Heavy truck braking heat energy recovery device and method and new energy heavy truck

Abstract

The invention discloses a heavy truck braking heat energy recovery device and method and a new energy heavy truck. The recovery device comprises a heating loop, a preheating loop and a heat pump recovery system. The enhanced heat dissipation module comprises an unloading loop, and the unloading loop communicates with the auxiliary heat dissipation pipeline and is used for unloading heat; the heat energy distribution module comprises a passage control valve, the first end of the passage control valve is connected with a cooling water outlet of the condenser, the second end of the passage control valve is connected with the heating loop, the third end of the passage control valve is connected with the preheating loop, and the fourth end of the passage control valve is connected with the unloading loop; the integrated control system comprises a main controller, a sensing assembly and an execution unit. The main controller is electrically connected with the sensing assembly, and the main controller is electrically connected with the execution unit; the sensing assembly is used for detecting the temperature of a brake drum, the temperature of a cab and the temperature of a battery pack, detecting the pressure of a heat pump recovery system and detecting the stroke of a brake pedal. The execution unit is used for driving the compressor and the passage control valve.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy heavy-duty trucks, and in particular to a heavy-duty truck brake heat energy recovery device and method, and a new energy heavy-duty truck. Background Art

[0002] Heavy-duty trucks (HMTs) brake frequently and intensely due to their heavy loads. The intense friction between the brake drum and brake pads during braking generates significant heat. According to statistics, this heat energy accounts for approximately 30%-40% of the vehicle's total energy consumption. This heat energy is wasted through natural heat dissipation, resulting in energy loss and potentially degraded braking performance due to excessive brake drum temperatures, compromising driving safety.

[0003] Existing brake heat recovery systems are mostly designed for ordinary passenger cars and are difficult to adapt to the high amount of brake heat generated and the complex operating conditions of heavy-duty trucks. Specifically, existing brake heat recovery systems for heavy-duty trucks suffer from the following main issues: first, low recovery efficiency, which prevents them from quickly absorbing the large amounts of heat generated by braking; second, insufficient system stability, making them prone to overload failures under the high-intensity braking conditions of heavy-duty trucks. Summary of the Invention

[0004] The present invention provides a heavy-duty truck brake heat energy recovery device, method and new energy heavy-duty truck to adapt to the characteristics of heavy-duty trucks with large brake heat energy output and complex working conditions, and improve heat energy recovery efficiency and system stability.

[0005] According to one aspect of the present invention, a brake heat energy recovery device for a heavy truck is provided. The heavy truck includes a brake drum, a cab, and a battery pack. The recovery device includes:

[0006] a heating circuit, the heating circuit being connected to the cab and providing warm air to the cab;

[0007] a preheating circuit, the preheating circuit being connected to the battery pack and providing thermal energy to the battery pack;

[0008] A heat pump recovery system comprising an evaporator, a compressor, a condenser, and a throttling device connected in sequence by pipelines; wherein the outlet of the throttling device is connected to the inlet pipeline of the evaporator; coolant circulates through the evaporator, the compressor, the condenser, and the throttling device; the evaporator is attached to the outside of the brake drum to absorb brake heat energy;

[0009] An enhanced heat dissipation module, the enhanced heat dissipation module including an unloading circuit, the unloading circuit being connected to the auxiliary heat dissipation pipeline for unloading heat;

[0010] a heat energy distribution module, the heat energy distribution module comprising a passage control valve, a first end of the passage control valve being connected to the cooling water outlet of the condenser, a second end of the passage control valve being connected to the heating circuit, a third end of the passage control valve being connected to the preheating circuit, and a fourth end of the passage control valve being connected to the unloading circuit;

[0011] An integrated control system includes a main controller, a sensing component and an execution unit; the main controller is electrically connected to the sensing component, and the main controller is electrically connected to the execution unit; wherein the sensing component is used to detect the temperature of the brake drum, the cab, and the battery pack, detect the pressure of the heat pump recovery system, and detect the brake pedal stroke; the execution unit is used to drive the compressor and the passage control valve.

[0012] Optionally, the sensing component includes:

[0013] a brake drum temperature sensor, the brake drum temperature sensor being arranged on the outside of the brake drum and being used to detect the temperature of the brake drum;

[0014] A cab temperature sensor is provided in the cab and is used to detect the temperature of the cab;

[0015] a battery pack temperature sensor, the battery pack temperature sensor being disposed outside the battery pack and configured to detect the temperature of the battery pack;

[0016] A system pressure sensor is provided in the pipeline of the heat pump recovery system and is used to detect the system pressure;

[0017] a brake intensity sensor, the brake intensity sensor being mechanically connected to the brake pedal and configured to identify a travel of the brake pedal;

[0018] The brake drum temperature sensor, the cab temperature sensor, the battery pack temperature sensor, the system pressure sensor, and the brake intensity sensor are all electrically connected to the main controller.

