Simulation analysis method of high-power charging gun based on liquid cooling pipeline

Abstract

The invention relates to a simulation analysis method for a high-power charging gun based on a liquid cooling pipeline, and belongs to the technical field of high-power liquid cooling gun system simulation, and the method comprises the steps: obtaining a simulation instruction triggered by a detector, and constructing a charging gun three-dimensional model with a liquid cooling structure; importing the three-dimensional model of the charging gun into a preset simulation platform, and defining physical characteristics of different parts of the three-dimensional model of the charging gun; wherein the physical attributes at least comprise material attributes; dividing grids for the surface of the three-dimensional model of the charging gun, and constructing a coupled physical field of a current field and a solid heat transfer field for the three-dimensional model of the charging gun; and carrying out simulation solving through the simulation platform to obtain a simulation result, and outputting the temperature distribution condition and the current density distribution condition of the surface of the three-dimensional model of the charging gun based on the simulation result and a preset visual form for detection personnel to know. The method has the effect of efficiently evaluating the temperature rise influence of the liquid cooling measures on the high-power charging gun.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of simulation of high-power liquid-cooled gun systems, in particular to a simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline. BACKGROUND

[0002] With the promotion of clean energy worldwide, the new energy industry (including electric vehicles, lithium batteries, photovoltaics, and energy storage) has gradually become a pillar industry for China's development, and the future development space is huge. As the charging technology of electric vehicles, the connector is an important part, and its performance determines the charging efficiency of electric vehicles.

[0003] Currently, there is no clear definition of high-power charging technology, and the new energy industry generally believes that the characteristics of high-power charging technology are high voltage, large current, and output power exceeding 350kW. When the charging system carries a high current of 200A or more, the thermal effect of the current per unit time will increase exponentially, and the temperature rise of the charging system will be very obvious. If the heat dissipation is not good, it may cause a major safety accident. To meet the use requirements of the charging connector, the temperature during the charging process must be cooled to more than 90℃. The current mature cooling scheme is to set a liquid cooling pipeline inside the high-power charging connector cable, use low-temperature liquid to flow through the cooling pipeline, and then use the cooling pipeline to contact the heating components to achieve heat exchange and reduce the temperature of the heating components.

[0004] However, at present, the cooling effect test of the liquid cooling technology on the high-power charging gun still stays in the artificial test stage. The method of using artificial multiple tests to determine the influence of cooling liquid flow rate, flow, and other variables on the temperature rise control of the high-power charging connector is time-consuming and labor-intensive, and therefore needs to be improved. SUMMARY

[0005] In order to efficiently evaluate the influence of liquid cooling measures on the temperature rise of the high-power charging gun, the present application provides a simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline.

[0006] In a first aspect, the present application provides a simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline, comprising: obtaining a simulation instruction triggered by a detection personnel, and constructing a three-dimensional model of a charging gun with a liquid cooling structure; importing the three-dimensional model of the charging gun into a preset simulation platform, and defining physical properties of different parts of the three-dimensional model of the charging gun; wherein the physical properties at least include material properties; dividing a grid for the surface of the three-dimensional model of the charging gun, and constructing a coupled physical field of a current field and a solid heat transfer field for the three-dimensional model of the charging gun; The simulation result is obtained by simulation solving through the simulation platform, and based on the simulation result and a preset visual form, a temperature distribution and a current density distribution of a surface of the three-dimensional model of the charging gun are output for a detection personnel to know.

[0007] By adopting the technical solution, the three-dimensional model of the charging gun with the liquid cooling structure is constructed, is imported into a preset simulation platform, and a systematic multi-physical field coupling simulation process is used to solve the precision and efficiency of the thermal design of the liquid cooling system of the high-power charging gun, and to realize efficient analysis of the influence of the liquid cooling measure on the temperature rise of the high-power charging gun.

[0008] Optionally, the method further comprises: extracting and analyzing a temperature gradient and a current density value of each grid element in real time according to the simulation result, and determining whether there is a sensitive grid element that needs to adjust the size of the grid element; if there is a sensitive grid element, adjusting the size of the sensitive grid element according to a preset adjustment strategy; updating the simulation result by solving through the simulation platform based on the adjusted grid.

[0009] By adopting the technical solution, the traditional static grid cannot adapt to the local high gradient change in the multi-physical field coupling, which leads to waste of computing resources or insufficient precision. To this end, the application proposes to realize adaptive grid size adjustment based on the temperature gradient and the current density value (such as realizing local grid encryption by reducing the grid size, and realizing grid sparsification by increasing the grid size), to realize field variable feedback driving local grid size adjustment, and to solve the contradiction between precision and efficiency in multi-physical field simulation.

