Distributed three-in-one thermal management system

Abstract

The invention discloses a distributed three-in-one thermal management system, and relates to the field of engineering machinery. The invention discloses a distributed three-in-one thermal management system, and the system comprises a vehicle control unit which serves as a core control unit; the battery system comprises a battery pack and a temperature sensor; the motor electric control system comprises a motor, an electric controller and a temperature sensor; the air conditioning system comprises a compressor, a condenser, an evaporation box and a control module; heat management resources of the battery system, the motor electric control system and the air conditioning system are integrated, the VCU is used as a core control unit, efficient management and control of the three systems are achieved, and the system has the advantages of reducing cost, improving performance, simplifying software workload, being convenient to clean and maintain and the like, is suitable for engineering machinery such as electric loaders and the like and has wide application prospects. The host and the shared heat dissipation unit are separately and independently arranged, so that each sub-module can be mounted at a position convenient to clean and maintain after being miniaturized, and the problem that each heat dissipation sub-module is easily blocked by filth is solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of engineering machinery, and in particular relates to a distributed three-in-one thermal management system. Background Art

[0002] With the continuous development of electrification of construction machinery, technological innovation has become an inevitable trend. In order to improve product competitiveness, the industry has gradually tended to integrate multiple systems of the entire vehicle into one. This integration can effectively reduce manufacturers' costs, improve performance, and at the same time change the previous model of independent control of a single system.

[0003] However, most current construction machinery still uses traditional designs, with the laminated battery pack (BMS), power system, and air conditioning system (AC) each equipped with an independent thermal management system. This practice leads to serious waste of resources. Since each system is independently configured with hardware such as cooling units and condenser fans, it not only increases production costs but also causes space occupation and energy loss. In view of this, the present invention is specially proposed. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the deficiencies of the prior art and provide a distributed three-in-one thermal management system that can overcome the above problems or at least partially solve the above problems.

[0005] In order to solve the above technical problems, the basic concept of the technical solution adopted by the present invention is: a distributed three-in-one thermal management system, including: a vehicle controller as a core control unit; a battery system, including a battery pack and a temperature sensor; a motor and electronic control system, including a motor, an electronic control and a temperature sensor; an air-conditioning system, including a compressor, a condenser, an evaporator and a control module; a shared heat dissipation unit, including a condenser radiator fan, which provides heat dissipation support for the battery system cooling unit, the motor and electronic control system radiator and the air-conditioning system condenser; the vehicle controller is respectively communicated with the battery management module in the battery system, the sensor in the power system, and the DC controller in the air-conditioning system, for receiving temperature signals and controlling the operation of the shared heat dissipation unit.

[0006] Furthermore, the shared heat dissipation unit includes four groups of condenser radiator fans, wherein fan 1 and fan 2 are connected in parallel for heat dissipation of the air-conditioning system condenser, and fan 3 and fan 4 are connected in parallel for shared heat dissipation of the battery system cooling unit motor and electronic control system radiator.

[0007] Furthermore, it also includes: a battery-side water pump and a motor-side water pump, which are used to drive the coolant circulation of the battery system and the motor electronic control system respectively; an electronic expansion valve, which is used to adjust the refrigerant flow of the air-conditioning system; a high-pressure pressure sensor and a low-pressure pressure sensor, which are used to monitor the refrigerant pressure of the air-conditioning system.

[0008] Furthermore, the battery system integrates a temperature acquisition module, which is directly connected to the battery inlet and outlet water temperature sensors, the motor electronic control temperature sensor, the evaporator temperature sensor, the ambient temperature sensor and the air outlet temperature sensor.

[0009] Furthermore, the battery system, motor and electronic control system, air conditioning system and common heat dissipation unit are arranged independently and installed in designated areas of the electric loader respectively.

[0010] Furthermore, the vehicle controller is connected to the actuator via the LIN bus or the CAN bus, including a drive circuit for controlling the brushless blower, the relay and the fan speed.

[0011] After adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art: the present invention reduces the investment in hardware equipment and effectively reduces the cost by sharing the heat dissipation device.

[0012] After integrating resources, the heat dissipation management of each system is more efficient and coordinated, which helps to improve the performance of the entire electric loader.

[0013] The VCU replaces the TMS controller as the core control. The sensors and actuators inside the unit are directly controlled by the VCU, reducing the workload of software development and debugging.