[0019] Optionally, the execution unit includes:

[0020] a compressor driving module, the compressor driving module being electrically connected to the compressor and configured to drive the compressor;

[0021] A valve group control module is electrically connected to the passage control valve, and the valve group control module is used to control the state of the passage control valve.

[0022] Optionally, the throttling device includes: at least two electronic expansion valves connected in parallel;

[0023] The valve group control module is also electrically connected to each of the electronic expansion valves for controlling the state of the electronic expansion valve.

[0024] Optionally, the enhanced heat dissipation module further includes:

[0025] A fan heat dissipation group is arranged on the side of the evaporator, and the fan heat dissipation group is used to dissipate heat from the evaporator.

[0026] Optionally, the execution unit further includes:

[0027] A heat dissipation control module is electrically connected to the fan heat dissipation group, and is used to control the operating state of the fan heat dissipation group.

[0028] Optionally, the evaporator adopts a multi-group parallel fin-tube structure; and / or the compressor adopts a scroll structure; and / or the condenser adopts a double-circuit shell and tube structure.

[0029] Optionally, the passage control valve is a four-way electromagnetic reversing valve, which is electrically connected to the execution unit; the four-way electromagnetic reversing valve is used to execute at least the following working modes: separate heating, separate preheating, simultaneous heating and preheating, and heat unloading;

[0030] Among them, in the separate heating working mode, the condenser is connected to the heating circuit; in the separate preheating working mode, the condenser is connected to the preheating circuit; in the simultaneous heating and preheating working mode, the condenser is connected to the heating circuit and the preheating circuit at the same time; in the heat unloading mode, the condenser is connected to the unloading circuit.

[0031] According to another aspect of the present invention, a method for recovering brake heat energy from a heavy truck is provided, using the brake heat energy recovery device for a heavy truck according to any embodiment of the present invention; the method comprises:

[0032] The main controller collects the temperature of the brake drum, the temperature of the cab, the temperature of the battery pack, the pressure of the heat pump recovery system, and the brake pedal travel;

[0033] When the brake pedal stroke exceeds a start threshold and does not exceed a full load threshold, the controller controls the heat pump recovery system to start; when the brake pedal stroke exceeds the full load threshold, the controller controls the heat pump recovery system to operate at full load;

[0034] When the temperature of the cab is lower than a room temperature threshold and the temperature of the battery pack is not lower than a preheating threshold, the controller controls the condenser to be connected to the heating circuit;

[0035] When the temperature of the battery pack is lower than the preheating threshold and the temperature of the cab is not lower than the room temperature threshold, the controller controls the condenser to be connected to the preheating circuit;

[0036] When the temperature of the cab is lower than a room temperature threshold and the temperature of the battery pack is lower than a preheating threshold, the controller controls the condenser to be connected to the heating circuit, and controls the condenser to be connected to the preheating circuit, and the ratio of the flow rates of the heating circuit and the preheating circuit is a set ratio;

[0037] When the temperature of the brake drum exceeds a brake temperature threshold and the compressor is overclocked, the controller controls the enhanced heat dissipation module to start;

[0038] When the pressure of the heat pump recovery system exceeds a set pressure threshold, the controller controls the compressor to stop.

[0039] According to another aspect of the present invention, a new energy heavy-duty truck is provided, comprising a brake drum, a cab, a battery pack, and a heavy-duty truck brake heat energy recovery device as described in any one of claims 1 to 8; the heavy-duty truck brake heat energy recovery device is used to recover the brake heat energy of the new energy heavy-duty truck.

[0040] The embodiments of the present invention can achieve at least the following beneficial effects:

[0041] First, in view of the large amount of brake heat energy output of heavy trucks, a heat pump recovery system is used to recover the brake heat energy using the heat pump principle, which is conducive to quickly absorbing the large amount of heat generated during the braking process and improving the recovery efficiency of brake heat energy.

[0042] Secondly, combined with the specific needs of heavy trucks for cab heating and battery preheating, graded distribution can be achieved through the passage control valve to improve the practicality and economy of heat utilization.

[0043] Thirdly, it is equipped with an enhanced heat dissipation module and an adaptive protection mechanism that combines brake pedal travel and pressure detection of the heat pump recovery system. It can maintain stable operation under complex working conditions such as frequent braking and high-intensity operation of heavy trucks, thereby reducing the risk of failure.

[0044] It should be understood that the content described in this section is not intended to identify the key or important features of the embodiments of the present invention, nor is it intended to limit the scope of the present invention. Other features of the present invention will become readily understood through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0046] Figure 1 A schematic structural diagram of a heavy truck brake heat recovery device provided by an embodiment of the present invention;

[0047] Figure 2 A schematic structural diagram of another heavy truck brake heat recovery device provided by an embodiment of the present invention;

[0048] Figure 3 A control block diagram of a heavy truck brake heat recovery device provided by an embodiment of the present invention;

[0049] Figure 4 A schematic flow chart of a heavy truck brake heat energy recovery method provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0050] In order to enable those skilled in the art to better understand the solutions of the present invention, 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 embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of the present invention.

