Direct cooling unit temperature control system with fluorine pump and natural cooling function

Abstract

The invention relates to the technical field of energy storage direct current cabin temperature control, in particular to a direct cooling unit temperature control system with a fluorine pump and a natural cooling function, which comprises a compressor, a fluorine pump branch and a compressor loop are connected in parallel, and the other mode is that a single fluorine pump is arranged on the main inlet pipeline outside the battery cabin. The control device integrates the environment sensing module to collect outdoor temperature data and compressor operation state data, the mode decision module outputs an instruction based on a temperature threshold value, the execution control module controls the electromagnetic valve to be opened and closed, the cooling capacity transfer module switches a refrigerant flowing path, and a compression refrigeration mode or a fluorine pump natural cooling mode is achieved. By automatically closing the compressor and switching to a fluorine pump mode and a natural cooling mode depending on air convection heat exchange, the dynamic cooperative control module optimizes the switching process and maintains pressure balance, the number of interfaces and heat exchange links are reduced, and the energy efficiency and the system reliability are improved.

Description

Technical Field

[0001] This invention relates to the field of temperature control technology for energy storage DC compartments, and in particular to a temperature control system for a direct-cooling unit with a fluorine pump and natural cooling function. Background Technology

[0002] In the energy storage industry, the heat generated by battery system operation can lead to performance degradation and shortened lifespan, making efficient thermal management crucial. Direct-cooling units with refrigerant pumps and natural cooling capabilities are designed for this scenario. The refrigerant pump system achieves precise temperature regulation under low-temperature conditions by pumping refrigerant, reducing compressor usage and thus lowering energy consumption. The natural cooling function utilizes air convection to complete the cooling process directly when the external ambient temperature is suitable, requiring no additional power input. The structure optimizes the integration and deployment of equipment within limited spaces.

[0003] Existing direct-cooling unit temperature control systems suffer from the following technical pain points: Firstly, the control system lacks an intelligent switching mechanism in low-temperature environments, failing to automatically transition from compressor cooling mode to refrigerant pump or natural cooling mode based on ambient temperature changes, forcing the compressor to operate under unfavorable conditions. Secondly, due to the lack of integrated temperature adaptive algorithms in the control system, continuous compressor operation is unavoidable in cold-region battery energy storage applications when ambient temperatures are too low, leading to reduced refrigerant oil return efficiency and poor oil return. Simultaneously, liquid refrigerant entering the compression chamber poses a risk of liquid slugging. For example, in northern winter energy storage scenarios, the control system cannot dynamically shut down the compressor and start the parallel refrigerant pump system. When the compressor operates at low temperatures, oil circuit blockage or insufficient flow rate prevents complete refrigerant evaporation, causing liquid media to impact the cylinder and lead to mechanical failure, thereby reducing system stability and lifespan. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a temperature control system for direct-cooling units with a refrigerant pump and natural cooling function. This invention solves the technical problem that the lack of intelligent mode switching capability of the control system in low-temperature environments causes the compressor to run continuously, resulting in poor oil return and liquid slugging failures in energy storage applications in cold regions.

[0005] To solve the above-mentioned technical problems, the specific contents of the present invention are as follows: This invention provides a temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function, comprising: Compressors, electric valves, fans, liquid storage devices, refrigerant pumps, energy storage battery compartments, inlet pipes, outlet pipes, condensers, throttling devices, direct cooling two-stage inlet pipes, direct cooling two-stage outlet pipes, direct cooling three-stage inlet pipes, direct cooling three-stage outlet pipes, refrigerant heaters, and control devices; The compressor and refrigerant pump branch are connected in parallel to the compressor circuit; the temperature sensor group is deployed at the condenser outlet and the direct cooling secondary inlet pipe; The pressure sensor array is installed at the compressor exhaust port, intake port, and refrigerant pump chamber, respectively. The electromagnetic noise monitoring module is integrated into the battery management system of the energy storage battery compartment; The control device is connected to the temperature sensor group, pressure sensor group, electromagnetic noise monitoring module, compressor, fan, refrigerant heater, fluorine pump and electric valve via signal lines. The control device includes an environmental sensing module, a mode decision module, an execution control module, and a cold energy transfer module; The environmental sensing module collects outdoor temperature data, battery compartment temperature data, and compressor operating status data, and generates demand signals based on the battery compartment temperature data. When the battery compartment temperature exceeds the cooling set threshold, a cooling demand signal is output. When the battery compartment temperature is lower than the heating set threshold, a heating demand signal is output. The control device pre-stores a set of system threshold parameters, including: Cooling setting threshold: The upper limit of the battery compartment temperature that triggers the cooling demand signal; Heating setting threshold: The lower limit of the battery compartment temperature that triggers the heating demand signal; The trigger threshold for the refrigerant pump natural cooling mode is the upper limit of the outdoor temperature at which the refrigerant pump is switched to natural cooling mode. Compressor protection threshold: The lower limit of the battery compartment temperature that forces the compressor to shut down; Liquid slugging protection threshold: The lower limit of refrigerant return pressure that triggers liquid slugging protection; Energy efficiency optimization threshold: The lower limit of the power consumption difference for startup mode optimization; Noise safety threshold: Safety limits for the electromagnetic noise spectrum; The mode decision module receives data and demand signals from the environmental perception module, including cooling demand signals and heating demand signals. When there is a cooling demand signal and the outdoor temperature is lower than the set threshold, the refrigerant pump natural cooling mode command is output. When there is a cooling demand signal and the outdoor temperature is higher than the set threshold, output the compressor cooling mode command; When there is a heating demand, a heating mode command is output; The execution control module responds to the instructions output by the mode decision module and performs the following control actions: When responding to the refrigerant pump's natural cooling mode command: the compressor is turned off, while the refrigerant pump remains running; When responding to the compressor's cooling mode command: Start the compressor and keep the refrigerant pump running; When responding to the heating mode command: turn on the refrigerant heater, turn off the compressor, and keep the refrigerant pump running; The cold energy transfer module responds to the control actions of the execution control module and switches the refrigerant flow path: When responding to the natural cooling mode command of the refrigerant pump: the refrigerant flows through the condenser and the throttling device and then enters the direct cooling secondary inlet pipe, where the cooling capacity is transferred through air convection heat exchange. When responding to the compressor's cooling mode command: the refrigerant enters the direct cooling secondary inlet pipe after passing through the condenser; When responding to the heating mode command: the refrigerant is delivered to the direct cooling secondary inlet pipe via the refrigerant heater, heats the battery compartment, and then returns to the refrigerant pump.

[0006] Furthermore, in the temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function described in this invention, the mode decision module includes: The temperature determination unit receives the outdoor temperature data from the environmental sensing module, compares the outdoor temperature data with a preset threshold, and outputs the comparison result. The compressor protection unit receives the comparison results and the compressor operating status data collected by the environmental perception module. When the battery compartment temperature data is lower than the compressor protection threshold and the compressor operating status is "started", it outputs a compressor shutdown request to the mode decision module. The mode decision module responds to the compressor shutdown request, interrupts the current mode command, and outputs the refrigerant pump natural cooling mode command.

[0007] Furthermore, in the direct-cooling unit temperature control system with refrigerant pump and natural cooling function described in this invention, when the execution control module responds to the refrigerant pump natural cooling mode command, it opens the electric valve, maintains the refrigerant pump operation, and shuts off the compressor power.

[0008] Furthermore, in the direct-cooling unit temperature control system with refrigerant pump and natural cooling function described in this invention, the natural cooling mode of the refrigerant pump completes the natural cooling cycle in the following manner: The refrigerant pump runs continuously, and as the refrigerant flows through the condenser, the fan drives the air to exchange heat with the refrigerant through convection. After heat exchange, the refrigerant is depressurized by a throttling device and enters the direct-cooling secondary inlet pipe to cool the battery compartment.