[0014] The main unit and the shared heat dissipation unit are arranged separately and independently, which is conducive to the miniaturization of each sub-module and its installation in a location that is easy to clean and maintain, solving the problem of each heat dissipation sub-module being easily dirty and blocked.

[0015] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In the attached figure:

[0017] Figure 1 This is a system module connection diagram of the present invention;

[0018] Figure 2 Schematic diagram of the system principle of the present invention;

[0019] Figure 3 For the present invention Figure 2 Schematic diagram of part A;

[0020] Figure 4 For the present invention Figure 2 Schematic diagram of part B;

[0021] Figure 5 For the present invention Figure 2 Schematic diagram of part C;

[0022] Figure 6 Schematic diagram of the system structure of the present invention. DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. The following embodiments are used to illustrate the present invention but are not used to limit the scope of the present invention.

[0024] Example: Refer to Figures 1-6 As shown, a distributed three-in-one thermal management system includes: a vehicle controller as a core control unit; a battery system, including a battery pack and a temperature sensor; a motor and electronic control system, including a motor, an electronic control and a temperature sensor; an air-conditioning system, including a compressor, a condenser, an evaporator and a control module; a shared heat dissipation unit, including a condenser radiator fan, which provides heat dissipation support for the battery system cooling unit, the motor and electronic control system radiator and the air-conditioning system condenser; the vehicle controller is respectively communicated with the battery management module in the battery system, the sensor in the power system, and the DC controller in the air-conditioning system, for receiving temperature signals and controlling the operation of the shared heat dissipation unit.

[0025] The shared heat dissipation unit includes four groups of condenser radiator fans, wherein fan 1 and fan 2 are connected in parallel for heat dissipation of the air conditioning system condenser, and fan 3 and fan 4 are connected in parallel for shared heat dissipation of the battery system cooling unit motor and electronic control system radiator.

[0026] It also includes: a battery-side water pump and a motor-side water pump, which are used to drive the coolant circulation of the battery system and the motor electronic control system respectively; an electronic expansion valve, which is used to adjust the refrigerant flow of the air-conditioning system; a high-pressure pressure sensor and a low-pressure pressure sensor, which are used to monitor the refrigerant pressure of the air-conditioning system.

[0027] The battery system integrates a temperature acquisition module that is directly connected to the battery inlet and outlet water temperature sensors, the motor electronic control temperature sensor, the evaporator temperature sensor, the ambient temperature sensor, and the air outlet temperature sensor.

[0028] The battery system, motor and electronic control system, air conditioning system and common heat dissipation unit are arranged independently and installed in designated areas of the electric loader respectively.

[0029] The vehicle controller is connected to the actuator via a LIN bus or a CAN bus, and includes a drive circuit for controlling a brushless blower, a relay, and a fan speed.

[0030] Taking a certain model of electric loader as an example, the specific implementation of the distributed three-in-one thermal management system is as follows:

[0031] Hardware architecture: The vehicle controller unit (VCU) is installed in the electronic control box below the cab. It communicates with the BMS in the battery system, the motor controller in the motor electronic control system, and the DCU in the air conditioning system via the CAN bus, collecting real-time temperature data for the battery pack (25kWh lithium iron phosphate battery), the motor (peak power 180kW) electronic control temperature, and the air conditioning system operating parameters.

[0032] Four sets of 3000rpm brushless fans (fans 1-4) are integrated at the rear of the frame. Fans 1 and 2 correspond to the air conditioning system condenser (heat exchange area 8㎡), and fans 3 and 4 correspond to the battery system cooling plate (heat exchange area 5㎡) and the motor electronic control system radiator (heat exchange area 6㎡). The fans use PWM speed control.

[0033] The battery side is equipped with a 24V DC water pump (flow rate 15L / min), and the motor side is equipped with a water pump of the same specification. The air-conditioning system uses R134a refrigerant, and the opening of the electronic expansion valve is dynamically adjusted by the vehicle controller (VCU) according to the evaporator temperature (-5℃~10℃).

[0034] Battery heat dissipation control: When the BMS detects that the battery pack temperature is ≥45°C, the VCU starts fans 3 and 4 at low speed (1500rpm). When the temperature is ≥50°C, the fans run at full speed and the battery side water pump is turned on.

[0035] Motor and electronic control system heat dissipation: When the motor and electronic control temperature is ≥80°C, the VCU prioritizes fans 3 and 4 that are not occupied by the battery system. When the temperature is ≥95°C, the dual fans are started for collaborative heat dissipation.

