Integrated new energy vehicle heating control system and control method

Abstract

The application discloses an integrated new energy automobile heating control system and a control method, relates to the technical field of new energy automobile heaters, and comprises a film heater and a PTC heater; wherein a water-cooled film heating controller is arranged outside the film heater, a single MCU hardware architecture of a film heating control module and an air-cooled PTC control module is integrated in the water-cooled film heating controller; a connector is arranged on the lateral surface of the shell of the water-cooled film heating controller and is connected with the PTC heater through a high-voltage wire harness; and an IGBT power switch is arranged. The controller of the air-cooled PTC and the water-cooled film heater are integrated together, an output PTC connector is additionally arranged outside the control box of the film heater, the high-voltage positive pole and the high-voltage negative pole required by the air-cooled PTC are connected with the PTC core body through wires through the connector, so that the controller of the air-cooled PTC and the water-cooled film heater are integrated, and the space occupied by the control box can be reduced through the arrangement.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of new energy automobile heater, in particular to an integrated new energy automobile heating control system and a control method. BACKGROUND

[0002] The current new energy automobile air conditioner and battery thermal management system is composed of a heating and refrigeration system. The heating system is composed of an air-cooled PTC heating and a water-cooled heater; the air conditioner refrigeration and battery cooling and heat dissipation system is completed by a compressor refrigeration system. The heating of the air conditioner box is adjusted by an air-cooled PTC heating controller, and the battery thermal management system is adjusted by a water-cooled heater.

[0003] Now some new energy automobiles are provided with two heaters, one is an air-cooled heater and one is a water-cooled heater, which heat the passenger cabin and the battery system respectively. Since the two heaters are independently designed and each has an independent control unit, the control part of the whole vehicle heating system has the defects of high cost and large space occupation. In addition, the water-cooled heater adopts the conventional PTC heating mode, which has the defects of slow heating speed, low heating efficiency, large current impact on the whole vehicle and the like compared with the film heater of the application. SUMMARY

[0004] The technical scheme of the application provides a significantly different solution from the prior art to solve the technical problem that the prior art solution is too single. Specifically, the purpose of the application is to provide an integrated new energy automobile heating control system and a control method to solve the problem that the existing new energy automobile is provided with two heaters, which heat the passenger cabin and the battery system respectively, and the two heaters are independently designed and each has an independent control unit, resulting in high cost and large space occupation of the control part of the whole vehicle heating system.

[0005] To achieve the above purpose, the application provides the following technical scheme: an integrated new energy automobile heating control system, comprising:

[0006] a film heater and a PTC heater.

[0007] A water-cooled film heating controller is arranged outside the film heater, and a single MCU hardware architecture of an air-cooled PTC control module and a film heating control module is integrated in the water-cooled film heating controller.

[0008] A connector is arranged on the side surface of the water-cooled film heating controller and connected with the PTC heater through a high-voltage wire harness.

[0009] An IGBT power switch is arranged at the water inlet of the film heater and used for adjusting the power output of the PTC heater and the film heater.

[0010] Preferably, the PTC heater comprises a wind-cooled PTC chip assembly, and a control module of the wind-cooled PTC chip assembly is integrated in a single MCU hardware architecture.

[0011] The connector comprises a wind-cooled high-voltage wire harness and a wind-cooled low-voltage wire harness.

[0012] The water-cooled film heating controller is connected to the high-voltage positive and negative poles of the wind-cooled PTC chip assembly through the wind-cooled high-voltage wire harness, and the water-cooled film heating controller supplies power to the wind-cooled PTC chip assembly through the wind-cooled high-voltage wire harness.

[0013] The wind-cooled PTC chip assembly is connected to the water-cooled film heating controller through a low-voltage signal wire harness, and the water-cooled film heating controller transmits signals to the wind-cooled PTC chip assembly through the wind-cooled low-voltage wire harness.

[0014] Preferably, an EMC filter circuit is arranged at an interface of the wind-cooled high-voltage wire harness, and the EMC filter circuit comprises a common-mode inductor and an X capacitor.

[0015] The EMC filter circuit is used to suppress electromagnetic interference, solve the problem of electromagnetic noise generated by high-voltage switching of the integrated controller, and reduce the area occupied by an additional PCB and the conduction interference of the wire harness.