[0010] Optionally, the extracting and analyzing the temperature gradient and the current density value of each grid element, and determining whether there is a sensitive grid element that needs to adjust the size of the grid element, comprises: extracting a temperature gradient T and a current density value J of each grid element, and generating a fusion criterion value through a preset coupling weight function; wherein the coupling weight function includes preset coupling weight factors of the temperature gradient and the current density, and the coupling weight function includes a temperature gradient term, a current density term, and a product synergy term of the two; dividing a grid encryption level according to the fusion criterion value, and determining the sensitive grid element according to the grid encryption level.

[0011] By adopting the technical solution, the coupling weight factors of the temperature gradient and the current density are pre-constructed to reflect the demand of the synergy effect of the two on the grid precision, the grid encryption priority is automatically allocated according to the coupling weight, the concretization of a single criterion is avoided, the precision advantage of the criterion is verified through multi-physical field simulation, and finally the synergy of multi-physical field simulation precision and efficiency is realized.

[0012] Optionally, the liquid cooling structure comprises a liquid cooling pipeline, and the method further comprises: According to the simulation result, temperature gradient data of all the grids are analyzed and clustered, and the liquid cooling pipeline is divided into a plurality of liquid cooling pipe sections, and a controllable valve is configured for each liquid cooling pipe section; A high-temperature liquid cooling pipe section is identified, and a local booster pump is configured for each high-temperature liquid cooling pipe section; According to the temperature gradient data of each liquid cooling pipe section and a preset mapping relationship between temperature and valve opening degree, the opening degree of the controllable valve of each liquid cooling pipe section is determined; A liquid cooling pipeline design scheme is outputted for detection personnel to know; wherein the liquid cooling pipeline design scheme comprises the segmentation of all the liquid cooling pipe sections included in the liquid cooling pipeline, and the controllable valve and the opening degree of the controllable valve required for each liquid cooling pipe section, and the high-temperature liquid cooling pipe section and the corresponding local booster pump thereof.

[0013] By adopting the above technical solution, the temperature gradient data is analyzed and clustered based on the temperature distribution, and the liquid cooling pipeline is divided into a plurality of liquid cooling pipe sections, and a controllable valve for adjusting the flow rate of the cooling liquid in the corresponding liquid cooling pipe section is configured for each liquid cooling pipe section, and a local booster pump is further configured for the high-temperature liquid cooling pipe section, thereby providing a design scheme of the liquid cooling pipeline for the detection personnel, and optimizing the cooling effect of the charging gun at different positions by adjusting the flow rate of the cooling liquid.

[0014] Optionally, the method further comprises: According to the liquid cooling pipeline design scheme, controllable valves and local booster pumps are added in the three-dimensional model of the charging gun, and a coupling physical field of instantaneous fluid field and thermal field is constructed; The opening degree of all the controllable valves and the pump pressure of the local booster pump are dynamically adjusted based on the real-time temperature field by a preset temperature feedback control algorithm; and the temperature change during the adjustment process is simulated and outputted by the simulation platform.

[0015] By adopting the above technical solution, the flow rate of the cooling liquid is further simulated and analyzed on the charging gun at different cooling and heat dissipation effects based on the liquid cooling pipeline design scheme after the controllable valves and the local booster pumps are added, so as to visualize the effectiveness of the liquid cooling pipeline design scheme.

[0016] Optionally, the opening degree of all the controllable valves and the pump pressure of the local booster pump are dynamically adjusted based on the real-time temperature field by a preset temperature feedback control algorithm, comprising: The temperature field change in the future period is predicted in real time based on a preset prediction model, and the opening degree of all the controllable valves and the pump pressure of the local booster pump are dynamically adjusted based on the prediction result by using a preset temperature feedback control algorithm.

[0017] By using the above technical solutions, the temperature field change in the future period is predicted based on a preset prediction model, and the opening degree of the controllable valve and the pump pressure of the local booster pump are adjusted according to the prediction result by using a temperature feedback control algorithm, so that the responsiveness and timeliness of the valve opening and the pump pressure are realized.

[0018] Optionally, the method further comprises: Based on the simulation result, the temperature field is input as a thermal load into a preset thermal stress model to calculate stress. According to the maximum stress amplitude and a preset material stress and life corresponding relationship table, the fatigue degree of the three-dimensional model of the charging gun is evaluated and output.