[0009] Furthermore, in the temperature control system of the direct-cooling unit with refrigerant pump and natural cooling function described in this invention, the compressor protection unit is configured as follows: Receive refrigerant return gas pressure data provided by the pressure sensor group; When the return gas pressure data remains below the liquid hammer protection threshold for a set period of time, a liquid hammer protection command is output to the execution control module. The liquid hammer protection commands include: a command to cut off the compressor power supply and a command to activate the fault alarm.

[0010] Furthermore, in the temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function described in this invention, the environmental sensing module includes: Distributed temperature sensors are deployed on the inlet pipe of the direct cooling three-stage system, the outlet pipe of the direct cooling three-stage system, the compressor suction and exhaust ports, and the surface of the battery cluster to collect temperature data at the target locations. A pressure sensor array is installed at the compressor discharge port and the refrigerant pump chamber to collect refrigerant pressure data. Among them, temperature data and refrigerant pressure constitute the outdoor temperature data, battery compartment temperature data and compressor operating status data output by the environmental sensing module.

[0011] Furthermore, the temperature control system for the direct-cooling unit with fluorine pump and natural cooling function described in this invention also includes: The energy efficiency optimization module calculates the power consumption difference between the compressor cooling mode and the refrigerant pump natural cooling mode based on historical operating data. When the power consumption difference exceeds the energy efficiency optimization threshold, a mode optimization instruction is output to the mode decision module. The mode optimization instruction replaces the initial operation instruction generated by the mode decision module based on the ambient temperature. The mode optimization instruction is configured to: intercept the initial running instruction generated by the mode decision module based on the ambient temperature, and replace the intercepted initial running instruction with the optimized running instruction.

[0012] Furthermore, in the temperature control system of the direct-cooling unit with fluorine pump and natural cooling function described in this invention, the energy efficiency optimization module is configured as follows: Record the unit cooling capacity power consumption in the historical operating data collected by the environmental sensing module; Based on the recorded power consumption per unit of cooling capacity, a correction curve for the applicable temperature range of the natural cooling mode of the refrigerant pump is generated. Based on the generated correction curve, the natural cooling mode trigger threshold update command of the refrigerant pump is output to the mode decision module to update the natural cooling mode trigger threshold of the refrigerant pump in the mode decision module.

[0013] Furthermore, in the temperature control system of the direct cooling unit with fluorine pump and natural cooling function described in this invention, the control device further includes a dynamic collaborative control module; The electromagnetic noise monitoring module collects the electromagnetic noise spectrum of the fluorine pump and compressor drive circuit in real time. The control device inputs the noise spectrum data collected by the electromagnetic noise monitoring module into the dynamic collaborative control module; The dynamic collaborative control module performs the following operations based on noise spectrum data: During the operation of the fluorine pump, the PWM carrier phase of its drive circuit is dynamically adjusted; When the noise spectrum exceeds the noise safety threshold, a compressor shutdown protection command or a refrigerant pump speed reduction command is triggered.

[0014] Furthermore, in the temperature control system of the direct-cooling unit with refrigerant pump and natural cooling function described in this invention, the control device further includes a dynamic collaborative control module, and the system threshold parameter group further includes a pressure difference safety threshold, which is a limit value for the pressure difference between the compressor discharge pressure and the refrigerant pump chamber pressure. The dynamic collaborative control module includes: The mode switching feedback unit receives condenser outlet temperature data and battery cold plate temperature difference data from the environmental sensing module. When the outdoor temperature is lower than the trigger threshold of the refrigerant pump natural cooling mode, it controls the fan speed to increase to the turbulence critical value. After the temperature difference sensor confirms that the refrigerant subcooling meets the standard, it triggers the execution control module to execute the compressor shutdown action. The pump-valve linkage unit collects the pressure difference between the compressor discharge pressure and the refrigerant pump chamber pressure in real time. When the pressure difference exceeds the pressure difference safety threshold, the opening action of the electric valve is delayed, so that the movement trajectory of the electric valve core and the speed of the refrigerant pump are adjusted by negative feedback. The fault redirection unit cuts off the compressor power, adjusts the refrigerant pump to the preset safe speed, opens the electric valve to establish an emergency return path, and guides the refrigerant stagnant in the refrigerant pump chamber to the direct cooling stage 3 outlet pipe. The electromagnetic compatibility unit dynamically adjusts the PWM carrier phase of the pump drive circuit based on the noise spectrum fed back by the electromagnetic noise monitoring module during the operation of the fluorine pump. The energy efficiency optimization unit trains a load prediction model based on historical energy consumption data in the overlapping temperature range of the refrigerant pump natural cooling mode and the compressor cooling mode. When the battery heat generation is at a critical state, it allocates the proportion of parallel operation time of the two modes and controls the compressor to be used only to supplement the cooling capacity gap of the refrigerant pump natural cooling mode.

[0015] Beneficial effects of this invention; This invention utilizes a parallel structure between the refrigerant pump branch and the compressor circuit, combined with an intelligent control device, to automatically switch to refrigerant pump mode in low-temperature environments. This avoids forced compressor operation in cold conditions, eliminating lubrication failures caused by poor refrigerant oil return and liquid slugging mechanical failures caused by liquid refrigerant backflow. The dynamic collaborative control module, based on temperature and pressure data collected by the environmental sensing module, controls the fan speed to increase to the turbulence critical value, executes a nested sequence of actions—compressor shutdown and refrigerant pump operation—and establishes negative feedback regulation between the electric valve core movement trajectory and the refrigerant pump speed through the pump-valve linkage unit, maintaining system pressure balance and preventing high-pressure impacts from damaging components. The structural design of directly delivering refrigerant to the battery compartment cold plate eliminates the need for plate heat exchangers and refrigerant piping required for refrigerant circulation, reducing the number of interfaces, lowering the risk of refrigerant leakage, and shortening the heat conduction path to improve cooling efficiency. The direct-cooling secondary inlet, outlet, tertiary inlet, and outlet pipes maintain the original piping structure, but the flowing medium is changed from refrigerant to refrigerant. When the fault redirection unit detects system pressure imbalance or component jamming, it decouples the refrigerant pump's electromagnetic clutch and opens the electric valve to establish an emergency return path, continuously guiding the retained working fluid to ensure the system's continued safe operation. The energy efficiency optimization module dynamically adjusts the mode switching threshold based on historical energy consumption data, optimizing the synergistic efficiency of natural cooling and mechanical refrigeration, comprehensively achieving a dual improvement in equipment lifespan and energy consumption reduction. Attached Figure Description

[0016] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on the drawings without creative effort.

[0017] Figure 1 A schematic diagram of the independent arrangement scheme of the fluorine pump in the temperature control system of the direct cooling unit with fluorine pump and natural cooling function provided in the embodiment of the present invention.

[0018] Figure 2 A schematic diagram of the centralized arrangement scheme of the fluorine pump in the temperature control system of the direct cooling unit with fluorine pump and natural cooling function provided in the embodiment of the present invention.

[0019] Reference numerals: 1-Compressor, 2-Electric valve, 3-Fan, 4-Liquid storage device, 5-Freon pump, 6-Energy storage battery compartment, 7-Inlet pipe, 8-Outlet pipe, 9-Condenser, 10-Throttling device, 11-Direct cooling stage two inlet pipe, 12-Direct cooling stage two outlet pipe, 13-Direct cooling stage three inlet pipe, 14-Direct cooling stage three outlet pipe, 15-Refrigerant heater. Detailed Implementation

[0020] To make the technical solution of the present invention clearer, the present invention will be clearly and completely described below with reference to specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. The present invention provided by various embodiments will be described in detail below with reference to the accompanying drawings. To better understand the purpose of the present invention, the present invention will be described in further detail below.

