Intelligent heat management control system and method for air compressor
By building an intelligent thermal management system in the air compressor, and using a combination of electronic thermostat and three-way solenoid valve, the coolant circulation path is controlled according to the vehicle's operating conditions, which solves the problems of energy waste and insufficient heat dissipation in the air compressor, and improves low-temperature start-up performance and thermal management efficiency.
Patent Information
- Application Number
- CN202511791810.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-01
- Publication Date
- 2026-01-23
AI Technical Summary
Existing air compressor thermal management solutions suffer from serious energy waste, insufficient heat dissipation capacity, poor low-temperature start-up performance, and a lack of intelligent temperature control methods.
An intelligent thermal management system is constructed using an electronic thermostat and a three-way solenoid valve. The ECU controller controls the coolant circulation path according to the vehicle's operating conditions, realizing the internal and external circulation of the air compressor coolant. The system uses the higher temperature coolant to heat the engine intake air or the lower temperature coolant to cool the air compressor intake pipe.
It improves the vehicle's low-temperature start-up performance and the air compressor's thermal management efficiency, makes rational use of energy, avoids excessive cooling, extends equipment life, and reduces fuel consumption.
Smart Images
Figure CN121382584A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of vehicle thermal management technology, and in particular to an intelligent thermal management control system and method for an air compressor. Background Technology
[0002] Currently, automotive engine-driven air compressors (referred to as "air compressors") generally use mechanical gear drives, are directly connected to the engine crankshaft, and operate continuously during engine operation, supplying compressed air to the vehicle's air tank. When the pressure in the vehicle's air tank reaches a set upper limit, a pressure relief valve causes the air compressor to enter an unloading state, discharging excess compressed air to maintain stable system pressure. This traditional solution has the following problems: Significant energy waste: Even when unloaded, the air compressor, though not performing effective compression, is still driven by the engine, resulting in ineffective consumption of mechanical work and increased fuel consumption. Insufficient heat dissipation: Especially in high-temperature environments, the air compressor relies on air cooling, which has low efficiency, leading to excessively high internal temperatures, affecting lubrication performance and component lifespan. Poor low-temperature starting performance: In cold environments, the viscosity of the air compressor lubricating oil increases, resulting in high starting resistance, and the engine warms up slowly, further extending the preparation time for efficient operation. Ineffective utilization of waste heat: The air compressor generates a large amount of heat during operation, and existing systems lack effective waste heat recovery mechanisms, resulting in energy waste. Lack of intelligent temperature control: Traditional cooling systems are mostly passive or simple on / off controls, making it difficult to achieve efficient thermal management. Summary of the Invention
[0003] In view of this, it is necessary to provide an intelligent thermal management control system and method for air compressors to solve the problems of serious energy waste, poor low-temperature start-up performance, and low thermal management efficiency of existing air compressor thermal management solutions.
[0004] To address the aforementioned problems, in a first aspect, the present invention provides an intelligent thermal management control system for an air compressor, the air compressor including a water outlet and an air inlet pipe, the system comprising: An electronic thermostat is installed at the water outlet of the air compressor; The three-way solenoid valve has an input end connected to an electronic thermostat, a first output end connected to one end of a first heat exchanger, and a second output end connected to one end of a radiator. The first heat exchanger is connected at one end to the engine intake manifold at the other end. The radiator is connected at one end to one end of the second heat exchanger. The second heat exchanger is connected at one end to the air compressor intake pipe; The ECU controller communicates with the electronic thermostat and the three-way solenoid valve. The ECU controller is used to control the on / off state of the electronic thermostat and the conduction direction of the three-way solenoid valve based on the vehicle's operating conditions, so that the coolant circulation path of the air compressor is the first path, the second path, or the third path. With the electronic thermostat off, the coolant circulation path of the air compressor is the first path, and the coolant circulates inside the air compressor. When the electronic thermostat is turned on and the input end of the three-way solenoid valve is connected to the first output end, the coolant circulation path of the air compressor is the second path. The coolant of the air compressor flows to the first heat exchanger through the three-way solenoid valve and heats the engine intake manifold through the first heat exchanger. With the electronic thermostat turned on and the input and second output terminals of the three-way solenoid valve connected, the coolant circulation path of the air compressor is the third path. The coolant of the air compressor flows to the radiator through the three-way solenoid valve, is cooled by the radiator, and then flows to the second heat exchanger to cool the air compressor intake pipe.