[0019] By using the above technical solutions, the aging risk of the surface structure of the charging gun is quickly and efficiently evaluated through the correlation analysis of the temperature and stress.

[0020] In a second aspect, the application provides a simulation analysis system for a high-power charging gun based on a liquid cooling pipeline, comprising: a three-dimensional model construction module, configured to obtain a simulation instruction triggered by a detection personnel, and construct a three-dimensional model of a charging gun with a liquid cooling structure; A physical property definition module is configured to import the three-dimensional model of the charging gun into a preset simulation platform, and define the physical properties of different parts of the three-dimensional model of the charging gun; wherein the physical properties at least include material properties; A coupled physical field construction module is configured to divide a grid for the surface of the three-dimensional model of the charging gun, and construct a coupled physical field of a current field and a solid heat transfer field for the three-dimensional model of the charging gun; A simulation result solving and outputting module is configured to obtain a simulation result by simulating and solving through the simulation platform, and output the temperature distribution and the current density distribution of the surface of the three-dimensional model of the charging gun based on the simulation result and a preset visual form, so as to be known by the detection personnel.

[0021] In a third aspect, the application provides a simulation analysis device for a high-power charging gun based on a liquid cooling pipeline, comprising a memory and a processor, and the memory stores a computer program capable of being loaded and executed by the processor and performing the method of any one of the first aspect.

[0022] In a fourth aspect, the application provides a computer readable storage medium, which stores a computer program capable of being loaded and executed by a processor and performing the method of any one of the first aspect.

[0023] In summary, the present application includes the following beneficial technical effects: The present application solves the precision and efficiency problems of the thermal design of the liquid cooling system of the high-power charging gun by constructing a three-dimensional model of the charging gun with a liquid cooling structure, importing it into a preset simulation platform, and then through a systematic multi-physical field coupling simulation process, realizes efficient analysis of the influence of the liquid cooling measures on the temperature rise of the high-power charging gun. BRIEF DESCRIPTION OF DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0025] Figure 1 is a simulation analysis method flowchart of the high-power charging gun based on the liquid cooling pipeline disclosed by the embodiments of the present application.

[0026] Figure 2 is a structural block diagram of the simulation analysis system of the high-power charging gun based on the liquid cooling pipeline disclosed by the embodiments of the present application.

[0027] Explanation of reference signs: 201, three-dimensional model construction module; 202, physical property definition module; 203, coupled physical field construction module; 204, simulation result solving output module. DETAILED DESCRIPTION

[0028] The following will be described in combination with the drawings Figures 1-2 The present application will be further described in detail.

[0029] The embodiments of the present application disclose a simulation analysis method of a high-power charging gun based on a liquid cooling pipeline (hereinafter referred to as a simulation analysis method), and the execution subject is a simulation analysis system of a high-power charging gun based on a liquid cooling pipeline (hereinafter referred to as a simulation analysis system). The following will be described in combination with the drawings Figure 1 The execution process of the simulation analysis system on the simulation analysis method will be specifically described.

[0030] S101, obtaining a simulation instruction triggered by a detection personnel, constructing a three-dimensional model of a charging gun with a liquid cooling structure; S102, importing the three-dimensional model of the charging gun into a preset simulation platform, defining the physical properties of different parts of the three-dimensional model of the charging gun; wherein the physical properties at least include material properties; S103, dividing the surface of the three-dimensional model of the charging gun into a grid, and constructing a coupled physical field of the current field and the solid heat transfer field for the three-dimensional model of the charging gun; S104, a simulation result is obtained by simulating through the simulation platform, and based on the simulation result and a preset visual form, a temperature distribution and a current density distribution of a surface of a three-dimensional model of the charging gun are outputted for a detection personnel to know.

[0031] In implementation, a three-dimensional model of a large-power charging gun with a liquid cooling system (i.e., a large-power liquid cooling gun) is constructed through a three-dimensional modeling software (such as SolidWorks, CATIA), and the three-dimensional model contains key components such as a liquid cooling pipeline, a copper rod, a joint, and a contact terminal. Then, the three-dimensional model is imported into a simulation platform (such as COMSOL, ANSYS), the model is combined in a formed assembly manner, and continuity between contact surfaces is created in a "consistent pair" type definition, so as to eliminate the influence of geometric interference or a small gap on simulation accuracy. Simplification is performed on non-key features such as threads and chamfers, so as to avoid distortion units caused by geometric complexity during mesh division.

