Complete vehicle comprehensive heat management scheme and control method based on motor waste heat utilization

Abstract

The invention belongs to the technical field of automobile manufacturing, particularly relates to a vehicle comprehensive heat management scheme based on motor waste heat utilization and a control method, and provides a system for solving the problem that an existing commercial vehicle heat management system cannot achieve generalization and deep coupling. Comprising a double-channel integrated chiller, an electronic expansion valve, a high-temperature cooling liquid-low-temperature cooling liquid heat exchanger, a low-temperature cooling liquid-refrigerant heat exchanger, a first expansion water tank and a second expansion water tank. The system further comprises an independent cockpit refrigerating loop, an independent cockpit heating loop, an independent power battery liquid cooling loop, an independent power battery liquid heating loop, an independent driving motor and controller cooling loop and an independent OBC cooling loop. The multi-loop vehicle comprehensive heat management system for the light commercial vehicle based on motor waste heat utilization is achieved, full-chassis arrangement is achieved, arrangement is flexible, the multi-loop vehicle comprehensive heat management system is suitable for multiple types of vehicle types of the light commercial vehicle, and the 100-165 kWh electric quantity heat management requirement of a power battery can be met.

Description

Technical Field

[0001] This invention relates to the field of automobile manufacturing technology, and in particular to a comprehensive vehicle thermal management scheme and control method based on the utilization of waste heat from motors. Background Technology

[0002] Currently, the applications of new energy light commercial vehicles are transitioning from short-distance urban distribution to medium- and long-distance intercity delivery. The selection of power batteries for these vehicles is trending towards single-pack, high-capacity models. Based on the demands for super-fast charging and high-rate charging / discharging, the thermal management requirements of the power battery have become a major point of contention. In recent years, the export of new energy vehicle models has increased significantly. To adapt to the overseas demand for DC integrated charging, the vehicle's thermal management system still needs to consider the added OBC cooling requirements.

[0003] How to meet the power battery requirements of multi-capacity systems, while taking into account the overall vehicle cost, weight, and winter range, and also the unique thermal management requirements of export models, makes the standardization and deep integration of vehicle thermal management systems a top priority for major OEMs. Summary of the Invention

[0004] To address the technical limitations of current commercial vehicle thermal management systems in achieving universality and deep integration, this invention proposes a comprehensive vehicle thermal management scheme and control method based on the utilization of motor waste heat.

[0005] This invention proposes a comprehensive vehicle thermal management scheme and control method based on the utilization of motor waste heat, including a dual-channel integrated chiller, an electronic expansion valve, a high-temperature coolant-low-temperature coolant heat exchanger, a low-temperature coolant-refrigerant heat exchanger, an expansion tank I, and an expansion tank II, which can realize liquid cooling and liquid heating of the power battery. It also includes separate cooling circuits for the driver's cabin, heating circuits for the driver's cabin, liquid cooling circuits for the power battery, liquid heating circuits for the power battery, cooling circuits for the drive motor and its controller, cooling circuits for the OBC, cooling-battery liquid cooling circuits for the driver's cabin, heating-battery liquid heating circuits for the driver's cabin, heating-battery liquid cooling circuits for the driver's cabin, waste heat from the motor-driver's cabin, waste heat from the motor-power battery, and waste heat from the motor-driver's cabin, and liquid heating circuits for the motor.

[0006] Preferably, the separate cockpit cooling circuit includes a compressor, condenser, electric fan, three-state pressure switch, shut-off valve, evaporator, and gas-liquid separator connected in sequence via pipelines. The blower is turned on to cool the cockpit.

[0007] Preferably, the separate cockpit heating circuit includes an electronic water pump three, a WPTC, a water temperature sensor three, a three-way valve, a heater tank, a water temperature sensor four, a four-way valve two, and a four-way valve one, which are connected in sequence through pipelines. The vehicle controller detects the water temperature, controls the electronic water pump three and the WPTC, and achieves cockpit heating by adjusting the opening of the three-way valve, the four-way valve one, and the four-way valve two.

[0008] Preferably, the separate power battery liquid cooling circuit includes two parts: one is that the coolant side is connected in sequence through pipelines to a dual-channel integrated chiller, water temperature sensor one, power battery, water temperature sensor five, and electronic water pump two;

[0009] Secondly, the refrigerant side is connected in sequence to the compressor, condenser, electric fan, three-state pressure switch, dual-channel integrated chiller, and PT sensor through pipelines to achieve liquid cooling of the power battery.