[0021] Please see Figure 1 as well as Figure 2 The present invention provides a temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function, comprising: 1. Compressor; 2. Electric valve; 3. Fan; 4. Liquid storage device; 5. Refrigerant pump; 6. Energy storage battery compartment; 7. Inlet pipe; 8. Outlet pipe; 9. Condenser; 10. Throttling device; 11. Direct cooling secondary inlet pipe; 12. Direct cooling secondary outlet pipe; 13. Direct cooling tertiary inlet pipe; 14. Direct cooling tertiary outlet pipe; 15. Refrigerant heater; and 16. Control device. Compressor 1 and refrigerant pump 5 are connected in parallel to the compressor circuit; temperature sensor group is deployed at the outlet of condenser 9 and the direct cooling secondary inlet pipe 11; The pressure sensor group is installed at the exhaust port and suction port of compressor 1 and the chamber of refrigerant pump 5, respectively; The electromagnetic noise monitoring module is integrated into the battery management system of the energy storage battery compartment 6; The control device is connected to the temperature sensor group, pressure sensor group, electromagnetic noise monitoring module, compressor 1, fan 3, refrigerant heater 15, fluorine pump 5 and electric valve 2 via signal lines. The control device includes an environmental sensing module, a mode decision module, an execution control module, and a cold energy transfer module; The environmental sensing module collects outdoor temperature data, battery compartment temperature data, and compressor 1 operating status data, and generates demand signals based on the battery compartment temperature data. When the battery compartment temperature exceeds the cooling set threshold, a cooling demand signal is output. When the battery compartment temperature is lower than the heating set threshold, a heating demand signal is output. The control device pre-stores a set of system threshold parameters, including: Cooling setting threshold: The upper limit of the battery compartment temperature that triggers the cooling demand signal; Heating setting threshold: The lower limit of the battery compartment temperature that triggers the heating demand signal; The trigger threshold for the refrigerant pump natural cooling mode is the upper limit of the outdoor temperature at which the refrigerant pump is switched to natural cooling mode. Compressor protection threshold: The lower limit of the battery compartment temperature that forces the compressor to shut down; Liquid slugging protection threshold: The lower limit of refrigerant return pressure that triggers liquid slugging protection; Energy efficiency optimization threshold: The lower limit of the power consumption difference for startup mode optimization; Noise safety threshold: Safety limits for the electromagnetic noise spectrum; The mode decision module receives data and demand signals from the environmental perception module, including cooling demand signals and heating demand signals. When there is a cooling demand signal and the outdoor temperature is lower than the set threshold, the refrigerant pump natural cooling mode command is output. When there is a cooling demand signal and the outdoor temperature is higher than the set threshold, output the compressor cooling mode command; When there is a heating demand, a heating mode command is output; The execution control module responds to the instructions output by the mode decision module and performs the following control actions: When responding to the refrigerant pump's natural cooling mode command: compressor 1 is turned off, while refrigerant pump 5 remains running; When responding to the compressor cooling mode command: start compressor 1 and keep refrigerant pump 5 running; When responding to the heating mode command: turn on the refrigerant heater 15, turn off the compressor 1, and keep the refrigerant pump 5 running; The cold energy transfer module responds to the control actions of the execution control module and switches the refrigerant flow path: When responding to the natural cooling mode command of the refrigerant pump: the refrigerant flows through the condenser 9 and the throttling device 10 and then enters the direct cooling secondary inlet pipe 11, where the cooling capacity is transferred through air convection heat exchange. When responding to the compressor's cooling mode command: the refrigerant enters the direct cooling secondary inlet pipe 11 after passing through the condenser 9; When responding to the heating mode command: the refrigerant is delivered to the direct cooling secondary inlet pipe 11 via the refrigerant heater 15, heats the battery compartment 6, and then returns to the refrigerant pump 5.

[0022] This invention provides a temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function, comprising a compressor 1, an electric valve 2, a fan 3, a liquid storage device 4, a refrigerant pump 5, an energy storage battery compartment 6, an inlet pipe 7, an outlet pipe 8, a condenser 9, a throttling device 10, a second-stage direct-cooling inlet pipe 11, a second-stage direct-cooling outlet pipe 12, a third-stage direct-cooling inlet pipe 13, a third-stage direct-cooling outlet pipe 14, a refrigerant heater 15, and a control device. The compressor 1 and the refrigerant pump 5 are connected in parallel to the compressor circuit. A temperature sensor group is deployed at the outlet of the condenser 9 and the second-stage direct-cooling inlet pipe 11 to monitor the refrigerant temperature. A pressure sensor group is installed at the exhaust port and suction port of the compressor 1 and the cavity of the refrigerant pump 5 to collect pressure data. An electromagnetic noise monitoring module is integrated into the battery management system of the energy storage battery compartment 6 to monitor electromagnetic noise. The control device is connected to the temperature sensor group, pressure sensor group, electromagnetic noise monitoring module, compressor 1, fan 3, refrigerant heater 15, refrigerant pump 5, and electric valve 2 via signal lines to achieve data acquisition and equipment control.

[0023] The control unit includes an environmental sensing module, a mode decision module, an execution control module, and a cooling capacity transfer module. The environmental sensing module collects outdoor temperature data, battery compartment temperature data, and compressor 1 operating status data, and generates a demand signal based on the battery compartment temperature data. When the battery compartment temperature is higher than the cooling set threshold, the environmental sensing module outputs a cooling demand signal; when the battery compartment temperature is lower than the heating set threshold, it outputs a heating demand signal. The control unit pre-stores a set of system threshold parameters, including a cooling set threshold, a heating set threshold, a refrigerant pump natural cooling mode trigger threshold, a compressor protection threshold, a liquid slugging protection threshold, an energy efficiency optimization threshold, and a noise safety threshold. These thresholds are used for decision-making.

[0024] The mode decision module receives data and demand signals from the environmental sensing module, including cooling demand signals and heating demand signals. When a cooling demand signal exists and the outdoor temperature is below the refrigerant pump natural cooling mode trigger threshold, the mode decision module outputs a refrigerant pump natural cooling mode command; when a cooling demand signal exists and the outdoor temperature is above the refrigerant pump natural cooling mode trigger threshold, it outputs a compressor cooling mode command; when a heating demand signal exists, it outputs a heating mode command. The mode decision module compares the outdoor temperature with a preset threshold through the temperature determination unit, and triggers mode switching by outputting a compressor shutdown request through the compressor protection unit when the battery compartment temperature is below the compressor protection threshold and compressor 1 is running.

[0025] The execution control module responds to the instructions output by the response mode decision module and executes specific control actions. When responding to the refrigerant pump natural cooling mode instruction, the execution control module opens electric valve 2, maintains the refrigerant pump 5 in operation, and shuts off the power to compressor 1; when responding to the compressor cooling mode instruction, it starts compressor 1 and maintains the refrigerant pump 5 in operation; when responding to the heating mode instruction, it starts refrigerant heater 15, shuts off compressor 1, and maintains the refrigerant pump 5 in operation. The execution control module drives the equipment through electrical signals to achieve accurate execution of actions.

[0026] The cold energy transfer module responds to the control actions of the execution control module, switching the refrigerant flow path. In response to the refrigerant pump's natural cooling mode command, the refrigerant flows through the condenser 9 and the throttling device 10 before entering the direct cooling secondary inlet pipe 11, where cold energy is transferred through air convection heat exchange driven by the fan 3. In response to the compressor's cooling mode command, the refrigerant enters the direct cooling secondary inlet pipe 11 after passing through the condenser 9. In response to the heating mode command, the refrigerant is delivered to the direct cooling secondary inlet pipe 11 via the refrigerant heater 15, heating the battery compartment 6 before returning to the refrigerant pump 5. The cold energy transfer module optimizes thermal management efficiency through path switching.

[0027] The system monitors data in real time through an environmental sensing module, outputs commands based on threshold judgments through a mode decision module, drives equipment execution through an execution control module, and adjusts refrigerant flow through a cooling capacity transfer module, forming a closed-loop control system. This design enables automatic switching to refrigerant pump natural cooling mode in low-temperature environments, preventing compressor 1 from operating under adverse conditions and improving system reliability and energy efficiency. The modules work collaboratively to achieve intelligent temperature control, resolving issues such as poor oil return and liquid slugging risks.