[0032] Material parameters are assigned to each part in the model, wherein the pipeline joint is made of 304L stainless steel, and based on the material characteristics, low thermal conductivity parameters (such as 16 W / m·K) and high resistivity parameters (such as 7.2 x 10 -7 Ω·m) are set for the pipeline joint; the contact terminal is made of T2 red copper, and high thermal conductivity parameters (such as 5.8 x 10 7 S / m) are set for the contact terminal, so as to ensure that the Joule heat can be quantified when the current is concentrated; the inlet and outlet cooling liquid pipelines are made of modified nylon material, and low thermal expansion coefficients (such as 8 x 10 -5 K -1 ) are correspondingly set, so as to avoid structural deformation when the fluid circulates.

[0033] Then, a Joule heat physical field, i.e., a coupled physical field of a current field and a solid heat transfer field, is added, wherein in the current field, a current source parameter (such as 500 A) is applied to an input end of the current, and a grounding state is applied to an output end of the terminal, so that the liquid cooling system forms a closed current loop, and the current density distribution is calculated through Ohm's law (J = σE). In the solid heat transfer field, the current field result is taken as a heat source based on the Joule heat formula (Q = J 2 / σ), and a convection boundary condition (q = h (T - T0), wherein q refers to a heat flux, i.e., a convection heat transfer amount per unit area; h is a convection heat transfer coefficient, reflecting the cooling capacity of the fluid to the surface of the solid, and is related to the fluid properties (such as flow rate and viscosity) and surface roughness; T is the surface temperature of the solid, and T0 is a constant value, i.e., the fluid environment temperature (such as the cooling liquid inlet temperature or the environment temperature)), so as to simulate the heat exchange between the liquid cooling pipeline and the cooling liquid; and the Joule heat power generated by the current field is automatically mapped to the heat source term of the heat field through a preset coupling interface.

[0034] Then, a physical field control network (such as a boundary layer to refine the current concentration region) is adopted, and a free tetrahedral mesh is adapted to the complex geometry. The element quality is estimated by the Jacobian matrix.

[0035] Finally, simulations are performed to calculate the temperature distribution under steady-state and transient conditions by solving the Poisson equation. and heat balance equation The coupled solution is used to evaluate the steady-state temperature field. A time term (from the transient heat conduction equation, representing the rate of change of heat energy per unit volume with time) is introduced, and a time step (e.g., 0.1 s) is set to study the temperature distribution at different times. The coupled solver is selected, the multiphysics interface (current field and solid heat transfer field) is checked, the convergence tolerance is set, and adaptive step size (transient analysis) is enabled. If convergence fails, the initial value is adjusted, the tolerance is increased, and a damping term is added. Finally, the converged numerical solution file (containing field variables such as temperature and current density for each part) is output. It should be noted that by relaxing the shadow or residual threshold (e.g., 1e...),... -6 To improve convergence, an artificial diffusion term is added to suppress numerical oscillations. This is a dynamic tolerance adjustment algorithm based on residual history, which automatically increases tolerance during the oscillation phase.

[0036] The surface temperature and current density distribution of the charging gun are output based on a preset visualization format, such as a temperature trend cloud map to represent the temperature distribution and a current density surface cloud map / potential trend map to represent the current density distribution. Hot spots (such as terminal contact surfaces) are located by temperature cloud map, and the current congestion effect is analyzed by combining the current density cloud map.

[0037] Optionally, the simulation analysis method may also include the following steps: S301 extracts and analyzes the temperature gradient and current density values ​​of each grid cell in real time based on the simulation results, and determines whether there are sensitive grid cells that need to be adjusted in size. S302, if sensitive grid cells exist, adjust the size of the sensitive grid cells according to the preset adjustment strategy; S303 updates the simulation results by solving the adjusted mesh through a simulation platform.

[0038] Specifically, S301's "extracting and analyzing the temperature gradient and current density values ​​of each grid cell, and determining whether there are sensitive grid cells that require adjustment of grid cell size" further includes the following steps: Extract the temperature gradient T and current density J of each grid cell, and generate a fusion criterion value through a preset coupling weight function; wherein, the coupling weight function contains preset coupling weight factors for temperature gradient and current density, and the coupling weight function includes temperature gradient term, current density term and their product co-term. According to the fusion criterion value, the grid encryption level is divided, and the sensitive grid unit is determined according to the grid encryption level.