[0016] Preferably, the film heater comprises a shell, an S-shaped water channel is arranged in the shell, a film heating assembly is arranged on an inner wall of the water channel, and a water inlet and a water outlet connected to the water channel are arranged on the shell.

[0017] In actual installation, the film heater is arranged laterally, the water inlet is arranged at the bottom, the water outlet is arranged at the upper portion, the cross-sectional area of the water channel is constant, and the inner wall is rounded, the cooling liquid flows from bottom to top in the water channel during operation of the film heater.

[0018] Preferably, the IGBT power switch is arranged on a side metal substrate of the water inlet, and the IGBT power switch of the PTC heater and the film heater is arranged on one side of the water inlet of the shell, so that the heat generated by the IGBT can be transmitted to the cooling liquid through the shell, the IGBT can work at low temperature, and the heat generated by the IGBT power switch can help the cooling liquid to warm up, and the heat energy is not wasted.

[0019] Preferably, a water inlet temperature sensor, a water outlet temperature sensor, and an IGBT temperature sensor are arranged at the water inlet, the water outlet, and the vicinity of the IGBT power switch, respectively, and the water inlet temperature sensor, the water outlet temperature sensor, and the IGBT temperature sensor are coupled to the water-cooled film heating controller.

[0020] Preferably, the single MCU hardware architecture adopts an upper and lower bridge IGBT driving scheme.

[0021] An integrated new energy vehicle heating system control method, comprising:

[0022] Step S1: detecting the battery temperature T_batt and the passenger cabin temperature T_cabin;

[0023] Step S2: when T_batt<5℃, allocate water-cooled film heating power≥80%; when T_cabin<15℃, allocate air-cooled PTC power≥70%;

[0024] Step S3: delay 0.5s to start air-cooled PTC and water-cooled film heater in off-peak;

[0025] Step S4: monitor the IGBT area temperature, and reduce the PWM duty cycle when it is≥90℃.

[0026] Preferably, the power allocation in step S2 satisfies: water-cooled film heating power+air-cooled PTC power≤system total power upper limit.

[0027] Preferably, the power reduction strategy of step S4 includes: if the temperature is≥90℃ for 10s, turn off the corresponding heater.

[0028] Compared with the prior art, the beneficial effects of the present application are:

[0029] The controller of the air-cooled PTC and the water-cooled film heater are integrated together in the present application, an output PTC connector is added outside the control box of the film heater, the high-voltage positive and high-voltage negative required by the air-cooled PTC are connected to the PTC core through wires through the connector, so that the controller of the air-cooled PTC and the water-cooled film heater are integrated, through this setting, on the one hand, the space occupied by the control box can be reduced; on the other hand, the product cost can be reduced, only one controller can realize integrated control of the PTC heater and the film heater. BRIEF DESCRIPTION OF DRAWINGS

[0030] Figure 1 It is a structure schematic view of the PTC heater and the film heater assembly in the integrated new energy vehicle heating control system of the present application;

[0031] Figure 2 It is a right view structure schematic view of the PTC heater and the film heater assembly in the integrated new energy vehicle heating control system of the present application;

[0032] Figure 3 It is a left view structure schematic view of the PTC heater and the film heater assembly in the integrated new energy vehicle heating control system of the present application;

[0033] Figure 4 It is a rear view structural schematic diagram of PTC heater and film heater assembly in an integrated new energy automobile heating control system of the application;

[0034] Figure 5 It is a structural schematic diagram of PTC heater and film heater assembly in an integrated new energy automobile heating control system of the application;

[0035] Figure 6 It is a structural schematic diagram of PTC heater in an integrated new energy automobile heating control system of the application;

[0036] Figure 7 It is a structural schematic diagram of PTC heater in an integrated new energy automobile heating control system of the application;

[0037] Figure 8 It is a structural schematic diagram of PTC heater in an integrated new energy automobile heating control system of the application;

[0038] Figure 9 It is a structural schematic diagram of PTC heater in an integrated new energy automobile heating control system of the application;

[0039] Figure 10 It is a structural schematic diagram of film heater in an integrated new energy automobile heating control system of the application;

[0040] Figure 11 It is an internal structural schematic diagram of film heater in an integrated new energy automobile heating control system of the application;

[0041] Figure 12 It is a sectional structural schematic diagram of film heater in an integrated new energy automobile heating control system of the application;