[0028] Specifically, the temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function as described in this invention includes a mode decision module comprising: The temperature determination unit receives the outdoor temperature data from the environmental sensing module, compares the outdoor temperature data with a preset threshold, and outputs the comparison result. The compressor protection unit receives the comparison results and the compressor 1 operating status data collected by the environmental perception module. When the battery compartment temperature data is lower than the compressor protection threshold and the compressor 1 is in the start state, it outputs a compressor shutdown request to the mode decision module. The mode decision module responds to the compressor shutdown request, interrupts the current mode command, and outputs the refrigerant pump natural cooling mode command.

[0029] The mode decision-making module includes a temperature determination unit and a compressor protection unit. The temperature determination unit receives outdoor temperature data collected by the environmental sensing module, compares the outdoor temperature data with a preset threshold in real time, and outputs the comparison result. The comparison result includes a status signal indicating whether the outdoor temperature is higher or lower than the preset threshold, which is used in subsequent decision-making processes.

[0030] The compressor protection unit receives the comparison results output by the temperature judgment unit and the compressor 1 operating status data collected by the environmental sensing module. When the battery compartment temperature data is lower than the compressor protection threshold and the compressor 1 is in the start state, it outputs a compressor shutdown request to the mode decision module. The compressor protection unit continuously monitors the battery compartment temperature data and the compressor 1 operating status to enable timely triggering of the protection mechanism in low-temperature environments.

[0031] The mode decision module responds to the compressor shutdown request output by the compressor protection unit, interrupts the currently executing mode command, and outputs a refrigerant pump natural cooling mode command. The mode decision module prioritizes the protection request through an interrupt handling mechanism, enabling the system to quickly switch to a safe operating mode and preventing compressor 1 from continuing to operate under adverse conditions.

[0032] Specifically, in the direct-cooling unit temperature control system with refrigerant pump and natural cooling function described in this invention, when the execution control module responds to the refrigerant pump natural cooling mode command, it opens the electric valve 2, keeps the refrigerant pump 5 running, and shuts off the power to the compressor 1.

[0033] Specifically, the temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function described in this invention completes the natural cooling cycle in the refrigerant pump natural cooling mode through the following method: As the refrigerant pump 5 continues to run, and the refrigerant flows through the condenser 9, the fan 3 drives the air to exchange heat with the refrigerant through convection. After heat exchange, the refrigerant is depressurized by the throttling device 10 and enters the direct cooling secondary inlet pipe 11 to cool the battery compartment 6.

[0034] When the control module responds to the refrigerant pump's natural cooling mode command, it drives the electric valve 2 to open via a control signal, thus connecting the refrigerant flow path; simultaneously, it maintains the operation of the refrigerant pump 5 to ensure continuous refrigerant circulation power; and it cuts off the power to the compressor 1, stopping its operation. This series of actions ensures that the system relies solely on the refrigerant pump 5 for power in the refrigerant pump's natural cooling mode, avoiding unnecessary energy consumption by the compressor 1.

[0035] In the refrigerant pump natural cooling mode, the refrigerant pump 5 continuously circulates the refrigerant. As the refrigerant flows through the condenser 9, the fan 3 accelerates, driving the air to undergo forced convection heat exchange with the surface of the condenser 9, thus lowering the refrigerant temperature. After heat exchange, the refrigerant enters the throttling device 10 for pressure reduction, forming a low-temperature, low-pressure state. Finally, the low-temperature refrigerant flows into the direct cooling secondary inlet pipe 11, contacting the surface of the battery clusters inside the battery compartment 6, absorbing heat to achieve cooling. The entire process utilizes ambient air as a cold source, completing heat exchange through a combination of natural convection and forced ventilation, without the need for the compressor 1, achieving highly efficient and energy-saving operation.

[0036] Specifically, in the temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function described in this invention, the compressor protection unit is configured as follows: Receive refrigerant return gas pressure data provided by the pressure sensor group; When the return gas pressure data remains below the liquid hammer protection threshold for a set period of time, a liquid hammer protection command is output to the execution control module. The liquid hammer protection commands include: a command to cut off the compressor power supply and a command to activate the fault alarm.

[0037] The compressor protection unit receives refrigerant return gas pressure data from the pressure sensor group. The pressure sensor group monitors the refrigerant pressure at the compressor suction port in real time, collects the return gas pressure signal, and transmits it to the compressor protection unit. The compressor protection unit continuously compares the return gas pressure data with the pre-stored liquid slugging protection threshold. When the return gas pressure data remains below the liquid slugging protection threshold for a set period of time, it determines that the system has a risk of liquid slugging.

[0038] The compressor protection unit outputs liquid slugging protection commands to the execution control module. These commands include a command to cut off the compressor power supply and a command to activate the fault alarm. The command to cut off the compressor power supply directly disconnects the compressor's power circuit, immediately stopping the compressor and preventing liquid refrigerant from entering the compression chamber and causing mechanical damage. The command to activate the fault alarm triggers an audible and visual alarm, alerting the operator to a system malfunction requiring intervention and inspection.

[0039] The compressor protection unit, through real-time pressure monitoring and a time-delay judgment mechanism, ensures that protection actions are triggered only under sustained low-pressure conditions, preventing malfunctions. The execution of liquid slugging protection commands effectively prevents the compressor from operating under adverse conditions, improving system safety and reliability. The entire protection process is integrated into the control device, achieving automated fault response.

[0040] Specifically, the environmental sensing module of the direct-cooling unit temperature control system with fluorine pump and natural cooling function described in this invention includes: Distributed temperature sensors are deployed on the direct cooling three-stage inlet pipe 13, the direct cooling three-stage outlet pipe 14, the suction and exhaust ports of compressor 1, and the surface of the battery cluster to collect temperature data at the target locations. A pressure sensor array is installed at the discharge port of compressor 1 and the chamber of refrigerant pump 5 to collect refrigerant pressure data. Among them, temperature data and refrigerant pressure constitute the outdoor temperature data, battery compartment temperature data and compressor operating status data output by the environmental sensing module.

[0041] The environmental sensing module collects real-time temperature data from key locations in the system using distributed temperature sensors. These sensors are deployed on the inlet pipe 13 of the direct-cooling third-stage compressor, the outlet pipe 14 of the direct-cooling third-stage compressor, the suction and discharge ports of compressor 1, and the surface of the battery cluster. The temperature data from the inlet pipe 13 and the outlet pipe 14 of the direct-cooling third-stage compressor reflects the heat exchange state of the refrigerant within the battery compartment. The temperature data from the suction and discharge ports of compressor 1 indicates the operating efficiency and heat load of compressor 1, while the surface temperature data of the battery cluster directly characterizes the internal heat distribution of the battery compartment 6. The environmental sensing module integrates this temperature data and calculates the average or peak value through the signal processing unit to generate battery compartment temperature data and compressor operating status data.

[0042] A pressure sensor array is installed at the discharge port of compressor 1 and the chamber of refrigerant pump 5 to continuously monitor changes in refrigerant pressure. The pressure data at the compressor 1 discharge port reflects the refrigerant output status of the compressor, while the pressure data in the refrigerant pump 5 chamber indicates the flow resistance of the refrigerant driven by the pump. The environmental sensing module compares the pressure data with preset thresholds to identify system pressure anomalies and outputs refrigerant pressure parameters.

[0043] The environmental sensing module fuses and processes the collected temperature and pressure data. Temperature data is used to derive outdoor and battery compartment temperature data, while pressure data assists in determining the compressor's operating status. Outdoor temperature data is calculated using the temperature difference between the direct-cooling three-stage inlet pipe 13 and the direct-cooling three-stage outlet pipe 14, combined with an environmental calibration algorithm. Battery compartment temperature data is generated based on a weighted average of battery cluster surface temperature data. Compressor operating status data integrates the compressor 1's intake and exhaust port temperatures and pressures, outputting an operating status identifier through a state machine model. The environmental sensing module packages and transmits this data to the mode decision module as the basic input for mode switching decisions.