[0039] In the implementation, the calculation formula of the coupling weight function is as follows: Wherein, ω1, ω2 are respectively preset coupling weight factors of temperature gradient and current density, T is the temperature gradient obtained by the current extraction, J is the current density value obtained by the current extraction, T' and J' are respectively preset temperature gradient reference value (different according to different material properties corresponding to different grids, set by material thermal expansion coefficient, exceeding this value may cause structural failure; such as 100℃ / mm) and current density reference value (different according to different material properties corresponding to different grids, the current density reference value is the maximum safe current density allowed by the material, such as 1×10 6 A / m 2 ); ε is a preset synergistic effect coefficient (such as 0.3, and ω1+ω2+ε=1), n and m are nonlinear indexes (such as 1.5 and 1.2) A plurality of criterion intervals related to the fusion criterion value α are preset, and each criterion interval corresponds to an encryption level. When the encryption level is a specified encryption level, the corresponding grid is considered as a sensitive grid unit. Exemplarily, the adjustment strategy can include the following contents: Criterion interval 1: (α≥1), encryption level is first level, corresponding grid is sensitive grid unit, and the grid unit edge length needs to be reduced to 1 / 4 of the original size Criterion interval 2: (0.5≤α≤1), encryption level is second level, corresponding grid is sensitive grid unit, and the unit edge length is reduced to 1 / 2 of the original size Criterion interval 3: (α<0.2) encryption level is third level, corresponding grid is sensitive unit, and the unit edge length is enlarged to 2 times of the original size.

[0040] The adaptive adjustment of the grid size is realized by using the front advance method, according to the method of high to low encryption level (first level>second level>third level), the field variables (T, J) of the original grid are transmitted to the new grid through the shape function interpolation, and the simulation model continues to solve until convergence or next step transient analysis.

[0041] Optionally, the liquid cooling structure includes a liquid cooling pipeline, and the simulation analysis method further includes the following steps: According to the simulation results, the temperature gradient data of all grids are analyzed and clustered, and the liquid cooling pipeline is divided into a plurality of liquid cooling pipe sections, and a controllable valve is configured for each liquid cooling pipe section; High-temperature liquid cooling pipe sections are identified, and a local booster pump is configured for each high-temperature liquid cooling pipe section; According to the temperature gradient data of each liquid cooling pipe section and the preset mapping relationship between temperature and valve opening, the controllable valve opening of each liquid cooling pipe section is determined; The liquid cooling pipe design scheme is outputted for the detection personnel to know; wherein, the liquid cooling pipe design scheme includes the segmentation of all liquid cooling pipe sections included in the liquid cooling pipe, and the controllable valve and the opening of the controllable valve required for each liquid cooling pipe section, and the high-temperature liquid cooling pipe section and the corresponding local booster pump.

[0042] According to the liquid cooling pipe design scheme, controllable valves and local booster pumps are added in the three-dimensional model of the charging gun, and the coupling physical field of the instantaneous fluid field and the thermal field is constructed; Based on the preset prediction model, the temperature field change in the future period is predicted in real time, and through the preset temperature feedback control algorithm, the opening of all controllable valves and the pump pressure of the local booster pump are dynamically adjusted based on the prediction result; the temperature change in the adjustment process is simulated and outputted through the simulation platform.

[0043] In implementation, according to the temperature distribution finally obtained from the simulation result (i.e. the temperature gradient data of all grid elements on the surface of the high-power charging gun), the foregoing temperature gradient data is clustered, so that the corresponding grid is also clustered to form several groups, and the liquid cooling pipe is segmented to form several liquid cooling pipe sections according to the liquid cooling pipe corresponding to the physical position of the grid in each group. It can be seen that each liquid cooling pipe section corresponds to a temperature gradient data set, and the highest temperature in the corresponding temperature gradient data set can be used as the identification basis for identifying the high-temperature liquid cooling pipe section. For example, if the highest temperature is higher than the preset threshold, it is considered that the corresponding liquid cooling pipe section is a high-temperature liquid cooling pipe section.

[0044] The simulation analysis system is used to configure controllable valves for each liquid cooling pipe section, and local booster pumps for high-temperature liquid cooling pipe sections, so as to generate a liquid cooling pipe design scheme, which provides a design idea for the detection personnel. It needs to be noted that, considering that the installation space of the booster pump is limited due to the structure of the charging gun in actual use, the booster pump can be directly used in an external manner to set the booster pump on the side of the charging pile, and the booster pump is connected with the liquid cooling pipe of the charging gun through a high-pressure quick connector, or a flat pump (such as a micro diaphragm pump) is embedded in the side wall of the charging gun body. It needs to be noted that, when the booster pump is connected with the liquid cooling pipe, it is only connected with the high-temperature liquid cooling pipe section to pressurize the high-temperature liquid cooling pipe section, so as to ensure that the flow of the cooling liquid in the high-temperature liquid cooling pipe section is sufficient.