[0051] It should be noted that the terms "first", "second", etc. in the description and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0052] An embodiment of the present invention provides a heavy truck brake heat energy recovery device. Figure 1 This is a schematic diagram of the structure of a heavy truck brake heat recovery device provided by an embodiment of the present invention. Figure 1 , the heavy truck includes a brake drum 1, a cab 2 and a battery pack 3;

[0053] Heavy truck brake heat recovery device includes:

[0054] The heating circuit 410 is connected to the cab 2 to provide warm air to the cab 2;

[0055] The preheating circuit 420 is connected to the battery pack 3 to provide heat energy to the battery pack 3;

[0056] Heat pump recovery system 430 includes an evaporator 431, a compressor 432, a condenser 433, and a throttling device 434, which are sequentially connected by pipelines. The outlet of throttling device 434 is connected to the inlet pipeline of evaporator 431. Coolant circulates through evaporator 431, compressor 432, condenser 433, and throttling device 434. Evaporator 431 is attached to the outside of brake drum 1 to absorb brake heat energy.

[0057] Enhanced heat dissipation module 440, enhanced heat dissipation module 440 includes an unloading circuit 441, the unloading circuit 441 is connected to the auxiliary heat dissipation pipeline 442 for unloading heat;

[0058] Heat energy distribution module 450, heat energy distribution module 450 includes a passage control valve 451, a first end of the passage control valve 451 is connected to the cooling water outlet of the condenser 433, a second end of the passage control valve 451 is connected to the heating circuit 410, a third end of the passage control valve 451 is connected to the preheating circuit 420, and a fourth end of the passage control valve 451 is connected to the unloading circuit 441;

[0059] Integrated control system 460, the integrated control system 460 includes a main controller ( Figure 1 Not shown), sensor component 462 and execution unit ( Figure 1 ); the main controller is electrically connected to the sensor component 462, and the main controller 461 is electrically connected to the execution unit 463; wherein the sensor component 462 is used to detect the temperature of the brake drum 1, the cab 2, and the battery pack 3, detect the pressure of the heat pump recovery system 430, and detect the brake pedal stroke; the execution unit 463 is used to drive the compressor 432 and the passage control valve 451.

[0060] The evaporator 431 in the heat pump recovery system 430 is attached to the outside of the brake drum 1, fully absorbing the brake heat energy generated by the brake drum 1. The sensor assembly not only detects the temperatures of the brake drum 1, the cab 2, and the battery pack 3, but also detects the pressure of the heat pump recovery system 430 and the brake pedal travel. If the pressure in the heat pump recovery system 430 is detected to be excessive, it indicates an overpressure problem in the operation of the heat pump recovery system 430, indicating that the heavy truck is generating excessive brake heat energy. Appropriate measures can be taken to prevent damage to the heat pump recovery system 430. Brake pedal travel indicates braking intensity. A greater brake pedal travel indicates greater braking intensity and, accordingly, more brake heat energy is generated. A smaller brake pedal travel indicates less braking intensity and, accordingly, less brake heat energy is generated.

[0061] Exemplarily, the method for recovering brake heat energy using the heavy truck brake heat energy recovery device is as follows: the main controller collects the temperature of the brake drum 1, the temperature of the cab 2, the temperature of the battery pack 3, the pressure of the heat pump recovery system 430, and the brake pedal stroke; when the brake pedal stroke exceeds the start threshold and does not exceed the full load threshold, the controller controls the heat pump recovery system 430 to start; when the brake pedal stroke exceeds the full load threshold, the controller controls the heat pump recovery system 430 to operate at full load; when the temperature of the cab 2 is lower than the room temperature threshold and the temperature of the battery pack 3 is not lower than the preheating threshold, the controller controls the condenser 433 to be connected to the heating circuit 410; when the temperature of the battery pack 3 is lower than the preheating threshold and When the temperature of the cab 2 is not lower than the room temperature threshold, the controller controls the condenser 433 and the preheating circuit 420 to be connected; when the temperature of the cab 2 is lower than the room temperature threshold and the temperature of the battery pack 3 is lower than the preheating threshold, the controller controls the condenser 433 and the heating circuit 410 to be connected, and controls the condenser 433 and the preheating circuit 420 to be connected, and the flow ratio of the heating circuit 410 and the preheating circuit 420 is a set ratio (for example, 6:4); when the temperature of the brake drum 1 exceeds the brake temperature threshold and the compressor 432 is overclocked, the controller controls the enhanced heat dissipation module 440 to start; when the pressure of the heat pump recovery system 430 exceeds the set pressure threshold, the controller controls the compressor 432 to stop.

[0062] The embodiments of the present invention can achieve at least the following beneficial effects:

[0063] Firstly, in view of the large amount of heat energy output from braking of heavy trucks, the heat pump recovery system 430 is used to recover the brake heat energy using the heat pump principle, which is conducive to quickly absorbing the large amount of heat generated during the braking process.