[0005] In one possible implementation, the system further includes: A pressure sensor is used to acquire the pressure in the air compressor's storage tank and transmit it to the ECU controller; Temperature sensors are used to acquire the temperature of the air compressor outlet and the ambient temperature and transmit them to the ECU controller.
[0006] In one possible implementation, the vehicle operating conditions are determined based on the pressure in the air compressor's storage tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed.
[0007] In one possible implementation, when the ambient temperature is less than a first temperature threshold, the vehicle operating condition is determined to be an extremely cold environment condition. When the ambient temperature is greater than the second temperature threshold, the vehicle operating condition is determined to be a high-temperature environment condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is less than the first speed threshold, and the temperature at the air compressor outlet is less than the third temperature threshold, the vehicle operating condition is determined to be a cold start condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the first speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's air tank is greater than the first pressure threshold, the vehicle's operating condition is determined to be the idling condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the second speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's storage tank is less than or equal to the second pressure threshold, the vehicle's operating condition is determined to be either an unloaded condition or a medium-low load condition. The vehicle is identified as being in a high-load condition when the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is greater than the second speed threshold, the temperature at the air compressor outlet is greater than the fourth temperature threshold, and the pressure in the air compressor's storage tank is greater than the second pressure threshold.
[0008] In one possible implementation, the on / off state of the vehicle operating condition control electronic thermostat and the conduction direction of the three-way solenoid valve include: When the vehicle is in cold start, idling, no-load, or medium-low load condition, turn off the electronic thermostat. When the vehicle is under high load or high temperature conditions, the electronic thermostat is turned on and the three-way solenoid valve is controlled to open the channel to the radiator and close the channel to the first heat exchanger. When the vehicle is operating in an extremely cold environment, the electronic thermostat is activated, and the three-way solenoid valve is used to close the channel to the radiator and open the channel to the first heat exchanger.
[0009] In one possible implementation, the ECU controller is further configured to adjust the opening degree of the electronic thermostat based on the temperature at the air compressor outlet when the electronic thermostat is on, the channel from the three-way solenoid valve to the radiator is open, and the channel to the first heat exchanger is closed.
[0010] On the other hand, the present invention also provides an intelligent thermal management control method for an air compressor based on the intelligent thermal management control system of the above-mentioned air compressor, applied to an ECU controller, comprising: The pressure in the air compressor's air tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed are obtained. The vehicle operating conditions are determined based on the pressure in the air compressor's storage tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed. The on / off state of the electronic thermostat and the conduction direction of the three-way solenoid valve are controlled based on vehicle operating conditions.
[0011] In one possible implementation, determining vehicle operating conditions based on the pressure in the air compressor's air tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed includes: When the ambient temperature is below the first temperature threshold, the vehicle operating condition is determined to be an extremely cold environment condition. When the ambient temperature is greater than the second temperature threshold, the vehicle operating condition is determined to be a high-temperature environment condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is less than the first speed threshold, and the temperature at the air compressor outlet is less than the third temperature threshold, the vehicle operating condition is determined to be a cold start condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the first speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's air tank is greater than the first pressure threshold, the vehicle's operating condition is determined to be the idling condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the second speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's storage tank is less than or equal to the second pressure threshold, the vehicle's operating condition is determined to be either an unloaded condition or a medium-low load condition. The vehicle is identified as being in a high-load condition when the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is greater than the second speed threshold, the temperature at the air compressor outlet is greater than the fourth temperature threshold, and the pressure in the air compressor's storage tank is greater than the second pressure threshold.
[0012] In one possible implementation, the on / off state of the vehicle operating condition control electronic thermostat and the conduction direction of the three-way solenoid valve include: When the vehicle is in cold start, idling, no-load, or medium-low load condition, turn off the electronic thermostat. When the vehicle is under high load or high temperature conditions, the electronic thermostat is turned on and the three-way solenoid valve is controlled to open the channel to the radiator and close the channel to the first heat exchanger. When the vehicle is operating in an extremely cold environment, the electronic thermostat is activated, and the three-way solenoid valve is used to close the channel to the radiator and open the channel to the first heat exchanger.