[0045] Further, the simulation analysis system is also used for perfecting the three-dimensional model of the charging gun according to the foregoing liquid cooling pipeline design scheme, that is, segmenting the liquid cooling pipeline structure in the three-dimensional model of the charging gun, adding 3D models of the valve and the booster pump on each liquid cooling pipe segment, and performing mesh encryption processing at the controllable valve and the pump interface of the local booster pump, so as to reserve the mesh deformation capability (which can be based on the Remeshing method in ANSYS) for subsequent valve opening degree change.

[0046] Then, a fluid field (instantaneous incompressible flow, K-ε turbulent flow model (Realizable k-ε)) and a thermal field (energy equation and fluid-solid conjugate heat transfer (conjugate heat transfer between the cooling liquid and the liquid cooling pipe wall), wherein the fluid and the liquid cooling pipeline wall interface satisfy the temperature and heat flux continuity conditions) are established, and the dynamic response of the valve and the pump is simulated through UDF / COMSOL built-in functions.

[0047] The specific logic of the temperature feedback control algorithm is inserted in the transient solver, such as increasing the opening degree when the temperature is greater than a first threshold value, decreasing the opening degree when the temperature is less than a second threshold value, adjusting the valve opening degree of the corresponding controllable valve when the temperature difference between the high-temperature liquid cooling pipe segment and the adjacent liquid cooling pipe segment exceeds a preset first temperature difference and is less than a second temperature difference, and triggering the start of the corresponding local booster pump when the temperature difference between the high-temperature liquid cooling pipe segment and the adjacent liquid cooling pipe segment exceeds a preset second temperature difference, so as to ensure that the cooling liquid flow of the high-temperature liquid cooling pipe segment is sufficient; the transient simulation is performed through the simulation platform, and the curve (i.e., the temperature change during the adjustment process) of the temperature change with the valve opening degree and the booster pump pressure is output. The prediction model includes a short-time prediction model (such as <10 seconds): ARIMA time series model and a long-time prediction model (such as >10 seconds): LSTM neural network, by inputting the historical temperature data into the prediction model, so as to output the temperature field change curve in the future period, and taking the prediction result (i.e., the temperature field change curve) as the input of the temperature feedback control algorithm, so that the temperature feedback control algorithm outputs the opening degree of the controllable valve and the pump pressure of the local booster pump.

[0048] Optionally, the simulation analysis method further includes the following steps: Based on the simulation result, the temperature field is taken as a thermal load to input a preset thermal stress model, and the stress is calculated; According to the maximum stress amplitude and a preset material stress and life corresponding relationship table, the fatigue degree of the three-dimensional model of the charging gun is evaluated and output.

[0049] In implementation, the simulation analysis system is used to output the temperature distribution based on the simulation result, and to obtain the thermal stress distribution by ANSYS analysis, such as outputting the thermal strain nephogram, reading the maximum alternating stress amplitude Δσ (such as Δσ = 80 MPa at the terminal) from the thermal strain nephogram, and outputting the fatigue life (i.e. the fatigue degree mentioned above) according to the material S-N curve table (i.e. the material stress and life table) in a table lookup manner.

[0050] The embodiment of the application further discloses a simulation analysis system of a high-power charging gun based on a liquid cooling pipeline. Figure 2 , comprising: A three-dimensional model construction module 201 is configured to acquire a simulation instruction triggered by a detection personnel, and construct a three-dimensional model of a charging gun with a liquid cooling structure. A physical property definition module 202 is configured to import the three-dimensional model of the charging gun into a preset simulation platform, and define physical properties of different parts of the three-dimensional model of the charging gun; wherein the physical properties at least include material properties. A coupled physical field construction module 203 is configured to divide a grid for a surface of the three-dimensional model of the charging gun, and construct a coupled physical field of a current field and a solid heat transfer field for the three-dimensional model of the charging gun. A simulation result solving and outputting module 204 is configured to obtain a simulation result by simulation solving through the simulation platform, and output a temperature distribution and a current density distribution of the surface of the three-dimensional model of the charging gun based on the simulation result and a preset visual form, so as to be known by the detection personnel.

