hydraulic oil, the six-in-one combined motor controller 101 controls the three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side to close. The fourth temperature sensor 506 is used to monitor the outlet water temperature of the fourth three-way valve 406 in real time. When the outlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combined motor controller 101 controls the three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side to close. The temperature sensor is used to monitor the outlet water temperature of the fourth three-way valve 406 in real time. When the outlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combined motor controller 101 controls the three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side to close. Measuring the water inlet temperature of the battery water pump 401. When the water inlet temperature is higher than the fifth preset temperature of the battery, the six-in-one combined motor controller 101 controls the three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side to close. When the temperature is lower than the fourth preset temperature of the battery, the three-way valve is controlled to open. Using the fifth temperature sensor 507 to monitor the water outlet temperature on the battery side of the hydraulic oil waste heat recovery heat exchanger 205 in real time. When the water outlet temperature is lower than the third preset temperature of the battery, the six-in-one combined motor controller 101 controls the three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side to close.

[0054] When the three-way valve 405 on the motor waste heat recovery heat exchanger side and the three-way valve 407 on the hydraulic oil waste heat recovery heat exchanger side are both in the closed state, the seventh temperature sensor 509 is used to monitor the water inlet temperature of the power battery pack 404 in real time. When the water inlet temperature is higher than the third preset temperature of the battery, the six-in-one combination motor controller 101 controls the heating power of the PTC heater 403 to be the fifth preset power. When the temperature is lower than the first preset temperature of the battery, the heating power is controlled to be the fourth preset power. The sixth temperature sensor 508 is used to monitor the water inlet temperature of the power battery pack 404 in real time. When the water inlet temperature is higher than the fourth preset temperature of the battery and less than When the battery is at the fifth preset temperature, the heating power is controlled to be the first preset power; when the temperature is higher than the third preset temperature of the battery and lower than the fourth preset temperature of the battery, the heating power is controlled to be the second preset power; when the temperature is higher than the second preset temperature of the battery and lower than the third preset temperature of the battery, the heating power is controlled to be the third preset power; when the temperature is higher than the first preset temperature of the battery and lower than the second preset temperature of the battery, the heating power is controlled to be the fifth preset power; when the temperature is lower than the first preset temperature of the battery, the heating power is controlled to be the fourth preset power; when the inlet water temperature is higher than the fifth preset temperature of the battery, the PTC heater 403 is controlled to stop heating;

[0055] The fan wind speed requirements required by the motor water circuit system, hydraulic oil circuit system, battery water circuit system, chilled water circuit system, and cab refrigeration circuit are fed back to the six-in-one combination motor controller 101. After comparison, the six-in-one combination motor controller 101 selects the maximum wind speed as the output wind speed to control the speed of the fan 106.

[0056] The first preset temperature of the motor is 65°C, and the second preset temperature of the motor is 25°C.

[0057] The first preset temperature of the hydraulic oil is 75°C, and the second preset temperature of the hydraulic oil is 25°C.

[0058] The first preset power is 25% of the full power, the second preset power is 50% of the full power, the third preset power is 75% of the full power, the fourth preset power is full power, and the fifth preset power is 60% of the full power.

[0059] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A thermal management system for an electric loader, characterized in that: include: It includes a motor water circuit system, a hydraulic oil circuit system, a battery water circuit system, a water cooling circuit system, a cab refrigeration circuit and a temperature sensor group; the motor water circuit system and the hydraulic oil circuit system are all connected to the battery water circuit system; The motor water circuit system sequentially comprises a six-in-one combined motor controller (101), a drive motor (102), a working motor (103), a first expansion kettle (104), a motor water radiator (107), a motor water radiator side three-way valve (105), a first three-way valve (108), a motor water pump (109), and a motor waste heat recovery heat exchanger (110); The hydraulic oil circuit system sequentially comprises a hydraulic working motor pump (201), a hydraulic working device (202), a hydraulic oil flow control tee (203), a hydraulic oil radiator (209), a hydraulic oil radiator side tee valve (204), a hydraulic oil waste heat recovery heat exchanger (205), a second tee (206), a third tee (207), and a hydraulic oil tank (208); The battery water circuit system sequentially comprises a battery water pump (401), a second expansion kettle (402), a PTC heater (403), a power battery pack (404), a motor waste heat recovery heat exchanger side three-way valve (405), a fourth three-way valve (406), a hydraulic oil waste heat recovery heat exchanger side three-way valve (407), and a fifth three-way valve (408); The water cooling circuit system sequentially comprises a compressor (301), a condenser (302), an expansion valve (303), and a battery pack cooling heat exchanger (304); The cab refrigeration circuit comprises a compressor (301), a condenser (302), an expansion valve (303), an evaporator (305), and a blower (306) in sequence.