[0013] In one possible implementation, the method further includes: With the electronic thermostat turned on, the channel from the three-way solenoid valve to the radiator open, and the channel to the first heat exchanger closed, the opening degree of the electronic thermostat is adjusted based on the temperature of the air compressor outlet.
[0014] The beneficial effects of this invention are as follows: The intelligent thermal management control system and method for air compressors provided by this invention control the specific circulation path of the air compressor coolant according to the vehicle's operating conditions, thereby enabling the air compressor coolant to circulate in a small loop within the air compressor to avoid overcooling. The higher temperature of the air compressor coolant improves the heating efficiency of the engine intake air during cold starts, rationally utilizing energy to improve the vehicle's low-temperature starting performance. The lower temperature of the air compressor coolant is used to cool the air compressor intake pipe, thereby improving the air compressor's thermal management efficiency. This invention fully utilizes the energy generated during the air compressor cooling process, improving the vehicle's low-temperature starting performance and the air compressor's thermal management efficiency. Attached Figure Description
[0015] Figure 1 A schematic diagram of an embodiment of the intelligent thermal management control system for an air compressor provided by the present invention; Figure 2 A schematic flowchart of an embodiment of the intelligent thermal management control method for an air compressor provided by the present invention; Figure 3 A schematic diagram of another embodiment of the intelligent thermal management control system for an air compressor provided by the present invention; Figure 4 This is a schematic flowchart of an embodiment of the intelligent thermal management control process for an air compressor provided by the present invention. Detailed Implementation
[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.
[0017] In the description of the embodiments of the present invention, unless otherwise stated, "multiple" means two or more. "And / or" describes the relationship between related objects, indicating that there can be three relationships. For example, A and / or B can represent three situations: A exists alone, A and B exist simultaneously, and B exists alone.
[0018] The terms "first," "second," etc., used in the embodiments of this invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a technical feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature.
[0019] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.
[0020] This invention provides an intelligent thermal management control system and method for an air compressor, which will be described below.
[0021] Figure 1 A schematic diagram of an embodiment of the intelligent thermal management control system for an air compressor provided by the present invention is shown below. Figure 1 As shown, the air compressor includes a water outlet and an air inlet pipe. The intelligent thermal management control system 100 of the air compressor includes: Electronic thermostat 102 is installed at the water outlet of the air compressor; The three-way solenoid valve 103 has its input end connected to the electronic thermostat 102, its first output end connected to one end of the first heat exchanger 104, and its second output end connected to one end of the radiator 105. The first heat exchanger 104 is connected at one end to the engine intake manifold; The other end of the radiator 105 is connected to one end of the second heat exchanger 106; The second heat exchanger 106 is connected at one end to the air compressor intake pipe; The ECU controller 101 is communicatively connected to the electronic thermostat 102 and the three-way solenoid valve 103. The ECU controller 101 is used to control the on / off state of the electronic thermostat 102 and the conduction direction of the three-way solenoid valve 103 based on the vehicle operating conditions, so that the coolant circulation path of the air compressor is the first path, the second path, or the third path. With the electronic thermostat 102 off, the coolant circulation path of the air compressor is the first path, and the coolant of the air compressor circulates inside the air compressor. When the electronic thermostat 102 is turned on and the input end of the three-way solenoid valve 103 is connected to the first output end, the coolant circulation path of the air compressor is the second path. The coolant of the air compressor flows to the first heat exchanger 104 through the three-way solenoid valve 103 and heats the engine intake manifold through the first heat exchanger 104. When the electronic thermostat 102 is turned on and the input end of the three-way solenoid valve 103 is connected to the second output end, the coolant circulation path of the air compressor is the third path. The coolant of the air compressor flows to the radiator through the three-way solenoid valve 103, is cooled by the radiator 105, and then flows to the second heat exchanger 106 to cool the air compressor intake pipe.
[0022] It should be noted that the intelligent thermal management control system for air compressors provided by this invention can be applied to vehicle thermal management scenarios, especially vehicle air compressor thermal management scenarios.