[0044] Specifically, the temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function described in this invention further includes: The energy efficiency optimization module calculates the power consumption difference between the compressor cooling mode and the refrigerant pump natural cooling mode based on historical operating data. When the power consumption difference exceeds the energy efficiency optimization threshold, a mode optimization instruction is output to the mode decision module. The mode optimization instruction replaces the initial operation instruction generated by the mode decision module based on the ambient temperature. The mode optimization instruction is configured to: intercept the initial running instruction generated by the mode decision module based on the ambient temperature, and replace the intercepted initial running instruction with the optimized running instruction.

[0045] The energy efficiency optimization module calculates the power consumption difference between the compressor cooling mode and the refrigerant pump natural cooling mode based on historical operating data. This historical data includes the power consumption records of compressor 1 and refrigerant pump 5. The module analyzes the energy consumption differences between the two modes under the same cooling capacity using a data comparison algorithm, generating a power consumption difference report. When the power consumption difference exceeds the energy efficiency optimization threshold, the module outputs a mode optimization command to the mode decision module.

[0046] The mode optimization instruction replaces the initial operating instruction generated by the mode decision module based on the ambient temperature. The mode optimization instruction is configured to intercept the initial operating instruction generated by the mode decision module based on the ambient temperature. The energy efficiency optimization module replaces the intercepted initial operating instruction with the optimized operating instruction through an instruction rewriting mechanism. The optimized operating instruction prioritizes the operating mode with lower power consumption. After receiving the mode optimization instruction, the mode decision module adjusts its decision logic, prioritizing the use of the more energy-efficient operating mode while meeting temperature control requirements.

[0047] The energy efficiency optimization module continuously monitors system operating data, periodically updates the power consumption difference calculation, and dynamically adjusts the energy efficiency optimization threshold. When environmental conditions change and cause the power consumption difference to fall below the energy efficiency optimization threshold, the energy efficiency optimization module stops outputting mode optimization commands, and the mode decision module resumes the normal decision-making process of generating initial operating commands based on the ambient temperature. The entire process achieves adaptive adjustment of energy efficiency optimization, enabling the system to maintain optimal energy efficiency under different operating conditions.

[0048] Specifically, in the temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function described in this invention, the energy efficiency optimization module is configured as follows: Record the unit cooling capacity power consumption in the historical operating data collected by the environmental sensing module; Based on the recorded power consumption per unit of cooling capacity, a correction curve for the applicable temperature range of the natural cooling mode of the refrigerant pump is generated. Based on the generated correction curve, the natural cooling mode trigger threshold update command of the refrigerant pump is output to the mode decision module to update the natural cooling mode trigger threshold of the refrigerant pump in the mode decision module.

[0049] The energy efficiency optimization module collects historical data during system operation through the environmental sensing module, recording the electrical energy consumption per unit of cooling capacity during the cooling process, forming a database of electricity consumption per unit of cooling capacity. This database includes energy consumption comparison data between compressor 1 cooling mode and refrigerant pump natural cooling mode under different outdoor temperature conditions, providing basic data support for subsequent analysis.

[0050] Based on the recorded power consumption per unit cooling capacity, the energy efficiency optimization module uses a curve fitting algorithm to generate a correction curve for the applicable temperature range of the refrigerant pump natural cooling mode. This correction curve reflects the energy efficiency advantage range of the refrigerant pump natural cooling mode compared to the compressor refrigeration mode at different temperature points. The horizontal axis represents the outdoor temperature value, and the vertical axis represents the energy efficiency ratio difference. The curve shape characterizes the critical temperature change law of the energy efficiency intersection between the two modes.

[0051] Based on the generated correction curve, the energy efficiency optimization module outputs an update command for the refrigerant pump natural cooling mode trigger threshold to the mode decision module. This command includes temperature threshold parameters recalculated based on the energy efficiency optimization results. After receiving the update command, the mode decision module adjusts its built-in refrigerant pump natural cooling mode trigger threshold to the optimized value, enabling the system to prioritize the more energy-efficient operating mode in subsequent operations.

[0052] Specifically, the temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function described in this invention further includes a dynamic collaborative control module. The electromagnetic noise monitoring module collects the electromagnetic noise spectrum of the drive circuits of the fluorine pump 5 and the compressor 1 in real time. The control device inputs the noise spectrum data collected by the electromagnetic noise monitoring module into the dynamic collaborative control module; The dynamic collaborative control module performs the following operations based on noise spectrum data: During the operation of the fluorine pump 5, the PWM carrier phase of its drive circuit is dynamically adjusted; When the noise spectrum exceeds the noise safety threshold, the compressor 1 shutdown protection command or the refrigerant pump 5 speed reduction command is triggered.

[0053] The dynamic collaborative control module is integrated into the control device. The electromagnetic noise monitoring module captures the electromagnetic noise signals generated by the drive circuits of the refrigerant pump 5 and the compressor 1 in real time through a high-frequency sampling circuit, and converts these signals into spectrum data. The spectrum data includes frequency distribution and amplitude information. The electromagnetic noise monitoring module extracts characteristic parameters through digital signal processing technology.

[0054] The control device transmits the noise spectrum data collected by the electromagnetic noise monitoring module to the dynamic collaborative control module via an internal data bus. After receiving the spectrum data, the dynamic collaborative control module executes a real-time analysis algorithm to compare the current noise spectrum with the pre-stored noise safety threshold.

[0055] During the operation of the fluorine pump 5, the dynamic collaborative control module dynamically adjusts the carrier phase of the PWM control signal of the fluorine pump 5 drive circuit based on the noise spectrum analysis results. The phase adjustment algorithm optimizes the conduction timing of the switching elements, reducing harmonic interference and electromagnetic radiation, and improving the power conversion efficiency of the drive circuit.

[0056] When noise spectrum analysis shows that the amplitude of a specific frequency band exceeds the noise safety threshold, the dynamic collaborative control module triggers a protection mechanism. This protection mechanism includes outputting a shutdown protection command to the compressor 1 execution control module to cut off the power supply to the compressor 1; or outputting a speed reduction command to the refrigerant pump 5 drive circuit to reduce the operating speed of the refrigerant pump 5. These commands aim to eliminate electromagnetic noise sources and prevent overload or thermal damage to circuit components.

[0057] The dynamic collaborative control module maintains the system's electromagnetic compatibility through continuous monitoring and real-time adjustments, enabling stable operation of the refrigerant pump 5 and compressor 1 under complex conditions. The noise safety threshold is set based on equipment electromagnetic compatibility standards, and the dynamic collaborative control module periodically calibrates the threshold to adapt to environmental changes.

[0058] Specifically, the temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function described in this invention includes a dynamic collaborative control module in the control device, and the system threshold parameter group includes a pressure difference safety threshold, which is the limit value of the pressure difference between the discharge pressure of compressor 1 and the pressure difference in the refrigerant pump chamber 5. The dynamic collaborative control module includes: The mode switching feedback unit receives the condenser outlet temperature data and battery cold plate temperature difference data from the environmental sensing module. When the outdoor temperature is lower than the trigger threshold of the refrigerant pump natural cooling mode, it controls the fan 3 speed to increase to the turbulence critical value. After the temperature difference sensor confirms that the refrigerant subcooling meets the standard, it triggers the execution control module to execute the compressor 1 shutdown action. The pump-valve linkage unit collects the pressure difference between the discharge pressure of compressor 1 and the pressure difference in the chamber of refrigerant pump 5 in real time. When the pressure difference exceeds the safety threshold, the opening action of electric valve 2 is delayed, so that the movement trajectory of the valve core of electric valve 2 and the speed of refrigerant pump 5 are adjusted by negative feedback. The fault redirection unit cuts off the power supply to compressor 1, adjusts refrigerant pump 5 to the preset safe speed, opens electric valve 2 to establish an emergency return path, and guides the refrigerant stagnant in refrigerant pump 5 to the direct cooling third-stage outlet pipe 14. The electromagnetic compatibility unit dynamically adjusts the PWM carrier phase of the pump drive circuit based on the noise spectrum fed back by the electromagnetic noise monitoring module during the operation of the fluorine pump 5. The energy efficiency optimization unit trains a load prediction model based on historical energy consumption data in the overlapping temperature range of the refrigerant pump natural cooling mode and the compressor cooling mode. When the battery heat generation is at a critical state, it allocates the parallel operation time ratio of the two modes and controls the compressor 1 to be used only to supplement the cooling capacity gap of the refrigerant pump natural cooling mode.