2. The thermal management system for an electric loader according to claim 1, characterized in that: The temperature sensor group includes a first temperature sensor (501), a second temperature sensor (502), a third temperature sensor (505), a fourth temperature sensor (506), a fifth temperature sensor (507), a sixth temperature sensor (508), a seventh temperature sensor (509), an eighth temperature sensor (510), and a ninth temperature sensor (511).

3. A waste heat recovery control method based on the electric loader thermal management system according to claim 1, characterized in that: The control steps include: The first temperature sensor (501) is used to monitor the water temperature at the water inlet of the six-in-one combined motor controller (101) in real time. When the water temperature is higher than the first preset temperature of the motor, the six-in-one combined motor controller (101) controls the three-way valve (105) on the motor water radiator side to open. At the same time, the opening degree of the three-way valve (105) on the motor water radiator side and the speed of the fan (106) are controlled according to the outlet temperature monitored in real time by the eighth temperature sensor (510) and the second temperature sensor (502), so that the water temperature monitored in real time by the first temperature sensor (501) is higher than the second preset temperature of the motor. and lower than the first preset temperature of the motor; when the temperature is lower than the second preset temperature of the motor, the six-in-one combined motor controller (101) controls the three-way valve (105) on the motor water radiator side to close, and simultaneously controls the speed of the fan (106) to make the water inlet temperature between the second preset temperature of the motor and the first preset temperature of the motor; a third temperature sensor (505) is used to monitor the water outlet temperature on the battery side of the motor waste heat recovery heat exchanger (110) in real time, and when the water outlet temperature is lower than the third preset temperature of the battery, the six-in-one combined motor controller (101) controls the three-way valve (105) on the motor water radiator side to close; The first temperature sensor (501) is used to monitor the water temperature at the water inlet of the six-in-one combined motor controller (101) in real time. When the water temperature is lower than the second preset temperature of the motor, the six-in-one combined motor controller (101) controls the three-way valve (405) on the side of the motor waste heat recovery heat exchanger to close. The fourth temperature sensor (506) is used to monitor the water outlet temperature of the fourth three-way valve (406) in real time. When the water outlet temperature is higher than the fifth preset temperature of the battery, the six-in-one combined motor controller (101) controls the three-way valve (405) on the side of the motor waste heat recovery heat exchanger to close. When the temperature is lower than the fourth preset temperature of the battery, the three-way valve is controlled to open. The third temperature sensor (505) is used to monitor the water outlet temperature of the battery side of the motor waste heat recovery heat exchanger (110) in real time. When the water outlet temperature is lower than the third preset temperature of the battery, the six-in-one combined motor controller (101) controls the three-way valve (405) on the side of the motor waste heat recovery heat exchanger to close. The ninth temperature sensor (511) is used to monitor the hydraulic oil temperature at the oil inlet of the hydraulic oil tank (208) in real time. When the hydraulic oil temperature at the inlet is higher than the first preset temperature of the hydraulic oil, the six-in-one combined motor controller (101) controls the hydraulic oil radiator side three-way valve (204) to open. At the same time, the opening of the hydraulic oil radiator side three-way valve (204), the hydraulic oil flow control three-way valve (203) and the speed of the fan (106) are controlled according to the outlet temperature monitored in real time by the eighth temperature sensor (510) and the second temperature sensor (502), so that the hydraulic oil temperature is between the second preset temperature of the hydraulic oil and the first preset temperature of the hydraulic oil. When the temperature is lower than the second preset temperature of the hydraulic oil, the six-in-one combined motor controller (101) controls the hydraulic oil radiator side three-way valve (204) to open. The controller (101) controls the hydraulic oil radiator side three-way valve (204) to close, and controls the rotation speed of the fan (106) at the same time, so that the hydraulic oil temperature is within the above-mentioned range; uses the fourth temperature sensor (506) to monitor the outlet water temperature of the fourth three-way valve (406) in real time, and when the outlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combined motor controller (101) controls the hydraulic oil radiator side three-way valve (204) to close; uses the fifth temperature sensor (507) to monitor the battery side outlet water temperature of the hydraulic oil waste heat recovery heat exchanger (205) in real time, and when the outlet water