[0064] Secondly, in combination with the specific needs of heavy trucks for cab heating and battery preheating, graded distribution can be achieved through the passage control valve 451, thereby improving the practicality and economy of heat utilization.

[0065] Thirdly, it is equipped with an enhanced heat dissipation module 440 and an adaptive protection mechanism that combines brake pedal travel and pressure detection of the heat pump recovery system 430. This can maintain stable operation under complex working conditions such as frequent braking and high-intensity operation of heavy trucks, thereby reducing the risk of failure.

[0066] Continue to see Figure 1 Based on the above embodiments, sensor assembly 462 optionally includes a brake drum temperature sensor 4621, which is positioned outside the brake drum 1 to detect the temperature of the brake drum 1. In other embodiments, brake drum temperature sensor 4621 may also be positioned inside the brake drum 1. This configuration can be tailored to actual application needs. For example, brake drum temperature sensor 4621 has a measurement range of -40°C to 500°C, with an accuracy of ±1°C, which improves detection accuracy.

[0067] Continue to see Figure 1 Based on the above embodiments, the sensing assembly 462 optionally further includes a cab temperature sensor 4622, which is disposed in the cab 2 and is used to detect the temperature of the cab 2. Exemplarily, the cab temperature sensor 4622 has a measurement range of -40°C to 500°C and an accuracy of ±0.5°C, which helps improve detection accuracy.

[0068] Continue to see Figure 1 Based on the above embodiments, the sensor assembly 462 optionally further includes a battery pack temperature sensor 4623, which is disposed outside the battery pack 3 and is used to detect the temperature of the battery pack 3. Exemplarily, the battery pack temperature sensor 4623 has a measurement range of -40°C to 500°C and an accuracy of ±0.5°C, which helps improve detection accuracy.

[0069] Continue to see Figure 1 Based on the above embodiments, the sensor assembly 462 optionally further includes a system pressure sensor 4624, which is disposed in the piping of the heat pump recovery system 430 and is used to detect system pressure. Optionally, the system pressure sensor 4624 is disposed in the piping between the evaporator 431 and the compressor 432, between the compressor 432 and the condenser 433, between the condenser 433 and the throttling device 434, or between the throttling device 434 and the evaporator 431. Exemplarily, the system pressure sensor 4624 has a measurement range of 0-3 MPa and an accuracy of ±0.5% FS, which facilitates improved detection accuracy.

[0070] Continue to see Figure 1Based on the above embodiments, the sensor assembly 462 may optionally further include a brake intensity sensor 4625. The brake intensity sensor 4625 is mechanically connected to the brake pedal to identify the brake pedal travel. The brake intensity sensor 4625 can identify 0-100% of the brake pedal travel.

[0071] Continue to see Figure 1 Based on the above embodiments, the evaporator 431 can optionally employ a multiple-group parallel fin-and-tube structure, which can be tightly fitted to the outside of the brake drum 1. This multiple-group parallel fin-and-tube evaporator utilizes several U-shaped copper tubes, each fully pierced with aluminum fins, inserted side by side between two horizontal headers. Refrigerant flows through the tubes in parallel, and air sweeps across the fins. This provides a large heat exchange area, facilitating the rapid absorption of brake heat energy generated by the brake drum 1. For example, the heat exchange area of ​​the evaporator 431 is designed to be 1.5-2.5 square meters, depending on the size of the brake drum 1. Each group of fins has independent flow channels, enabling rapid absorption of the large amount of heat dissipated by the brake drum 1. Therefore, this evaporator 431 can also be called a high-efficiency evaporator.

[0072] Continue to see Figure 1 Based on the above embodiments, compressor 432 optionally employs a scroll structure. Scroll compressors are valveless, clearance-free, low-vibration, and highly efficient, facilitating efficient operation of heat pump recovery system 430 and rapidly absorbing the large amounts of heat dissipated by brake drum 1. Scroll compressors, for example, have a rated power of 5-8 kW and can compress low-temperature, low-pressure refrigerant vapor into high-temperature, high-pressure vapor, meeting the high heat recovery requirements generated by heavy-duty truck braking. Therefore, compressor 432 is also referred to as a high-power compressor.

[0073] Continue to see Figure 1 Based on the above embodiments, condenser 433 optionally employs a dual-circuit shell-and-tube structure. Condenser 433 is connected to the heating circuit 410 of cab 2, the preheating circuit 420 of battery pack 3, and the unloading circuit 441. Exemplarily, the heat exchange area of ​​condenser 433 is 2.0-3.0 m2. It can transfer heat to all three circuits simultaneously or individually, and is therefore also referred to as a composite condenser.

[0074] In view of the large amount of braking heat energy output of heavy trucks, the embodiment of the present invention adopts a large heat exchange area evaporator 431 and a high-power compressor 432. Compared with the existing technology, it can improve the recovery efficiency of braking heat energy by more than 30% and can quickly absorb the large amount of heat generated during the braking process.