[0023] In this invention, the electronic thermostat controls the internal and external circulation of the air compressor coolant by controlling whether or not the coolant flows out. The internal circulation refers to a small-scale circulation of the coolant within the air compressor to prevent overcooling. The external circulation is achieved through a three-way solenoid valve. There are two main external circulation paths for the coolant: one is through a first heat exchanger to exchange heat with the engine intake manifold, utilizing the higher-temperature coolant to improve the heating efficiency of the engine intake air during cold starts, thus optimizing energy utilization and improving the vehicle's low-temperature starting performance; the other is to first dissipate heat through the radiator, and then use the lower-temperature coolant to cool the air compressor intake manifold, thereby improving the air compressor's thermal management efficiency. The Electronic Control Unit (ECU) controller can control the on / off state of the electronic thermostat and the conduction direction of the three-way solenoid valve according to the vehicle's operating conditions, thereby controlling the specific circulation path of the air compressor coolant and achieving intelligent thermal management of the air compressor.
[0024] In summary, the intelligent thermal management control system for air compressors provided in this invention controls the specific circulation path of the air compressor coolant according to the vehicle's operating conditions. This allows the air compressor coolant to circulate within the air compressor in a small loop to avoid overcooling. The higher-temperature air compressor coolant improves the heating efficiency of the engine intake air during cold starts, thus rationally utilizing energy to improve the vehicle's low-temperature starting performance. The lower-temperature air compressor coolant is used to cool the air compressor intake pipe, thereby improving the air compressor's thermal management efficiency. This invention fully utilizes the energy generated during the air compressor cooling process, improving both the vehicle's low-temperature starting performance and the air compressor's thermal management efficiency.
[0025] In some embodiments of the present invention, the system further includes: A pressure sensor is used to acquire the pressure in the air compressor's storage tank and transmit it to the ECU controller; Temperature sensors are used to acquire the temperature of the air compressor outlet and the ambient temperature and transmit them to the ECU controller.
[0026] It should be noted that the intelligent thermal management control system for the air compressor provided by this invention also includes a pressure sensor and a temperature sensor. The pressure sensor can acquire the pressure in the air compressor's storage tank and transmit it to the ECU controller. The temperature sensor can acquire the temperature of the air compressor's outlet and the ambient temperature and transmit them to the ECU controller. The data collected by the pressure sensor and the temperature sensor can be used as the basis for the ECU to control and judge the vehicle's operating condition, thereby further improving the thermal management efficiency of the air compressor.
[0027] In some embodiments of the present invention, the vehicle operating conditions are determined based on the pressure in the air compressor's storage tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed.
[0028] It should be noted that when the ECU controller determines the vehicle's operating conditions, it can do so by measuring the pressure in the air compressor's reservoir, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed.
[0029] In some embodiments of the present invention, when determining the vehicle operating conditions based on the pressure in the air compressor's storage tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed, the specific determination rules are as follows: When the ambient temperature is below the first temperature threshold, the vehicle operating condition is determined to be an extremely cold environment condition. When the ambient temperature is greater than the second temperature threshold, the vehicle operating condition is determined to be a high-temperature environment condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is less than the first speed threshold, and the temperature at the air compressor outlet is less than the third temperature threshold, the vehicle operating condition is determined to be a cold start condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the first speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's air tank is greater than the first pressure threshold, the vehicle's operating condition is determined to be the idling condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the second speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's storage tank is less than or equal to the second pressure threshold, the vehicle's operating condition is determined to be either an unloaded condition or a medium-low load condition. The vehicle is identified as being in a high-load condition when the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is greater than the second speed threshold, the temperature at the air compressor outlet is greater than the fourth temperature threshold, and the pressure in the air compressor's storage tank is greater than the second pressure threshold.
[0030] In some embodiments of the present invention, the on / off state of the vehicle operating condition control electronic thermostat and the conduction direction of the three-way solenoid valve include: When the vehicle is in cold start, idling, no-load, or medium-low load condition, turn off the electronic thermostat. When the vehicle is under high load or high temperature conditions, the electronic thermostat is turned on and the three-way solenoid valve is controlled to open the channel to the radiator and close the channel to the first heat exchanger. When the vehicle is operating in an extremely cold environment, the electronic thermostat is activated, and the three-way solenoid valve is used to close the channel to the radiator and open the channel to the first heat exchanger.