temperature is lower than the third preset temperature of the battery, the six-in-one combined motor controller (101) controls the hydraulic oil radiator side three-way valve (204) to close; The ninth temperature sensor (511) is used to monitor the hydraulic oil temperature at the oil inlet of the hydraulic oil tank (208) in real time. When the hydraulic oil temperature at the inlet is lower than the second preset temperature of the hydraulic oil, the six-in-one combined motor controller (101) controls the hydraulic oil waste heat recovery heat exchanger side three-way valve (407) to close. The fourth temperature sensor (506) is used to monitor the outlet water temperature of the fourth three-way valve (406) in real time. When the outlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combined motor controller (101) controls the hydraulic oil waste heat recovery heat exchanger side three-way valve (407) to close. The temperature sensor is used to monitor the outlet water temperature of the fourth three-way valve (406) in real time. When the outlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combined motor controller (101) controls the hydraulic oil waste heat recovery heat exchanger side three-way valve (407) to close. The inlet water temperature of the battery water pump (401) is monitored. When the inlet water temperature is higher than the fifth preset temperature of the battery, the six-in-one combined motor controller (101) controls the hydraulic oil waste heat recovery heat exchanger side three-way valve (407) to close. When the temperature is lower than the fourth preset temperature of the battery, the three-way valve is controlled to open. The outlet water temperature of the hydraulic oil waste heat recovery heat exchanger (205) on the battery side is monitored in real time using the fifth temperature sensor (507). When the outlet water temperature is lower than the third preset temperature of the battery, the six-in-one combined motor controller (101) controls the hydraulic oil waste heat recovery heat exchanger side three-way valve (407) to close. When the motor waste heat recovery heat exchanger side three-way valve (405) and the hydraulic oil waste heat recovery heat exchanger side three-way valve (407) are both in the closed state, the seventh temperature sensor (509) is used to monitor the water inlet temperature of the power battery pack (404) in real time. When the water inlet temperature is higher than the third preset temperature of the battery, the six-in-one combined motor controller (101) controls the heating power of the PTC heater (403) to be the fifth preset power. When the temperature is lower than the first preset temperature of the battery, the heating power is controlled to be the fourth preset power. The sixth temperature sensor (508) is used to monitor the water inlet temperature of the power battery pack (404) in real time. When the water inlet temperature is higher than the fourth preset temperature of the battery, the heating power is controlled to be the fourth preset power. When the temperature is higher than the third preset temperature of the battery and lower than the fifth preset temperature of the battery, the heating power is controlled to be the first preset power; when the temperature is higher than the third preset temperature of the battery and lower than the fourth preset temperature of the battery, the heating power is controlled to be the second preset power; when the temperature is higher than the second preset temperature of the battery and lower than the third preset temperature of the battery, the heating power is controlled to be the third preset power; when the temperature is higher than the first preset temperature of the battery and lower than the second preset temperature of the battery, the heating power is controlled to be the fifth preset power; when the temperature is lower than the first preset temperature of the battery, the heating power is controlled to be the fourth preset power; when the inlet water temperature is higher than the fifth preset temperature of the battery, the PTC heater (403) is controlled to stop heating; The fan wind speed requirements of the motor water circuit system, the hydraulic oil circuit system, the battery water circuit system, the cold water circuit system, and the cab refrigeration circuit are fed back to the six-in-one combined motor controller (101). After comparison, the six-in-one combined motor controller (101) selects the maximum wind speed as the output wind speed to control the rotation speed of the fan (106).

4. The waste heat recovery control method according to claim 3, characterized in that: The first preset temperature of the motor is 65°C, and the second preset temperature of the motor is 25°C.

5. The waste heat recovery control method according to claim 3, characterized in that: The first preset temperature of the hydraulic oil is 75°C, and the second preset temperature of the hydraulic oil is 25°C.

6. The waste heat recovery control method according to claim 3, characterized in that: The first preset power is 25% of the full power, the second preset power is 50% of the full power, the third preset power is 75% of the full power, the fourth preset power is full power, and the fifth preset power is 60% of the full power.

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