[0042] Figure 13 It is a circuit connection structural schematic diagram of an integrated new energy automobile heating control system of the application;

[0043] Figure 14 It is a control program schematic diagram of film heater controller in an integrated new energy automobile heating control system of the application;

[0044] Figure 15 It is another sectional structural schematic diagram of film heater in an integrated new energy automobile heating control system of the application;

[0045] Figure 16 It is a control program schematic diagram of film heater controller in an integrated new energy automobile heating control system of the application; Figure 14

[0046] Figure 17 It is a control program schematic diagram of film heater controller in an integrated new energy automobile heating control system of the application; Figure 14 ​Part of the schematic diagram of the control program.

[0047] In the figure:

[0048] 1 membrane heater, 101 shell, 102 water inlet, 103 water outlet, 104 water channel, 105 membrane heating assembly, 106 water inlet temperature sensor, 107 water outlet temperature sensor, 108 IGBT temperature sensor;

[0049] 2 water-cooled membrane heating controller;

[0050] 3 PTC heater, 301 air-cooled PTC chip assembly, 302 air-cooled low-voltage wire harness, 303 air-cooled high-voltage wire harness;

[0051] 4 IGBT power switch. DETAILED DESCRIPTION

[0052] The technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0053] Please refer to Figures 1-17 The present application provides a technical solution: an integrated new energy vehicle heating control system, comprising:

[0054] Membrane heater 1 and PTC heater 3.

[0055] Among them, the water-cooled membrane heating controller 2 is arranged outside the membrane heater 1, and the single MCU hardware architecture of the air-cooled PTC control module and the membrane heating control module is integrated in the water-cooled membrane heating controller 2.

[0056] Connector, arranged on the side of the shell of the water-cooled membrane heating controller 2, connected with the PTC heater 3 through the high-voltage wire harness.

[0057] IGBT power switch 4, used for adjusting the power output of the PTC heater 3 and the membrane heater 1, arranged at the water inlet of the membrane heater 1.

[0058] In this embodiment, the PTC heater 3 includes the air-cooled PTC chip assembly 301, and the control module of the air-cooled PTC chip assembly 301 is integrated in the single MCU hardware architecture.

[0059] The connector includes: air-cooled high-voltage wire harness 303 and air-cooled low-voltage wire harness 302.

[0060] The water-cooled film heating controller 2 is connected with the high-voltage positive and negative electrodes of the air-cooled PTC chip assembly 301 through the air-cooled high-voltage wire harness 303, and the water-cooled film heating controller 2 supplies power to the air-cooled PTC chip assembly 301 through the air-cooled high-voltage wire harness 303.

[0061] The air-cooled PTC chip assembly 301 is connected with the water-cooled film heating controller 2 through the air-cooled low-voltage wire harness 302, and the water-cooled film heating controller 2 transmits signals to the air-cooled PTC chip assembly 301 through the air-cooled low-voltage wire harness 302.

[0062] Preferably, the EMC filter circuit is arranged at the interface of the air-cooled high-voltage wire harness 303, and the EMC filter circuit includes a common-mode inductor and an X capacitor.

[0063] The EMC filter circuit is used to suppress electromagnetic interference, solve the problem of electromagnetic noise generated by high-voltage switching of the integrated controller, and reduce the extra PCB area occupied and the line bundle conduction interference.

[0064] In the embodiment, the film heater 1 includes a shell 101, an S-shaped water channel 104 is arranged in the shell 101, a film heating assembly 105 is arranged on the inner wall of the water channel 104, and a water inlet 102 and a water outlet 103 connected with the water channel 104 are arranged on the shell 101.

[0065] In actual installation, the film heater 1 is arranged laterally, the water inlet 102 is arranged at the bottom, the water outlet 103 is arranged at the upper part, the cross-sectional area of the water channel 104 is constant, and the inner wall is chamfered, and when the film heater 1 works, the cooling liquid flows from bottom to top in the water channel 104.

[0066] The cooling liquid flows from bottom to top, and the gravity potential energy of the cooling liquid is used to ensure smooth flow of the cooling liquid and avoid generation of air bubbles.

[0067] The cross section of the water channel is constant, which is used to maintain uniform flow rate of the cooling liquid in the water channel 104 and avoid generation of air bubbles due to local acceleration of the cooling liquid.