[0075] Continue to see Figure 1On the basis of the above embodiments, optionally, the passage control valve 451 is a four-way electromagnetic reversing valve, which is electrically connected to the execution unit 463; the four-way electromagnetic reversing valve is used to execute at least the following working modes: separate heating, separate preheating, simultaneous heating and preheating, and heat unloading.

[0076] Among them, in the working mode of heating alone, the condenser 433 is connected to the heating circuit 410; in the working mode of preheating alone, the condenser 433 is connected to the preheating circuit 420; in the working mode of simultaneous heating and preheating, the condenser 433 is connected to the heating circuit 410 and the preheating circuit 420 at the same time; in the heat unloading mode, the condenser 433 is connected to the unloading circuit 441.

[0077] It can be seen that the embodiment of the present invention can accurately control the heat flow direction of the heat pump recovery system 430 through the passage control valve 451.

[0078] Based on the above embodiments, the heavy-duty truck brake heat recovery device optionally further includes four high-precision flow sensors to monitor the flow rates of the cooling water outlet of condenser 433, heating circuit 410, preheating circuit 420, and unloading circuit 441, respectively, to ensure balanced heat distribution. Exemplarily, the high-precision flow sensors have an accuracy of ±0.2% FS.

[0079] It should be noted that, based on the above embodiments, the passage between the unloading circuit 441 and the condenser 433 is optionally controlled by a passage control valve 451, which is not a limitation of the present invention. In other embodiments, the passage between the unloading circuit 441 and the condenser 433 may be controlled by a separate electromagnetic shutoff valve, with the auxiliary heat dissipation line 442 in the unloading circuit 441 connected in parallel with the condenser 433. When excess heat is detected in the brake drum 1, the controller controls the electromagnetic shutoff valve to open, dissipating the excess heat generated by the condenser 433 to the environment.

[0080] Figure 2 This is a schematic diagram of another heavy truck brake heat recovery device provided by an embodiment of the present invention. Figure 2 Based on the above embodiments, the enhanced heat dissipation module 440 optionally further includes a fan heat dissipation group 443, which is disposed on the side of the evaporator 431 and is used to dissipate heat from the evaporator 431. This configuration helps prevent malfunctions caused by excessive temperatures in the evaporator 431, thereby further improving system stability.

[0081] Exemplarily, the fan heat dissipation group 443 includes two high-power axial flow fans, wherein the power of a single fan is ≥500W, and the fan speed can be steplessly adjusted according to the temperature of the brake drum 1, so that the speed can be adjusted within the range of 500-3000r / min.

[0082] Figure 3 This is a control block diagram of a heavy truck brake heat recovery device provided by an embodiment of the present invention. Figure 3 Based on the above embodiments, optionally, the brake drum temperature sensor 4621, the cab temperature sensor 4622, the battery pack temperature sensor 4623, the system pressure sensor 4624, and the brake intensity sensor 4625 are all electrically connected to the main controller 461. This arrangement facilitates the main controller to obtain the temperature of the brake drum 1, the temperature of the cab 2, the temperature of the battery pack 3, the pressure of the heat pump recovery system 430, and the braking intensity of the brake pedal.

[0083] Combine Figure 2 and Figure 3 Based on the above embodiments, optionally, the execution unit 463 includes a compressor driving module 4631, which is electrically connected to the compressor 432 and is used to drive the compressor 432. Specifically, the compressor driving module 4631 receives control from the controller 461 and drives the compressor 432 to start or stop.

[0084] Combine Figure 2 and Figure 3 Based on the above embodiments, the execution unit 463 may optionally further include a valve group control module 4632. The valve group control module 4632 is electrically connected to the passage control valve 451 and is configured to control the state of the passage control valve 451. Specifically, the valve group control module 4632 receives control from the controller 461 and drives the passage control valve 451 to conduct one, two, or three passages.

[0085] Combine Figure 2 and Figure 3 Based on the above embodiments, the execution unit 463 optionally further includes a heat dissipation control module 4633. The heat dissipation control module 4633 is electrically connected to the fan heat dissipation group 443 and is configured to control the operating state of the fan heat dissipation group 443. Specifically, the heat dissipation control module 4633 receives control from the controller 461 and drives the fan heat dissipation group 443 to start or stop, or to drive one or more fans in the fan heat dissipation group 443 to operate.

[0086] Based on the above embodiments, optionally, the controller 461 adopts an industrial-grade microprocessor with a main frequency ≥120MHz, multi-channel data acquisition and fast control capabilities, and can process 16 sensor signals at the same time, which can meet the heavy-duty truck brake heat recovery device's detection requirements for its operating status.

[0087] Based on the above embodiments, optionally, the response time of the compressor driving module 4631, the valve group control module 4632 and the heat dissipation control module 4633 in the execution unit 463 is ≤50ms, which is conducive to improving its response speed.