[0010] Preferably, the separate power battery liquid thermal circuit includes two parts: one is an electronic water pump three, WPTC, water temperature sensor three, three-way valve, dual-channel integrated chiller, water temperature sensor four, four-way valve two, and four-way valve one connected in sequence through pipelines on the high-temperature coolant side.

[0011] Secondly, the low-temperature coolant side is connected in sequence through pipelines to a dual-channel integrated chiller, water temperature sensor one, power battery, water temperature sensor five, and electronic water pump two to achieve liquid cooling of the power battery.

[0012] Preferably, the cooling circuit of the individual drive motor and its controller includes a heat sink, an electric fan, a four-way valve, an electric water pump, a multi-function controller, a drive motor, a water temperature sensor, and a four-way valve connected in sequence through pipes to achieve cooling of the drive motor and its controller.

[0013] Preferably, the separate OBC cooling circuit includes a radiator, an electric fan, a four-way valve II, an electric water pump I, a straight-through valve, and the OBC connected in sequence via pipelines. When the vehicle requires AC slow charging, the electric fan and electric water pump I are controlled by the vehicle controller, and the opening of the four-way valve II, the four-way valve I, and the straight-through valve are adjusted to achieve OBC cooling.

[0014] The aforementioned cockpit cooling-battery liquid cooling circuit means that when both the cockpit and the power battery have cooling needs, the electric compressor, electric fan, and electric water pump II are sequentially activated by the vehicle controller to achieve dual cooling of the cockpit and battery liquid cooling.

[0015] The aforementioned cockpit heating-battery liquid cooling circuit achieves dual heating by sequentially activating electronic water pump two, WPTC, and electronic water pump three through the vehicle controller when both the cockpit and the power battery require heating. Simultaneously, the opening of the three-way valve is adjusted according to a certain strategy.

[0016] Preferably, the cockpit heating-battery liquid cooling circuit means that when there is a heating requirement in the cockpit and a cooling requirement in the power battery, the separate battery liquid cooling circuit and the separate cockpit heating circuit are connected simultaneously to achieve cockpit heating and battery liquid cooling.

[0017] The motor waste heat-cabin heating circuit package controls electronic water pump 2 and electronic water pump 1 through the vehicle controller, and adjusts the opening of four-way valve 2, four-way valve 1 and three-way valve to realize the use of motor waste heat to meet the heating needs of the cockpit.

[0018] The motor waste heat-power battery liquid heat circuit controls electronic water pump 2 and electronic water pump 1 through the vehicle controller, and adjusts the opening of four-way valve 2, four-way valve 1 and three-way valve to realize the use of motor waste heat to meet the liquid heat requirements of power battery.

[0019] Preferably, the motor waste heat-cabin heating-battery fluid heating circuit effectively utilizes the motor waste heat to simultaneously meet the heating needs of the cockpit and the power battery fluid by adjusting the opening of four-way valve two, four-way valve one, and three-way valve.

[0020] The beneficial effects of this invention are as follows:

[0021] 1. This invention relates to a comprehensive vehicle thermal management scheme and control method based on the utilization of motor waste heat. It realizes a multi-loop comprehensive vehicle thermal management system for light commercial vehicles based on the utilization of motor waste heat. The system is arranged on the entire chassis, is flexible in layout, and is applicable to multiple models of light commercial vehicles. It can meet the thermal management requirements of power battery capacity of 100-165kWh.

[0022] 2. The vehicle integrated thermal management scheme and control method based on the utilization of motor waste heat integrates the vehicle thermal management control into the vehicle controller VUC, eliminating the need for a separate thermal management controller and enabling flexible switching between multiple working modes of vehicle thermal management.

[0023] 3. This comprehensive vehicle thermal management scheme and control method based on the utilization of motor waste heat takes into account the needs of multiple modes such as DC ultra-fast charging and AC-DC integration, and realizes the system's universal design.

[0024] 4. The vehicle comprehensive thermal management scheme and control method based on the utilization of motor waste heat achieves flexible switching of the twelve major circuits of comprehensive vehicle thermal management through a dedicated control strategy, balances the vehicle's thermal management, realizes energy saving and consumption reduction, effectively utilizes motor waste heat, and improves winter driving range. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the overall process structure of a vehicle integrated thermal management scheme and control method based on the utilization of motor waste heat proposed in this invention.