[0059] The dynamic collaborative control module is integrated into the control device. The system threshold parameter group includes the pressure difference safety threshold, which is the limit of the pressure difference between the discharge pressure of compressor 1 and the pressure in chamber 5 of refrigerant pump. The dynamic collaborative control module optimizes system operation through the coordinated work of multiple functional units.

[0060] The mode switching feedback unit receives condenser 9 outlet temperature data and battery cold plate temperature difference data collected by the environmental sensing module. When the outdoor temperature is lower than the refrigerant pump natural cooling mode trigger threshold, the mode switching feedback unit controls the fan 3 speed to increase to the turbulence critical value to enhance air convection heat transfer efficiency; after the temperature difference sensor confirms that the refrigerant subcooling meets the standard, the mode switching feedback unit triggers the execution control module to execute the compressor 1 shutdown action to achieve smooth mode switching.

[0061] The pump-valve linkage unit collects the pressure difference between the discharge pressure of compressor 1 and the pressure in the chamber of refrigerant pump 5 in real time. When the pressure difference exceeds the safety threshold, the pump-valve linkage unit delays the opening of electric valve 2 and uses a control algorithm to establish negative feedback regulation between the movement trajectory of the valve core of electric valve 2 and the speed of refrigerant pump 5 to maintain system pressure balance and prevent high-pressure impact from damaging components.

[0062] When the fault redirection unit detects system pressure imbalance or component jamming, it cuts off the power to compressor 1, adjusts refrigerant pump 5 to a preset safe speed, and opens electric valve 2 to establish an emergency return path. The emergency return path guides the refrigerant retained in the chamber of refrigerant pump 5 to the direct-cooling tertiary outlet pipe 14, preventing refrigerant accumulation in a continuous flow manner and ensuring the continuous safe operation of the system.

[0063] During the operation of the refrigerant pump 5, the electromagnetic compatibility unit dynamically adjusts the PWM carrier phase of the pump 5 drive circuit based on the noise spectrum data fed back by the electromagnetic noise monitoring module. The adjustment process utilizes a spectrum analysis algorithm to optimize the conduction timing of switching elements, reduce electromagnetic interference, and improve circuit compatibility and stability.

[0064] The energy efficiency optimization unit trains a load prediction model based on historical energy consumption data in the overlapping temperature range of the refrigerant pump natural cooling mode and the compressor cooling mode. When the battery heat generation is at a critical state, the energy efficiency optimization unit allocates the parallel operation time ratio of the two modes, controlling compressor 1 to be used only to supplement the cooling capacity gap of the refrigerant pump natural cooling mode, thereby achieving energy efficiency optimization and power consumption reduction.

[0065] This invention utilizes a parallel structure between the refrigerant pump branch 5 and the compressor circuit, combined with an intelligent control device, to automatically switch to the refrigerant pump natural cooling mode in low-temperature environments, preventing the compressor 1 from being forced to operate under cold conditions. An environmental sensing module collects outdoor temperature data and battery compartment temperature data. When the battery compartment temperature is higher than the cooling set threshold and the outdoor temperature is lower than the refrigerant pump natural cooling mode trigger threshold, the mode decision module outputs a refrigerant pump natural cooling mode command. The execution control module responds to the command, shutting down the compressor 1 while maintaining the refrigerant pump 5 in operation. The refrigerant flows through the condenser 9 and the throttling device 10 before entering the direct cooling secondary inlet pipe 11, where cooling is transferred through air convection heat exchange. This process eliminates the problem of poor oil return caused by insufficient lubricating oil flow when the compressor 1 operates at low temperatures, and also prevents liquid refrigerant from flowing back into the compression chamber, causing liquid slugging mechanical failures. The compressor protection unit monitors the refrigerant return gas pressure data in real time. When the return gas pressure remains below the liquid slugging protection threshold, it outputs a liquid slugging protection command to the execution control module, cutting off the power to the compressor 1 and activating the fault alarm, further preventing the risk of liquid slugging. The dynamic collaborative control module maintains system pressure balance through pump and valve linkage units, reducing the number of interfaces and heat exchange links, and improving system reliability and energy efficiency.

[0066] This invention relates to a temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function, applied to the thermal management of an energy storage battery compartment in cold regions. The system includes a compressor 1, an electric valve 2, a fan 3, a liquid storage device 4, a refrigerant pump 5, an energy storage battery compartment 6, an inlet pipe 7, an outlet pipe 8, a condenser 9, a throttling device 10, a second-stage direct-cooling inlet pipe 11, a second-stage direct-cooling outlet pipe 12, a third-stage direct-cooling inlet pipe 13, a third-stage direct-cooling outlet pipe 14, a refrigerant heater 15, and a control device. The compressor 1 circuit is connected in parallel with the refrigerant pump 5 branch. A temperature sensor group is deployed at the outlet of the condenser 9 and the second-stage direct-cooling inlet pipe 11. A pressure sensor group is installed at the exhaust port, suction port, and cavity of the refrigerant pump 5, respectively. An electromagnetic noise monitoring module is integrated into the battery management system of the energy storage battery compartment 6. The control device is connected to the temperature sensor group, pressure sensor group, electromagnetic noise monitoring module, compressor 1, fan 3, refrigerant heater 15, refrigerant pump 5, and electric valve 2 via signal lines.

[0067] The control unit includes an environmental sensing module, a mode decision module, an execution control module, and a cooling capacity transfer module. The environmental sensing module collects outdoor temperature data, battery compartment temperature data, and compressor 1 operating status data, and generates a demand signal based on the battery compartment temperature data. When the battery compartment temperature is higher than the cooling set threshold, a cooling demand signal is output; when the battery compartment temperature is lower than the heating set threshold, a heating demand signal is output. The control unit pre-stores a set of system threshold parameters, including a cooling set threshold, a heating set threshold, a refrigerant pump natural cooling mode trigger threshold, a compressor protection threshold, a liquid slugging protection threshold, an energy efficiency optimization threshold, and a noise safety threshold.

[0068] The mode decision module receives data and demand signals from the environmental sensing module. When there is a cooling demand signal and the outdoor temperature is lower than the refrigerant pump natural cooling mode trigger threshold, it outputs a refrigerant pump natural cooling mode command; when there is a cooling demand signal and the outdoor temperature is higher than the refrigerant pump natural cooling mode trigger threshold, it outputs a compressor cooling mode command; when there is a heating demand signal, it outputs a heating mode command.

[0069] The control module executes the instructions output by the response mode decision module. When responding to the refrigerant pump natural cooling mode instruction, compressor 1 is turned off, while refrigerant pump 5 remains running; when responding to the compressor cooling mode instruction, compressor 1 is started, while refrigerant pump 5 remains running; when responding to the heating mode instruction, refrigerant heater 15 is turned on, compressor 1 is turned off, while refrigerant pump 5 remains running.