[0088] The embodiment of the present invention ensures the control accuracy and response speed of the system under various working conditions by adopting a high-performance controller 461 and a fast-response execution unit 463, thereby meeting the dynamic braking requirements of heavy trucks.

[0089] Continue to see Figure 2 and Figure 3 Based on the above embodiments, optionally, the throttling device 434 includes at least two electronic expansion valves 4341 connected in parallel; the valve group control module 4632 is also electrically connected to each electronic expansion valve 4341 to control the state of the electronic expansion valve 4341. At least two electronic expansion valves 4341 connected in parallel constitute an electronic expansion valve group. Exemplarily, the response speed of the electronic expansion valve 4341 is ≤100ms, and it can quickly respond to the drive of the valve group control module 4632. The electronic expansion valve group includes three independent electronic expansion valves 4341, which are connected in parallel and can dynamically adjust the refrigerant flow rate according to the system pressure and temperature under the control of the valve group control module 4632.

[0090] Based on the above embodiments, optionally, in the heat pump recovery system 430, the evaporator 431 uses three groups of parallel finned tubes with a total heat exchange area of ​​2.0 m2; the rated power of the compressor 432 is 6.5 kW; the heat exchange area of ​​the condenser 433 is 2.5 m2; and the throttling device 434 is composed of three electronic expansion valves with a diameter of 5 mm.

[0091] In the heat energy distribution module 450 , the operating pressure of the four-way electromagnetic reversing valve is ≤3 MPa; the measurement range of the flow sensor is 0-100 L / min, and the accuracy is ±0.2% FS.

[0092] In the integrated control system 460, the controller 461 adopts an industrial-grade MCU with a main frequency of 150 MHz; the measurement range of the brake drum temperature sensor 4621 is -40°C-500°C; and the resolution of the brake intensity sensor 4625 is 1% of the stroke.

[0093] In the enhanced heat dissipation module 440 , the power of a single fan of the dual fans is 600W, and the maximum speed is 3000r / min; the diameter of the auxiliary heat dissipation pipeline 442 is 20mm, and is equipped with a DN20 electromagnetic shut-off valve.

[0094] The present invention also provides a method for recovering brake heat energy from heavy trucks. The method uses a brake heat energy recovery device for heavy trucks as provided in any embodiment of the present invention and has corresponding beneficial effects. Figure 4This is a flow chart of a heavy truck brake heat energy recovery method provided by an embodiment of the present invention. Figure 4 The heavy truck brake heat energy recovery method comprises the following steps:

[0095] Step S510: The main controller collects the temperature of the brake drum, the temperature of the cab, the temperature of the battery pack, the pressure of the heat pump recovery system, and the brake pedal travel.

[0096] Step S520: When the brake pedal travel exceeds the start threshold and does not exceed the full load threshold, the controller controls the heat pump recovery system to start. When the brake pedal travel exceeds the full load threshold, the controller controls the heat pump recovery system to operate at full load.

[0097] For example, the activation threshold is 20% and the full load threshold is 60%. When the brake intensity sensor detects that the brake pedal travel is greater than 20%, the heat pump recovery system is activated to recover brake heat energy; when the brake intensity sensor detects that the brake pedal travel is greater than 60%, the compressor runs at full load and the evaporator absorbs heat at full capacity.

[0098] Step S530: When the temperature of the cab is lower than the room temperature threshold and the temperature of the battery pack is not lower than the preheating threshold, the controller controls the condenser to be connected to the heating circuit.

[0099] Optionally, in step S530, the controller controls the condenser and the preheating circuit to be connected simultaneously, but gives priority to heating. Exemplarily, the flow distribution ratio of the heating circuit is ≥70%.

[0100] Step S540: When the temperature of the battery pack is lower than the preheating threshold and the temperature of the cab is not lower than the room temperature threshold, the controller controls the condenser to be connected to the preheating circuit.

[0101] Optionally, in step S540, the controller controls the condenser and the heating circuit to be connected simultaneously, but gives priority to preheating. Exemplarily, the flow distribution ratio of the preheating circuit is ≥70%.

[0102] Step S550: When the temperature of the cab is lower than the room temperature threshold and the temperature of the battery pack is lower than the preheating threshold, the controller controls the condenser to be connected to the heating circuit, and controls the condenser to be connected to the preheating circuit, and the ratio of the flow of the heating circuit to the preheating circuit is the set ratio.

[0103] For example, the room temperature threshold is 15°C, the preheating threshold is 20°C, and the set ratio is 6:4. The controller prioritizes heating based on the data sent by the temperature sensor. Specifically, when the cab temperature is less than 15°C, heating is prioritized, with a flow allocation ratio of ≥70%; when the battery pack temperature is less than 20°C, preheating is prioritized, with a flow allocation ratio of ≥70%; if both are required, heating and preheating are allocated in a ratio of 6:4; when the cab temperature is ≥22°C and the battery pack temperature is ≥30°C, indicating that both the cab and battery pack temperatures meet the standards, the auxiliary cooling pipe is activated to unload heat.