[0026] In the diagram: 1. Compressor; 2. Condenser; 3. Electric Fan; 4. Three-State Pressure Switch; 5. Shut-off Valve; 6. Evaporator; 7. Gas-Liquid Separator; 8. Electric Water Pump 3; 9. WPTC; 10. Water Temperature Sensor 3; 11. Three-Way Valve; 12. Hot Water Tank; 13. Water Temperature Sensor 4; 14. Four-Way Valve 2; 15. Four-Way Valve 1; 16. Dual-Channel Integrated Chiller; 17. Water Temperature Sensor 1; 18. Power Battery; 19. Water Temperature Sensor 5; 20. Electric Water Pump 2; 21. PT Sensor; 22. Electric Water Pump 1; 23. All-in-One Controller; 24. Drive Motor; 25. Water Temperature Sensor 2; 26. Straight-through Valve; 27. OBC; 28. Expansion Tank 1; 29. ​​Expansion Tank 2. Detailed Implementation

[0027] Reference Figure 1 A comprehensive vehicle thermal management scheme and control method based on the utilization of motor waste heat includes a dual-channel integrated chiller 16, an electronic expansion valve, a high-temperature coolant-low-temperature coolant heat exchanger, a low-temperature coolant-refrigerant heat exchanger, an expansion tank 1 28, and an expansion tank 29, which can realize liquid cooling and liquid heating of the power battery. It also includes separate driver's cabin cooling circuit, separate driver's cabin heating circuit, separate power battery liquid cooling circuit, separate power battery liquid heating circuit, separate drive motor and its controller cooling circuit, separate OBC cooling circuit, driver's cabin cooling-battery liquid cooling circuit, driver's cabin heating-battery liquid heating circuit, driver's cabin heating-battery liquid cooling circuit, motor waste heat-driver's cabin heating circuit, motor waste heat-power battery liquid heating circuit, and motor waste heat-driver's cabin heating-battery liquid heating circuit.

[0028] Furthermore, the separate cockpit cooling circuit includes a compressor 1, a condenser 2, an electric fan 3, a three-state pressure switch 4, a shut-off valve 5, an evaporator 6, and a gas-liquid separator 7 connected in sequence via pipelines. The blower is turned on to cool the cockpit.

[0029] Furthermore, the separate cockpit heating circuit includes an electronic water pump 38, WPTC9, water temperature sensor 310, three-way valve 11, heater tank 12, water temperature sensor 413, four-way valve 214, and four-way valve 15 connected in sequence via pipelines. The vehicle controller detects the water temperature, controls the electronic water pump 38 and WPTC9, and achieves cockpit heating by adjusting the opening of three-way valve 11, four-way valve 15, and four-way valve 214.

[0030] Furthermore, the separate power battery liquid cooling circuit includes two parts: one is the coolant side connected in sequence through pipelines to a dual-channel integrated chiller 16, water temperature sensor 17, power battery 18, water temperature sensor 5 19, and electronic water pump 20.

[0031] Secondly, the refrigerant side is connected in sequence to the compressor 1, condenser 2, electric fan 3, three-state pressure switch 4, dual-channel integrated chiller 16, and PT sensor 21 through pipelines to achieve liquid cooling of the power battery.

[0032] Furthermore, the separate power battery liquid thermal circuit includes two parts: one is the high-temperature coolant side connected in sequence by pipelines to the following components: electronic water pump 38, WPTC9, water temperature sensor 310, three-way valve 11, dual-channel integrated chiller 16, water temperature sensor 413, four-way valve 214, and four-way valve 15.

[0033] Secondly, the low-temperature coolant side is connected in sequence through pipelines to a dual-channel integrated chiller 16, a water temperature sensor 17, a power battery 18, a water temperature sensor 5 19, and an electronic water pump 20 to achieve liquid cooling of the power battery.

[0034] Furthermore, the cooling circuit for the individual drive motor and its controller includes a heat sink, an electric fan 3, a four-way valve 2 14, an electric water pump 1 22, a multi-function controller 23, a drive motor 24, a water temperature sensor 2 25, and a four-way valve 15 connected in sequence through pipes to achieve cooling of the drive motor and its controller.