[0068] The inner wall is chamfered, which is used to eliminate the straight-angle vortex.

[0069] In this embodiment, the IGBT power switch 4 is arranged on the side metal base plate of the water inlet 102. The PTC heater 3 and the IGBT power switch 4 of the film heater 1 are arranged on the side of the water inlet 102 of the shell 101. In this way, the heat generated by the IGBT can be transmitted to the cooling liquid through the shell 101. On the one hand, the heat generated by the IGBT power switch 4 during operation can be taken away by the flow of the cooling liquid, thereby cooling the IGBT power switch 4. On the other hand, the heat generated by the IGBT power switch 4 during operation can also be used to heat the cooling liquid, thereby preheating the cooling liquid and assisting the heating of the cooling liquid, so that the heat energy is not wasted.

[0070] In one specific embodiment, as shown in FIG. 1, a water inlet temperature sensor 106, a water outlet temperature sensor 107, and an IGBT temperature sensor 108 are arranged near the water inlet 102, the water outlet 103, and the IGBT power switch 4, respectively. The water inlet temperature sensor 106, the water outlet temperature sensor 107, and the IGBT temperature sensor 108 are coupled to the water-cooled film heating controller 2. Figure 15 The water inlet temperature sensor 106 and the water outlet temperature sensor 107 arranged near the water inlet 102 and the water outlet 103 can detect whether the temperature of the cooling liquid in the water channel 104 reaches 90°C. If the temperature of the cooling liquid reaches 90°C, the water-cooled film heating controller 2 will adjust the duty cycle of the IGBT through PWM to adopt a power reduction strategy, so as to ensure that the temperature of the cooling liquid does not exceed the design temperature and the IGBT works within the safety threshold.

[0071] Ambient temperature 25°C: APTC, in this patent, APTC specifically refers to the working of the air-cooled PTC chip assembly 301 without an independent controller, which is integrated into the water-cooled film heating controller 2 through a high-voltage output connector, and the film heater does not work. The thermal simulation shows that the maximum temperature of the IGBT is less than 75°C, indicating that the IGBT works within the safety threshold. The IGBT temperature sensor 108 arranged near the IGBT can detect whether the IGBT works within the safety threshold.

[0072] Ambient temperature 85°C: APTC works, and the film heater does not work. The thermal simulation shows that the maximum temperature of the IGBT is less than 110°C, indicating that the IGBT works within the safety threshold. The IGBT temperature sensor 108 arranged near the IGBT can detect whether the IGBT works within the safety threshold. If the IGBT temperature sensor 108 detects that the temperature of the IGBT is greater than 125°C, the controller will adjust the duty cycle of the IGBT through PWM to adopt a power reduction strategy or a shutdown strategy, so as to protect the IGBT from working within the safety threshold.

[0073] Referring to the accompanying drawings

[0074] Figures 13-14 ​As shown, the single MCU hardware architecture adopts an upper and lower bridge IGBT driving scheme:

[0075] The upper and lower bridge IGBT driving scheme refers to a half-bridge circuit composed of high-voltage side IGBT (upper arm) and low-voltage side IGBT (lower arm), and the current direction is controlled by alternating conduction. In the present application, two PWM signals are output by the same MCU chip to drive the upper and lower arms of the PTC heater and the film heater, and the phase difference between the two PWM signals is 180°, so that the peak current is reduced by staggered conduction.

[0076] Preferably, the air-cooled PTC driving unit: the upper arm IGBT (Q1) is connected to the high-voltage bus, and the lower arm IGBT (Q2) is grounded, and the on-off is controlled by the PWM1 signal.

[0077] The water-cooled film heating driving unit: the upper arm IGBT (Q3) shares the high-voltage bus with Q1, and the lower arm IGBT (Q4) is grounded, and the on-off is controlled by the PWM2 signal.

[0078] Referring to Figure 14 As shown, a control method of an integrated new energy vehicle heating system comprises:

[0079] Step S1: detecting the battery temperature T_batt and the passenger cabin temperature T_cabin;

[0080] Step S2: when T_batt<5℃, the water-cooled film heating power is allocated ≥80%; when T_cabin<15℃, the air-cooled PTC power is allocated ≥70%;

[0081] Step S3: delay 0.5s to staggered start the air-cooled PTC and the water-cooled film heater;

[0082] Step S4: monitoring the IGBT area temperature, and reducing the PWM duty cycle when the temperature is ≥90℃.