[0104] Step S560: When the temperature of the brake drum exceeds the brake temperature threshold and the compressor is overclocked, the controller controls the enhanced heat dissipation module to start.

[0105] For example, if the brake temperature threshold is 350°C, compressor overclocking means the compressor power increases by more than 10% or more than 20%. In actual applications, the overclocking power increase can be set to 10%-20% as needed. The enhanced heat dissipation module uses dual fans. Therefore, when the brake drum temperature exceeds 350°C and the compressor is overclocked (with a 10%-20% power increase), the dual fans are controlled to operate at full speed.

[0106] Step S570: When the pressure of the heat pump recovery system exceeds a set pressure threshold, the controller controls the compressor to stop.

[0107] For example, the pressure threshold is set to >2.5MPa or <0.1MPa. When the system pressure is >2.5MPa or <0.1MPa, the controller immediately stops the compressor. Optionally, when the pressure of the heat pump recovery system exceeds the set pressure threshold, a light alarm can also be triggered.

[0108] Based on the above embodiments, optionally, when a heat exchange circuit (including a heating circuit, a preheating circuit and an unloading circuit) fails, it automatically switches to a single-circuit operation mode to ensure that the basic functions of the heavy-duty truck brake heat recovery device are normal.

[0109] It can be seen that the embodiment of the present invention can implement a dynamic recovery strategy (step S510 and step S520), hierarchical heat distribution (including steps S530 to S550), and an adaptive protection mechanism (including steps S560 and S570).

[0110] Based on the above embodiments, optionally, the heavy truck brake heat energy recovery method is:

[0111] Recovery start-up phase: When the brake pedal travel reaches 30%, the brake intensity sensor sends a signal, the controller starts the heat pump recovery system, the evaporator begins to absorb the heat of the brake drum, and the refrigerant evaporates into low-pressure steam.

[0112] Compression and heat exchange stage: The compressor compresses low-pressure steam into high-temperature and high-pressure steam and sends it to the condenser. At this time, if the cab temperature is 12°C (lower than 15°C) and the battery pack temperature is 25°C (higher than 20°C), the multi-channel control valve will distribute more than 70% of the heat to the cab heating circuit.

[0113] Working condition adjustment stage: When the brake pedal stroke increases to 70% (high-intensity braking) during heavy-duty truck driving, the compressor runs at full load and the evaporator absorbs heat at full capacity; at the same time, the brake drum temperature rises to 360°C, and the dual fans start running at full speed (3000r / min) to assist in heat dissipation.

[0114] Fault response phase: If the system pressure suddenly rises to 2.6MPa, the pressure sensor triggers the protection mechanism, the controller immediately stops the compressor, and the sound and light alarm in the cab is activated to indicate a fault.

[0115] Heat unloading stage: When the cab temperature reaches 22°C and the battery pack temperature reaches 30°C, the multi-channel control valve switches to heat unloading mode, and excess heat is dissipated through the auxiliary heat dissipation pipes.

[0116] An embodiment of the present invention further provides a new energy heavy-duty truck, characterized by comprising a brake drum, a cab, a battery pack, and a heavy-duty truck brake heat recovery device as provided in any embodiment of the present invention; the heavy-duty truck brake heat recovery device is configured to recover brake heat energy from the new energy heavy-duty truck. The beneficial effects achieved by this new energy heavy-duty truck are similar to those of the aforementioned embodiments and are not further described.

[0117] It should be understood that the various forms of the processes shown above can be used to reorder, add, or delete steps. For example, the steps described in the present invention can be performed in parallel, sequentially, or in a different order, as long as the desired results of the technical solution of the present invention can be achieved. This is not limited herein.

[0118] The above specific embodiments do not limit the scope of protection of the present invention. Those skilled in the art will appreciate that various modifications, combinations, sub-combinations, and substitutions may be made based on design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention are intended to be included within the scope of protection of the present invention.

Claims

1. A heavy truck brake heat recovery device, characterized in that: The heavy truck includes a brake drum, a cab and a battery pack; the recovery device includes: a heating circuit, the heating circuit being connected to the cab and providing warm air to the cab; a preheating circuit, the preheating circuit being connected to the battery pack and providing thermal energy to the battery pack; A heat pump recovery system comprising an evaporator, a compressor, a condenser, and a throttling device connected in sequence by pipelines; wherein the outlet of the throttling device is connected to the inlet pipeline of the evaporator; coolant circulates through the evaporator, the compressor, the condenser, and the throttling device; the evaporator is attached to the outside of the brake drum to absorb brake heat energy; An enhanced heat dissipation module, the enhanced heat dissipation module including an unloading circuit, the unloading circuit being connected to the auxiliary heat dissipation pipeline for unloading heat; a heat energy distribution module, the heat energy distribution module comprising a passage control valve, a first end of the passage control valve being connected to the cooling water outlet of the condenser, a second end of the passage control valve being connected to the heating circuit, a third end of the passage control valve being connected to the preheating circuit, and a fourth end of the passage control valve being connected to the unloading circuit; An integrated control system includes a main controller, a sensing component and an execution unit; the main controller is electrically connected to the sensing component, and the main controller is electrically connected to the execution unit; wherein the sensing component is used to detect the temperature of the brake drum, the cab, and the battery pack, detect the pressure of the heat pump recovery system, and detect the brake pedal stroke; the execution unit is used to drive the compressor and the passage control valve.