[0035] Furthermore, the separate OBC cooling circuit includes a radiator 21, an electric fan 3, a four-way valve 2 14, an electric water pump 1 22, a straight-through valve 26, and an OBC 27 connected in sequence via pipes. When the vehicle requires AC slow charging, the electric fan 3 and the electric water pump 1 22 are controlled by the vehicle controller to adjust the opening of the four-way valve 2 14, the four-way valve 1 15, and the straight-through valve 26 to achieve OBC 27 cooling.

[0036] Furthermore, the cockpit cooling-battery liquid cooling circuit means that when both the cockpit and the power battery have cooling needs, the electric compressor 1, electric fan 3, and electric water pump 20 are turned on sequentially through the vehicle controller to achieve dual cooling of the cockpit and the battery.

[0037] The cockpit heating-battery liquid cooling circuit is designed to achieve dual heating of the cockpit and battery liquid cooling when both the cockpit and the power battery have heating needs. This is achieved by sequentially activating electronic water pump 20, WPTC9, and electronic water pump 38 through the vehicle controller, while adjusting the opening of the three-way valve 11 according to a certain strategy.

[0038] Furthermore, the cockpit heating-battery liquid cooling circuit means that when there is a heating requirement in the cockpit and a cooling requirement in the power battery, the separate battery liquid cooling circuit and the separate cockpit heating circuit are connected simultaneously to achieve cockpit heating and battery liquid cooling.

[0039] The motor waste heat-cabin heating circuit package controls electronic water pump 20 and electronic water pump 12 through the vehicle controller, and adjusts the opening of four-way valve 214, four-way valve 15 and three-way valve 11 to meet the heating needs of the cockpit by utilizing the motor waste heat.

[0040] The motor waste heat-power battery liquid heat circuit controls electronic water pump 20 and electronic water pump 22 through the vehicle controller, and adjusts the opening of four-way valve 214, four-way valve 15 and three-way valve 11 to meet the liquid heat requirements of the power battery by utilizing the motor waste heat.

[0041] Furthermore, the motor waste heat-cabin heating-battery fluid heat circuit effectively utilizes the motor waste heat to simultaneously meet the heating needs of the cockpit and the power battery fluid by adjusting the opening of four-way valve 2 14, four-way valve 15, and three-way valve 11.

[0042] Among them, expansion tank 1 28 provides water replenishment for the motor and heating circuit, and expansion tank 2 29 provides water replenishment for the battery circuit.

[0043] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical system and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A comprehensive vehicle thermal management scheme and control method based on the utilization of motor waste heat, comprising a dual-channel integrated chiller (16), an electronic expansion valve, a high-temperature coolant-low-temperature coolant heat exchanger, a low-temperature coolant-refrigerant heat exchanger, an expansion tank one (28), and an expansion tank two (29), which can realize liquid cooling and liquid heating of the power battery, characterized in that, It also includes separate cockpit cooling circuit, separate cockpit heating circuit, separate power battery liquid cooling circuit, separate power battery liquid heating circuit, separate drive motor and its controller cooling circuit, separate OBC cooling circuit, cockpit cooling-battery liquid cooling circuit, cockpit heating-battery liquid heating circuit, cockpit heating-battery liquid cooling circuit, motor waste heat-cockpit heating circuit, motor waste heat-power battery liquid heating circuit, and motor waste heat-cockpit heating-battery liquid heating circuit.

2. The comprehensive vehicle thermal management scheme and control method based on motor waste heat utilization according to claim 1, characterized in that, The separate cockpit cooling circuit includes a compressor (1), a condenser (2), an electric fan (3), a three-state pressure switch (4), a shut-off valve (5), an evaporator (6), and a gas-liquid separator (7) connected in sequence through pipelines. The blower is turned on to cool the cockpit.

3. The comprehensive vehicle thermal management scheme and control method based on motor waste heat utilization according to claim 2, characterized in that, The separate cockpit heating circuit includes an electronic water pump three (8), a WPTC (9), a water temperature sensor three (10), a three-way valve (11), a heater tank (12), a water temperature sensor four (13), a four-way valve two (14), and a four-way valve one (15) connected in sequence by pipelines. The vehicle controller detects the water temperature, controls the electronic water pump three (8) and the WPTC (9), and achieves cockpit heating by adjusting the opening of the three-way valve (11), the four-way valve one (15), and the four-way valve two (14).