[0051] Optionally, the adaptive grid adjustment module is further configured to extract and analyze a temperature gradient and a current density value of each grid unit according to the simulation result in real time, determine whether there is a sensitive grid unit that needs to adjust the size of the grid unit, adjust the size of the sensitive grid unit according to a preset adjustment strategy if there is a sensitive grid unit, and update the simulation result by solving through the simulation platform based on the adjusted grid.

[0052] Optionally, the adaptive grid adjustment module is further configured to extract a temperature gradient T and a current density value J of each grid unit, generate a fusion criterion value through a preset coupling weight function; wherein the coupling weight function includes preset coupling weight factors of the temperature gradient and the current density, and the coupling weight function includes a temperature gradient term, a current density term and a product synergy term of the two; according to the fusion criterion value, divide a grid encryption level, and determine a sensitive grid unit according to the grid encryption level.

[0053] Optionally, the liquid cooling pipeline design module is further configured to analyze and cluster temperature gradient data of all the grids according to the simulation result, divide the liquid cooling pipeline into a plurality of liquid cooling pipe sections, and configure a controllable valve for each liquid cooling pipe section; identify a high-temperature liquid cooling pipe section and configure a local booster pump for each high-temperature liquid cooling pipe section; determine the opening degree of the controllable valve of each liquid cooling pipe section according to the temperature gradient data of each liquid cooling pipe section and a preset mapping relationship between temperature and valve opening degree; and output a liquid cooling pipeline design scheme for detection personnel to know, wherein the liquid cooling pipeline design scheme includes the segmentation of all liquid cooling pipe sections included in the liquid cooling pipeline, the controllable valve and the opening degree of the controllable valve required for each liquid cooling pipe section, and the high-temperature liquid cooling pipe section and the corresponding local booster pump.

[0054] Optionally, the liquid cooling pipeline design module is further configured to add controllable valves and local booster pumps in the charging gun three-dimensional model according to the liquid cooling pipeline design scheme, and construct a coupling physical field of transient fluid field and thermal field; dynamically adjust the opening degree of all the controllable valves and the pump pressure of the local booster pump based on real-time temperature field through a preset temperature feedback control algorithm; and simulate and output the temperature change during the adjustment process through the simulation platform.

[0055] Optionally, the liquid cooling pipeline design module is further configured to predict the temperature field change in a future period of time in real time based on a preset prediction model, and dynamically adjust the opening degree of all the controllable valves and the pump pressure of the local booster pump based on the prediction result through a preset temperature feedback control algorithm.

[0056] Optionally, the fatigue evaluation module is further configured to input the temperature field as a thermal load into a preset thermal stress model based on the simulation result to calculate stress, and evaluate and output the fatigue degree of the charging gun three-dimensional model according to the maximum stress amplitude and a preset material stress and life corresponding relationship table. The embodiment of the application further discloses a simulation analysis device for a high-power charging gun based on a liquid cooling pipeline, which comprises a memory and a processor, and the memory stores a computer program capable of being loaded and executed by the processor to execute the simulation analysis method for the high-power charging gun based on the liquid cooling pipeline.

[0057] The embodiment of the application further discloses a computer readable storage medium which stores a computer program capable of being loaded and executed by the processor to execute the simulation analysis method for the high-power charging gun based on the liquid cooling pipeline, and the computer readable storage medium includes, for example, a U disk, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, and various storage program codes.

[0058] It should be noted that the relational terms herein, such as first and second, and the like, are used solely to distinguish one from another entity or action without necessarily requiring or implying any such actual relationship or order between such entities or actions.

[0059] The above embodiments are merely used to illustrate the technical solutions of the present application, but not for limiting the scope of protection of the application. Obviously, the described embodiments are only part of the embodiments of the present application, but not all the embodiments. Based on these embodiments, all the other embodiments obtained by those of ordinary skill in the art without creative effort should belong to the scope of protection of the present application.

Claims

1. A simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline, characterized in that, include: Obtain simulation commands triggered by the testing personnel and construct a 3D model of the charging gun with a liquid cooling structure; The three-dimensional model of the charging gun is imported into a preset simulation platform, and the physical properties of different parts of the three-dimensional model of the charging gun are defined; wherein, the physical properties include at least material properties. Mesh the surface of the three-dimensional model of the charging gun, and construct a coupled physical field of current field and solid heat transfer field for the three-dimensional model of the charging gun. The simulation results are obtained by performing simulation on the simulation platform. Based on the simulation results and the preset visualization format, the temperature distribution and current density distribution on the surface of the three-dimensional model of the charging gun are output for the testing personnel to know.