[0070] The cold energy transfer module responds to the control actions of the execution control module, switching the refrigerant flow path. When responding to the natural cooling mode command of the refrigerant pump, the refrigerant flows through the condenser 9 and the throttling device 10 before entering the direct cooling secondary inlet pipe 11, where cold energy is transferred through air convection heat exchange. When responding to the compressor cooling mode command, the refrigerant enters the direct cooling secondary inlet pipe 11 after passing through the condenser 9. When responding to the heating mode command, the refrigerant is delivered to the direct cooling secondary inlet pipe 11 via the refrigerant heater 15, heats the battery compartment 6, and then returns to the refrigerant pump 5.

[0071] The mode decision module includes a temperature determination unit and a compressor protection unit. The temperature determination unit receives outdoor temperature data from the environmental sensing module, compares the outdoor temperature data with a preset threshold, and outputs the comparison result. The compressor protection unit receives the comparison result and the compressor 1 operating status data collected by the environmental sensing module. When the battery compartment temperature data is lower than the compressor protection threshold and the compressor 1 is in the start state, it outputs a compressor shutdown request to the mode decision module. The mode decision module responds to the compressor shutdown request, interrupts the current mode command, and outputs a refrigerant pump natural cooling mode command.

[0072] When the control module responds to the refrigerant pump's natural cooling mode command, it opens the electric valve 2, keeps the refrigerant pump 5 running, and shuts off the power to the compressor 1. The refrigerant pump's natural cooling mode completes the natural cooling cycle in the following way: the refrigerant pump 5 runs continuously, and when the refrigerant flows through the condenser 9, the fan 3 drives the air to perform convective heat exchange with the refrigerant; after heat exchange, the refrigerant is depressurized by the throttling device 10 and enters the direct cooling secondary inlet pipe 11 to cool the battery compartment 6.

[0073] The compressor protection unit receives refrigerant return gas pressure data from the pressure sensor group. When the return gas pressure data remains below the liquid slugging protection threshold for a set duration, it outputs a liquid slugging protection command to the execution control module; the liquid slugging protection command includes a command to cut off the compressor power supply and a command to activate the fault alarm.

[0074] The environmental sensing module includes distributed temperature sensors deployed on the direct cooling three-stage inlet pipe 13, the direct cooling three-stage outlet pipe 14, the compressor 1 suction and discharge ports, and the surface of the battery cluster to collect temperature data at the target location; a pressure sensor group is installed on the compressor 1 discharge port and the refrigerant pump 5 chamber to collect refrigerant pressure data; the temperature data and refrigerant pressure constitute the outdoor electrode temperature data, battery compartment temperature data, and compressor operating status data output by the environmental sensing module.

[0075] The system also includes an energy efficiency optimization module, which calculates the power consumption difference between the compressor cooling mode and the refrigerant pump natural cooling mode based on historical operating data. When the power consumption difference exceeds the energy efficiency optimization threshold, a mode optimization command is output to the mode decision module. This mode optimization command replaces the initial operating command generated by the mode decision module based on the ambient temperature. The mode optimization command is configured to intercept the initial operating command generated by the mode decision module based on the ambient temperature and replace it with the optimized operating command. The energy efficiency optimization module records the power consumption per unit of cooling capacity in the historical operating data collected by the environmental sensing module. Based on the recorded power consumption per unit of cooling capacity, it generates a correction curve for the applicable temperature range of the refrigerant pump natural cooling mode. Based on the generated correction curve, it outputs a refrigerant pump natural cooling mode trigger threshold update command to the mode decision module, updating the refrigerant pump natural cooling mode trigger threshold in the mode decision module.

[0076] The control device also includes a dynamic coordinated control module. An electromagnetic noise monitoring module collects the electromagnetic noise spectrum of the drive circuits of the refrigerant pump 5 and compressor 1 in real time; the control device inputs the noise spectrum data collected by the electromagnetic noise monitoring module into the dynamic coordinated control module. Based on the noise spectrum data, the dynamic coordinated control module performs the following operations: during the operation of the refrigerant pump 5, it dynamically adjusts the PWM carrier phase of its drive circuit; when the noise spectrum exceeds the noise safety threshold, it triggers a compressor 1 shutdown protection command or a refrigerant pump 5 speed reduction command.

[0077] The dynamic collaborative control module includes a mode switching feedback unit, a pump-valve linkage unit, a fault redirection unit, an electromagnetic compatibility unit, and an energy efficiency optimization unit. The mode switching feedback unit receives condenser outlet temperature data and battery cold plate temperature difference data from the environmental sensing module. When the outdoor temperature is lower than the trigger threshold for the refrigerant pump's natural cooling mode, it controls the fan 3 to increase its speed to the turbulence critical value. After the temperature difference sensor confirms that the refrigerant subcooling meets the standard, it triggers the execution control module to shut down the compressor 1. The pump-valve linkage unit collects the real-time pressure difference between the compressor 1 discharge pressure and the refrigerant pump 5 chamber pressure. When the pressure difference exceeds the safety threshold, it delays the opening of the electric valve 2, establishing negative feedback regulation between the electric valve 2's valve core movement trajectory and the refrigerant pump 5's speed. The fault redirection unit cuts off the power to the compressor 1, adjusts the refrigerant pump 5 to a preset safe speed, opens the electric valve 2 to establish an emergency return path, and guides the refrigerant retained in the refrigerant pump 5 chamber to the direct cooling stage 3 outlet pipe 14. During the operation of the refrigerant pump 5, the electromagnetic compatibility unit dynamically adjusts the PWM carrier phase of the pump drive circuit based on the noise spectrum fed back by the electromagnetic noise monitoring module. In the overlapping temperature range of the refrigerant pump natural cooling mode and the compressor cooling mode, the energy efficiency optimization unit trains a load prediction model based on historical energy consumption data. When the battery heat generation is at a critical state, it allocates the parallel operation time ratio of the two modes and controls the compressor 1 to be used only to supplement the cooling capacity gap of the refrigerant pump natural cooling mode.

[0078] Through the above implementation methods, the system automatically switches to the refrigerant pump natural cooling mode in low-temperature environments, avoiding forced operation of compressor 1 under cold conditions, eliminating lubrication failure caused by poor refrigerant oil return and liquid slugging mechanical failure caused by liquid refrigerant backflow. The dynamic collaborative control module optimizes the mode switching process based on temperature and pressure data collected by the environmental sensing module, maintaining system pressure balance, reducing the number of interfaces and heat exchange links, and improving energy efficiency and system reliability.