4. The comprehensive vehicle thermal management scheme and control method based on motor waste heat utilization according to claim 1, characterized in that, The separate power battery liquid cooling circuit includes two parts: one is the coolant side connected in sequence through pipelines to a dual-channel integrated chiller (16), water temperature sensor one (17), power battery (18), water temperature sensor five (19), and electronic water pump two (20); Secondly, the refrigerant side is connected in sequence to the compressor (1), condenser (2), electric fan (3), three-state pressure switch (4), dual-channel integrated chiller (16), and PT sensor (21) through pipelines to achieve liquid cooling of the power battery.

5. The comprehensive vehicle thermal management scheme and control method based on motor waste heat utilization according to claim 4, characterized in that, The separate power battery liquid thermal circuit includes two parts: one is the high temperature coolant side connected in sequence by pipelines to the electronic water pump three (8), WPTC (9), water temperature sensor three (10), three-way valve (11), dual-channel integrated chiller (16), water temperature sensor four (13), four-way valve two (14), and four-way valve one (15). Secondly, the low-temperature coolant side is connected in sequence through pipelines to a dual-channel integrated chiller (16), water temperature sensor one (17), power battery (18), water temperature sensor five (19), and electronic water pump two (20) to achieve liquid cooling of the power battery.

6. The comprehensive vehicle thermal management scheme and control method based on motor waste heat utilization according to claim 1, characterized in that, The cooling circuit of the individual drive motor and its controller includes a heat sink, an electric fan (3), a four-way valve (14), an electric water pump (22), a multi-function controller (23), a drive motor (24), a water temperature sensor (25), and a four-way valve (15) connected in sequence through pipes to achieve cooling of the drive motor and its controller.

7. The comprehensive vehicle thermal management scheme and control method based on motor waste heat utilization according to claim 1, characterized in that, The separate OBC cooling circuit includes a radiator (21), an electric fan (3), a four-way valve (14), an electric water pump (22), a straight-through valve (26), and an OBC (27) connected in sequence through pipes. When the vehicle needs AC slow charging, the electric fan (3) and the electric water pump (22) are controlled by the vehicle controller, and the opening of the four-way valve (14), the four-way valve (15), and the straight-through valve (26) are adjusted to achieve OBC (27) cooling.

8. The comprehensive vehicle thermal management scheme and control method based on motor waste heat utilization according to claim 1, characterized in that, The cockpit cooling-battery liquid cooling circuit is that when the cockpit and the power battery have cooling needs at the same time, the electric compressor (1), electric fan (3) and electric water pump II (20) are turned on in sequence through the vehicle controller to achieve dual cooling of the cockpit and battery liquid cooling. The cockpit heating-battery liquid heating circuit is that when the cockpit and the power battery have heating needs at the same time, the vehicle controller sequentially turns on the electronic water pump two (20), WPTC (9), and electronic water pump three (8), and at the same time adjusts the opening of the three-way valve (11) according to a certain strategy to achieve dual heating of cockpit cooling and battery liquid cooling.

9. The comprehensive vehicle thermal management scheme and control method based on motor waste heat utilization according to claim 1, characterized in that, The cockpit heating-battery liquid cooling circuit means that when the cockpit needs heating and the power battery needs cooling, the separate battery liquid cooling circuit and the separate cockpit heating circuit are connected simultaneously to achieve cockpit heating and battery liquid cooling. The motor waste heat-cabin heating circuit package controls the electronic water pump two (20) and electronic water pump one (22) through the vehicle controller, and adjusts the opening of four-way valve two (14), four-way valve one (15) and three-way valve (11) to meet the heating needs of the cockpit by utilizing the motor waste heat. The motor waste heat-power battery liquid heat circuit controls the electronic water pump two (20) and electronic water pump one (22) through the vehicle controller, and adjusts the opening of four-way valve two (14), four-way valve one (15) and three-way valve (11) to realize the use of motor waste heat to meet the liquid heat demand of power battery.

10. The comprehensive vehicle thermal management scheme and control method based on motor waste heat utilization according to claim 1, characterized in that, The motor waste heat-cabin heating-battery liquid heat circuit effectively utilizes the motor waste heat to simultaneously meet the heating needs of the cockpit and the power battery liquid by adjusting the opening of four-way valve two (14), four-way valve one (15), and three-way valve (11).

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