[0083] In this embodiment, the power allocation in step S2 satisfies: water-cooled film heating power + air-cooled PTC power ≤ system total power upper limit.

[0084] In this embodiment, the power reduction strategy in step S4 includes: if the temperature is ≥90℃ for 10s, the corresponding heater is turned off.

[0085] Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments, or make equivalent replacements to part of the technical features, and any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. An integrated heating control system for new energy vehicles, characterized in that, include: Membrane heater (1) and PTC heater (3); Among them, a water-cooled film heating controller (2) is provided outside the film heater (1), and a single MCU hardware architecture integrating an air-cooled PTC control module and a film heating control module is integrated in the water-cooled film heating controller (2); A connector is provided on the side of the housing of the water-cooled film heating controller (2) and is connected to the PTC heater (3) via a high-voltage wiring harness; IGBT power switch (4), used to adjust the power output of the PTC heater (3) and the membrane heater (1), is set at the inlet (102) of the membrane heater (1); The PTC heater (3) includes an air-cooled PTC chip assembly (301), and the control module of the air-cooled PTC chip assembly (301) is integrated in a single MCU hardware architecture; The connector includes: an air-cooled high-voltage wire harness (303) and an air-cooled low-voltage wire harness (302). The water-cooled film heating controller (2) supplies power to the air-cooled PTC chip assembly (301) through the air-cooled high-voltage wiring harness (303), and transmits signals to the air-cooled PTC chip assembly (301) through the air-cooled low-voltage wiring harness (302); The single MCU hardware architecture adopts an upper and lower bridge IGBT driving scheme: the same MCU chip outputs two PWM signals to drive the upper and lower bridge arms of the PTC heater and the film heater respectively. The two PWM signals have a phase difference of 180°, and staggered conduction reduces the peak current.

2. The integrated new energy vehicle heating control system according to claim 1, characterized in that: The membrane heater (1) includes a housing (101), an S-shaped water channel (104) is provided inside the housing (101), a membrane heating assembly (105) is provided on the inner wall of the water channel (104), and an inlet (102) and an outlet (103) connected to the water channel (104) are provided on the housing (101).

3. The integrated new energy vehicle heating control system according to claim 2, characterized in that: The membrane heater (1) is arranged laterally, the inlet (102) is located at the bottom, and the outlet (103) is located at the top, so that the coolant in the water channel (104) flows from bottom to top; The cross-sectional area of ​​the waterway (104) is constant and the inner wall is rounded.

4. The integrated new energy vehicle heating control system according to claim 1, characterized in that: The air-cooled high-voltage harness (303) is equipped with an EMC filter circuit at its interface, which includes a common-mode inductor and an X capacitor.

5. An integrated new energy vehicle heating control system according to claim 1, characterized in that: The IGBT power switch (4) is disposed on the side metal substrate of the inlet (102). An inlet temperature sensor (106), an outlet temperature sensor (107), and an IGBT temperature sensor (108) are respectively disposed at the inlet (102), the outlet (103), and the IGBT power switch (4). The inlet temperature sensor (106), the outlet temperature sensor (107), and the IGBT temperature sensor (108) are all coupled to the water-cooled film heating controller (2).

6. A control method for an integrated new energy vehicle heating system, applied to the integrated new energy vehicle heating control system according to any one of claims 1-5, characterized in that, include: Step S1: Detect the battery temperature T_batt and the crew cabin temperature T_cabin; Step S2: When T_batt < 5℃, allocate ≥ 80% of the water-cooled film heating power; when T_cabin < 15℃, allocate ≥ 70% of the air-cooled PTC power. Step S3: Delay for 0.5 seconds to start the air-cooled PTC and water-cooled film heater during off-peak hours; Step S4: Monitor the temperature of the IGBT area, and reduce the PWM duty cycle when the temperature is ≥90℃.

7. The integrated new energy vehicle heating system control method according to claim 6, characterized in that: In step S2, the power allocation satisfies the following condition: water-cooled film heating power + air-cooled PTC power ≤ the upper limit of the total system power.

8. The integrated new energy vehicle heating system control method according to claim 6, characterized in that: The power reduction strategy in step S4 includes: if the temperature remains ≥90℃ for 10 seconds, the corresponding heater is turned off.

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