Claims

1. A temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function, characterized in that, include: Compressor (1), electric valve (2), fan (3), liquid storage device (4), refrigerant pump (5), energy storage battery compartment (6), inlet pipe (7), outlet pipe (8), condenser (9), throttling device (10), direct cooling secondary inlet pipe (11), direct cooling secondary outlet pipe (12), direct cooling tertiary inlet pipe (13), direct cooling tertiary outlet pipe (14), refrigerant heater (15), and control device; The compressor (1) and the refrigerant pump (5) branch are connected in parallel to the compressor circuit; the temperature sensor group is deployed at the outlet of the condenser (9) and the direct cooling secondary inlet pipe (11). Pressure sensor groups are respectively installed at the exhaust port, suction port and fluorine pump (5) cavity of compressor (1); The electromagnetic noise monitoring module is integrated into the battery management system of the energy storage battery compartment (6); The control device is connected to the temperature sensor group, pressure sensor group, electromagnetic noise monitoring module, compressor (1), fan (3), refrigerant heater (15), fluorine pump (5) and electric valve (2) respectively via signal lines. The control device includes an environmental sensing module, a mode decision module, an execution control module, and a cold energy transfer module; The environmental sensing module collects outdoor temperature data, battery compartment temperature data and compressor (1) operating status data, and generates demand signals based on the battery compartment temperature data; When the battery compartment temperature exceeds the cooling set threshold, a cooling demand signal is output. When the battery compartment temperature is lower than the heating set threshold, a heating demand signal is output. The control device pre-stores a set of system threshold parameters, including: Cooling setting threshold: The upper limit of the battery compartment temperature that triggers the cooling demand signal; Heating setting threshold: The lower limit of the battery compartment temperature that triggers the heating demand signal; The trigger threshold for the refrigerant pump natural cooling mode is the upper limit of the outdoor temperature at which the refrigerant pump is switched to natural cooling mode. Compressor protection threshold: The lower limit of the battery compartment temperature that forces the compressor to shut down; Liquid slugging protection threshold: The lower limit of refrigerant return pressure that triggers liquid slugging protection; Energy efficiency optimization threshold: The lower limit of the power consumption difference for startup mode optimization; Noise safety threshold: Safety limits for the electromagnetic noise spectrum; The mode decision module receives data and demand signals from the environmental perception module, including cooling demand signals and heating demand signals. When there is a cooling demand signal and the outdoor temperature is lower than the set threshold, the refrigerant pump natural cooling mode command is output. When there is a cooling demand signal and the outdoor temperature is higher than the set threshold, output the compressor cooling mode command; When there is a heating demand, a heating mode command is output; The execution control module responds to the instructions output by the mode decision module and performs the following control actions: When responding to the natural cooling mode command of the refrigerant pump: shut down the compressor (1) and keep the refrigerant pump (5) running; When responding to the compressor refrigeration mode command: start the compressor (1) and keep the refrigerant pump (5) running; When responding to the heating mode command: turn on the refrigerant heater (15), turn off the compressor (1), and keep the refrigerant pump (5) running; The cold energy transfer module responds to the control actions of the execution control module and switches the refrigerant flow path: When responding to the natural cooling mode command of the fluorine pump: the refrigerant flows through the condenser (9) and the throttling device (10) and then enters the direct cooling secondary inlet pipe (11), and the cold energy is transferred through air convection heat exchange; When responding to the compressor's refrigeration mode command: the refrigerant enters the direct cooling secondary inlet pipe (11) after passing through the condenser (9); When responding to the heating mode command: the refrigerant is delivered to the direct cooling secondary inlet pipe (11) via the refrigerant heater (15), heats the battery compartment (6), and then returns to the refrigerant pump (5).

2. The temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function as described in claim 1, characterized in that, The pattern decision module includes: The temperature determination unit receives the outdoor temperature data from the environmental sensing module, compares the outdoor temperature data with a preset threshold, and outputs the comparison result. The compressor protection unit receives the comparison results and the compressor (1) operating status data collected by the environmental perception module. When the battery compartment temperature data is lower than the compressor protection threshold and the compressor (1) is in the start-up state, it outputs a compressor shutdown request to the mode decision module. The mode decision module responds to the compressor shutdown request, interrupts the current mode command, and outputs the refrigerant pump natural cooling mode command.

3. The temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function according to claim 2, characterized in that, When the execution control module responds to the natural cooling mode command of the fluorine pump, it opens the electric valve (2), keeps the fluorine pump (5) running, and shuts off the power to the compressor (1).

4. The temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function according to claim 3, characterized in that, The natural cooling mode of the fluorine pump completes the natural cooling cycle in the following way: The refrigerant pump (5) runs continuously. When the refrigerant flows through the condenser (9), the fan (3) drives the air to exchange heat with the refrigerant through convection. After heat exchange, the refrigerant is depressurized by the throttling device (10) and enters the direct cooling secondary inlet pipe (11) to cool the battery compartment (6).

5. The temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function according to claim 4, characterized in that, The compressor protection unit is configured as follows: Receive refrigerant return gas pressure data provided by the pressure sensor group; When the return gas pressure data remains below the liquid hammer protection threshold for a set period of time, a liquid hammer protection command is output to the execution control module. The liquid hammer protection commands include: a command to cut off the compressor power supply and a command to activate the fault alarm.

6. The temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function according to claim 5, characterized in that, The environment sensing module includes: Distributed temperature sensors are deployed on the direct cooling three-stage inlet pipe (13), the direct cooling three-stage outlet pipe (14), the compressor (1) intake and exhaust ports and the surface of the battery cluster to collect temperature data at the target location; The pressure sensor group is installed at the exhaust port of the compressor (1) and the cavity of the refrigerant pump (5) to collect refrigerant pressure data; Among them, temperature data and refrigerant pressure constitute the outdoor temperature data, battery compartment temperature data and compressor operating status data output by the environmental sensing module.

7. The temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function according to claim 6, characterized in that, Also includes: The energy efficiency optimization module calculates the power consumption difference between the compressor cooling mode and the refrigerant pump natural cooling mode based on historical operating data. When the power consumption difference exceeds the energy efficiency optimization threshold, a mode optimization instruction is output to the mode decision module. The mode optimization instruction replaces the initial operation instruction generated by the mode decision module based on the ambient temperature. The mode optimization instruction is configured to: intercept the initial running instruction generated by the mode decision module based on the ambient temperature, and replace the intercepted initial running instruction with the optimized running instruction.

8. The temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function according to claim 7, characterized in that, The energy efficiency optimization module is configured as follows: Record the unit cooling capacity power consumption in the historical operating data collected by the environmental sensing module; Based on the recorded power consumption per unit of cooling capacity, a correction curve for the applicable temperature range of the natural cooling mode of the refrigerant pump is generated. Based on the generated correction curve, the natural cooling mode trigger threshold update command of the refrigerant pump is output to the mode decision module to update the natural cooling mode trigger threshold of the refrigerant pump in the mode decision module.

9. The temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function according to claim 8, characterized in that, The control device also includes a dynamic collaborative control module; The electromagnetic noise monitoring module collects the electromagnetic noise spectrum of the drive circuits of the fluorine pump (5) and the compressor (1) in real time. The control device inputs the noise spectrum data collected by the electromagnetic noise monitoring module into the dynamic collaborative control module; The dynamic collaborative control module performs the following operations based on noise spectrum data: During the operation of the fluorine pump (5), the PWM carrier phase of its drive circuit is dynamically adjusted; When the noise spectrum exceeds the noise safety threshold, the compressor (1) is triggered to stop the protection command or the refrigerant pump (5) is triggered to reduce the speed.

10. The temperature control system for a direct-cooling unit with a refrigerant pump and natural cooling function according to claim 9, characterized in that, The control device also includes a dynamic collaborative control module, and the system threshold parameter group also includes a pressure difference safety threshold, which is the limit of the pressure difference between the compressor (1) discharge pressure and the refrigerant pump (5) chamber pressure. The dynamic collaborative control module includes: The mode switching feedback unit receives the condenser outlet temperature data and battery cold plate temperature difference data from the environmental sensing module. When the outdoor temperature is lower than the trigger threshold of the natural cooling mode of the refrigerant pump, it controls the fan (3) speed to increase to the turbulence critical value. After the temperature difference sensor confirms that the refrigerant subcooling meets the standard, it triggers the execution control module to execute the compressor (1) shutdown action. The pump-valve linkage unit collects the pressure difference between the compressor (1) discharge pressure and the fluorine pump (5) chamber pressure in real time. When the pressure difference exceeds the pressure difference safety threshold, the opening action of the electric valve (2) is delayed, so that the movement trajectory of the electric valve (2) valve core and the speed of the fluorine pump (5) are established for negative feedback regulation. The fault redirection unit cuts off the power supply to the compressor (1), adjusts the refrigerant pump (5) to the preset safe speed, opens the electric valve (2) to establish an emergency return path, and guides the residing working fluid in the refrigerant pump (5) chamber to the direct cooling third-stage outlet pipe (14). The electromagnetic compatibility unit dynamically adjusts the PWM carrier phase of the pump drive circuit based on the noise spectrum fed back by the electromagnetic noise monitoring module during the operation of the fluorine pump (5). The energy efficiency optimization unit trains a load prediction model based on historical energy consumption data in the overlapping temperature zone of the fluorine pump natural cooling mode and the compressor refrigeration mode. When the battery heat generation is at a critical state, it allocates the parallel operation time ratio of the two modes and controls the compressor (1) to be used only to supplement the cooling capacity gap of the fluorine pump natural cooling mode.

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