2. The heavy truck brake heat recovery device according to claim 1, characterized in that: The sensing component includes: a brake drum temperature sensor, the brake drum temperature sensor being arranged on the outside of the brake drum and being used to detect the temperature of the brake drum; A cab temperature sensor is provided in the cab and is used to detect the temperature of the cab; a battery pack temperature sensor, the battery pack temperature sensor being disposed outside the battery pack and configured to detect the temperature of the battery pack; A system pressure sensor is provided in the pipeline of the heat pump recovery system and is used to detect the system pressure; a brake intensity sensor, the brake intensity sensor being mechanically connected to the brake pedal and configured to identify a travel of the brake pedal; The brake drum temperature sensor, the cab temperature sensor, the battery pack temperature sensor, the system pressure sensor, and the brake intensity sensor are all electrically connected to the main controller.

3. The heavy truck brake heat recovery device according to claim 1, characterized in that: The execution unit includes: a compressor driving module, the compressor driving module being electrically connected to the compressor and configured to drive the compressor; A valve group control module is electrically connected to the passage control valve, and the valve group control module is used to control the state of the passage control valve.

4. The heavy truck brake heat recovery device according to claim 3, characterized in that: The throttling device includes: at least two electronic expansion valves connected in parallel; The valve group control module is also electrically connected to each of the electronic expansion valves for controlling the state of the electronic expansion valve.

5. The heavy truck brake heat recovery device according to claim 1, characterized in that: The enhanced heat dissipation module further includes: A fan heat dissipation group is arranged on the side of the evaporator, and the fan heat dissipation group is used to dissipate heat from the evaporator.

6. The heavy truck brake heat recovery device according to claim 5, characterized in that: The execution unit further includes: A heat dissipation control module is electrically connected to the fan heat dissipation group, and is used to control the operating state of the fan heat dissipation group.

7. The heavy truck brake heat recovery device according to claim 1, characterized in that: The evaporator adopts a multi-group parallel fin-tube structure; and / or the compressor adopts a scroll structure; and / or the condenser adopts a double-circuit shell and tube structure.

8. The heavy truck brake heat recovery device according to claim 1, characterized in that: The passage control valve is a four-way electromagnetic reversing valve, which is electrically connected to the execution unit; the four-way electromagnetic reversing valve is used to execute at least the following working modes: heating alone, preheating alone, simultaneous heating and preheating, and heat unloading; Among them, in the separate heating working mode, the condenser is connected to the heating circuit; in the separate preheating working mode, the condenser is connected to the preheating circuit; in the simultaneous heating and preheating working mode, the condenser is connected to the heating circuit and the preheating circuit at the same time; in the heat unloading mode, the condenser is connected to the unloading circuit.

9. A heavy truck brake heat energy recovery method, characterized in that: The heavy truck brake heat recovery device according to any one of claims 1 to 8 is used; the method comprises: The main controller collects the temperature of the brake drum, the temperature of the cab, the temperature of the battery pack, the pressure of the heat pump recovery system, and the brake pedal travel; When the brake pedal stroke exceeds a start threshold and does not exceed a full load threshold, the controller controls the heat pump recovery system to start; when the brake pedal stroke exceeds the full load threshold, the controller controls the heat pump recovery system to operate at full load; When the temperature of the cab is lower than a room temperature threshold and the temperature of the battery pack is not lower than a preheating threshold, the controller controls the condenser to be connected to the heating circuit; When the temperature of the battery pack is lower than the preheating threshold and the temperature of the cab is not lower than the room temperature threshold, the controller controls the condenser to be connected to the preheating circuit; When the temperature of the cab is lower than a room temperature threshold and the temperature of the battery pack is lower than a preheating threshold, the controller controls the condenser to be connected to the heating circuit, and controls the condenser to be connected to the preheating circuit, and the ratio of the flow rates of the heating circuit and the preheating circuit is a set ratio; When the temperature of the brake drum exceeds a brake temperature threshold and the compressor is overclocked, the controller controls the enhanced heat dissipation module to start; When the pressure of the heat pump recovery system exceeds a set pressure threshold, the controller controls the compressor to stop.

10. A new energy heavy truck, characterized in that: It comprises a brake drum, a cab, a battery pack and a heavy-duty truck brake heat energy recovery device as described in any one of claims 1 to 8; the heavy-duty truck brake heat energy recovery device is used to recover the brake heat energy of the new energy heavy-duty truck.

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