[0036] Air conditioning cooling control: When the DCU receives a cooling command and the evaporator temperature is ≥12°C, the VCU starts the compressor and controls fans 1 and 2 to adjust their speed according to the high pressure (1.5MPa~2.5MPa). When the pressure is ≥2.2MPa, the fans run at full speed.

[0037] Working principle: VCU serves as the core control unit and receives real-time battery pack status instructions from BMS, temperature information of the motor and electronic control, and air-conditioning system instructions from DCU. When BMS issues an instruction that the battery pack needs to be cooled, VCU controls the battery system cooling unit and the corresponding shared fan to start working to dissipate heat from the battery pack. When it is detected that the temperature of the motor and electronic control exceeds the set threshold, VCU controls the shared fan and heat dissipation device corresponding to the motor and electronic control system to start and dissipate heat for the motor and electronic control system. When DCU issues an instruction that the air-conditioning system needs to be cooled, VCU controls the condenser fan and other components of the air-conditioning system to operate and realize the cooling function. Since the battery system cooling unit shares the condenser fan of the air-conditioning system and the radiator condenser fan of the motor and electronic control system, the waste of resources caused by the independent cooling device of each system is avoided. At the same time, VCU directly controls the sensors and actuators inside the unit, which simplifies the workload of the software.

[0038] The shared cooling unit is installed in the rear grille area of ​​the vehicle frame, and the main unit (VCU, water pump, electronic expansion valve, etc.) is integrated into the maintenance compartment behind the cab. The spacing between each module is ≥300mm, which facilitates cleaning by operators from both sides of the loader, solving the problem of dirt and blockage caused by the compact space of traditional integrated modules.

[0039] This distributed three-in-one thermal management system integrates the thermal management resources of the battery system, motor and electronic control system, and air-conditioning system, and uses the VCU as the core control unit to achieve efficient control of the three major systems. It has the advantages of reducing costs, improving performance, simplifying software workload, and facilitating cleaning and maintenance. It is suitable for construction machinery such as electric loaders.

[0040] The above description is merely a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as above with the preferred embodiment, it is not intended to limit the present invention.

Claims

1. A distributed three-in-one thermal management system, characterized in that: include: Vehicle controller, serving as the core control unit; Battery system, including battery pack and temperature sensor; Motor and electronic control system, including motor, electronic control and temperature sensor; Air conditioning system, including compressor, condenser, evaporator and control module; A shared heat dissipation unit, including a condenser radiator fan, provides heat dissipation support for the battery system cooling unit, the motor and electronic control system radiator, and the air conditioning system condenser; The vehicle controller is respectively connected to the battery management module in the battery system, the sensor in the power system, and the DC controller in the air-conditioning system for receiving temperature signals and controlling the operation of the shared heat dissipation unit.

2. A distributed three-in-one thermal management system according to claim 1, characterized in that: The shared heat dissipation unit includes four groups of condenser radiator fans, wherein fan 1 and fan 2 are connected in parallel for heat dissipation of the air conditioning system condenser, and fan 3 and fan 4 are connected in parallel for shared heat dissipation of the battery system cooling unit motor and electronic control system radiator.

3. The distributed three-in-one thermal management system according to claim 1, characterized in that: Also includes: The battery side water pump and the motor side water pump are used to drive the coolant circulation of the battery system and the motor electronic control system respectively; an electronic expansion valve for regulating the refrigerant flow of the air conditioning system; The high-pressure sensor and the low-pressure sensor are used to monitor the refrigerant pressure of the air-conditioning system.

4. The distributed three-in-one thermal management system according to claim 1, characterized in that: The battery system integrates a temperature acquisition module that is directly connected to the battery inlet and outlet water temperature sensors, the motor electronic control temperature sensor, the evaporator temperature sensor, the ambient temperature sensor, and the air outlet temperature sensor.

5. The distributed three-in-one thermal management system according to claim 3, characterized in that: The vehicle controller, battery-side water pump, motor-side water pump, electronic expansion valve and common heat dissipation unit are arranged independently and installed in designated areas of the electric loader respectively.

6. A distributed three-in-one thermal management system according to any one of claims 1 to 5, characterized in that: The vehicle controller is connected to the actuator via a LIN bus or a CAN bus, and includes a drive circuit for controlling a brushless blower, a relay, and a fan speed.

Images