2. The simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline according to claim 1, characterized in that, The method further includes: Based on the simulation results in real time, the temperature gradient and current density values ​​of each grid cell are extracted and analyzed to determine whether there are sensitive grid cells that need to be adjusted in size. If sensitive grid cells exist, the size of the sensitive grid cells is adjusted according to a preset adjustment strategy; Based on the adjusted mesh, the simulation results are solved and updated through the simulation platform.

3. The simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline according to claim 2, characterized in that, The step of extracting and analyzing the temperature gradient and current density values ​​of each grid cell to determine whether there are sensitive grid cells that require adjustment of their size includes: The temperature gradient T and current density J of each grid cell are extracted, and a fusion criterion value is generated through a preset coupling weight function. The coupling weight function includes preset coupling weight factors for temperature gradient and current density, and includes a temperature gradient term, a current density term, and a product co-term of the two. Based on the fusion criterion value, the mesh encryption level is divided, and the sensitive mesh cells are determined according to the mesh encryption level.

4. The simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline according to claim 1, characterized in that, The liquid cooling structure includes liquid cooling piping, and the method further includes: Based on the simulation results, the temperature gradient data of all grids are analyzed and clustered, and the liquid cooling pipeline is divided into several liquid cooling pipe segments. A controllable valve is configured for each liquid cooling pipe segment. High-temperature liquid cooling pipe sections were identified, and local booster pumps were configured for each high-temperature liquid cooling pipe section; Based on the temperature gradient data of each liquid cooling pipe section and the preset mapping relationship between temperature and valve opening, the controllable valve opening of each liquid cooling pipe section is determined. Output the liquid cooling pipeline design scheme for testing personnel to understand; wherein, the liquid cooling pipeline design scheme includes the segmentation of all liquid cooling pipe sections included in the liquid cooling pipeline, the controllable valves to be added for each liquid cooling pipe section and the opening degree of the controllable valves, as well as the high-temperature liquid cooling pipe section and its corresponding local booster pump.

5. The simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline according to claim 4, characterized in that, The method further includes: According to the liquid cooling pipeline design scheme, a controllable valve and a local booster pump are added to the three-dimensional model of the charging gun, and a coupled physical field of instantaneous fluid field and thermal field is constructed. The opening degree of all controllable valves and the pump pressure of the local booster pump are dynamically adjusted based on the real-time temperature field using a preset temperature feedback control algorithm; the temperature change during the adjustment process is simulated and output through the simulation platform.

6. The simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline according to claim 5, characterized in that, The method of dynamically adjusting the opening degree of all controllable valves and the pump pressure of the local booster pump based on the real-time temperature field using a preset temperature feedback control algorithm includes: Based on a preset prediction model, the temperature field changes in the future are predicted in real time. Through a preset temperature feedback control algorithm, the opening degree of all controllable valves and the pump pressure of the local booster pump are dynamically adjusted based on the prediction results.

7. The simulation analysis method for a high-power charging gun based on a liquid-cooled pipeline according to claim 1, characterized in that, The method further includes: Based on the simulation results, the temperature field is used as the thermal load input to the preset thermal stress model to calculate the stress. Based on the maximum stress amplitude and the preset material stress-life correspondence table, the fatigue level of the charging gun 3D model is evaluated and output.

8. A simulation analysis system for a high-power charging gun based on a liquid-cooled pipeline, characterized in that, include, The 3D model building module (201) is used to obtain the simulation instructions triggered by the inspector and build a 3D model of the charging gun with a liquid cooling structure. The physical property definition module (202) is used to import the three-dimensional model of the charging gun into a preset simulation platform and define the physical properties of different parts of the three-dimensional model of the charging gun; wherein, the physical properties include at least material properties; The coupled physical field construction module (203) is used to divide the surface of the three-dimensional model of the charging gun into a mesh and construct the coupled physical field of the current field and the solid heat transfer field for the three-dimensional model of the charging gun. The simulation result solution output module (204) is used to perform simulation solution through the simulation platform to obtain simulation results, and based on the simulation results and the preset visualization form, output the temperature distribution and current density distribution on the surface of the three-dimensional model of the charging gun for the testing personnel to know.

9. A simulation analysis device for a high-power charging gun based on a liquid-cooled pipeline, characterized in that, It includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer program is stored that can be loaded by a processor and executed as described in any one of claims 1 to 7.

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