[0031] It should be noted that: When the vehicle is operating under cold start, idling, no-load, or low-to-medium load conditions, the electronic thermostat is turned off to keep the air compressor coolant in internal circulation, preventing over-cooling. When the vehicle is operating under high load or high-temperature conditions, the electronic thermostat is turned on, and the three-way solenoid valve is opened to the radiator while closing the channel to the first heat exchanger. This allows the low-temperature coolant to pre-cool the air compressor intake air, reducing the compression ratio and improving volumetric efficiency. When the vehicle is operating in extremely cold conditions, the electronic thermostat is turned on, and the three-way solenoid valve is closed to the radiator while opening the channel to the first heat exchanger. This uses the high-temperature coolant from the air compressor as a heat source to heat the engine intake manifold through the heat exchanger.
[0032] In some embodiments of the present invention, the ECU controller is further configured to adjust the opening degree of the electronic thermostat based on the temperature of the air compressor outlet when the electronic thermostat is turned on, the channel from the three-way solenoid valve to the radiator is open, and the channel to the first heat exchanger is closed.
[0033] It should be noted that when the air compressor coolant is cooled by the radiator, the ECU controller can also adjust the opening of the electronic thermostat according to the temperature of the air compressor outlet to ensure heat dissipation efficiency.
[0034] Figure 2 This is a schematic flowchart of an embodiment of the intelligent thermal management control method for an air compressor provided by the present invention. This method is executed based on the aforementioned intelligent thermal management control system for the air compressor and is applied to an ECU controller, such as... Figure 2 As shown, the intelligent thermal management control method for air compressors includes: S201. Obtain the pressure in the air compressor's air tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed.
[0035] S202. Determine vehicle operating conditions based on the pressure in the air compressor's storage tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed.
[0036] S203. Control the on / off state of the electronic thermostat and the conduction direction of the three-way solenoid valve based on vehicle operating conditions.
[0037] It should be noted that when the ECU controller performs intelligent thermal management control of the air compressor, it can first obtain the pressure in the air compressor's air tank, the temperature of the air compressor's outlet, the ambient temperature, and the engine speed. Then, it uses this data to determine the vehicle's operating conditions. Finally, it controls the on / off state of the electronic thermostat and the conduction direction of the three-way solenoid valve based on the vehicle's operating conditions, thereby controlling the specific circulation path of the air compressor's coolant and realizing intelligent thermal management of the air compressor.
[0038] In summary, the intelligent thermal management control method for air compressors provided in this invention controls the specific circulation path of the air compressor coolant according to the vehicle's operating conditions. This allows the air compressor coolant to circulate within the air compressor in a small loop to avoid overcooling. The higher temperature of the air compressor coolant improves the heating efficiency of the engine intake air during cold starts, thus rationally utilizing energy to improve the vehicle's low-temperature starting performance. Furthermore, the lower temperature of the air compressor coolant cools the air compressor intake pipe, thereby improving the air compressor's thermal management efficiency. This invention fully utilizes the energy generated during the air compressor cooling process, improving both the vehicle's low-temperature starting performance and the air compressor's thermal management efficiency.
[0039] In some embodiments of the present invention, determining vehicle operating conditions based on the pressure in the air compressor's air tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed may include: When the ambient temperature is below the first temperature threshold, the vehicle operating condition is determined to be an extremely cold environment condition. When the ambient temperature is greater than the second temperature threshold, the vehicle operating condition is determined to be a high-temperature environment condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is less than the first speed threshold, and the temperature at the air compressor outlet is less than the third temperature threshold, the vehicle operating condition is determined to be a cold start condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the first speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's air tank is greater than the first pressure threshold, the vehicle's operating condition is determined to be the idling condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the second speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's storage tank is less than or equal to the second pressure threshold, the vehicle's operating condition is determined to be either an unloaded condition or a medium-low load condition. The vehicle is identified as being in a high-load condition when the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is greater than the second speed threshold, the temperature at the air compressor outlet is greater than the fourth temperature threshold, and the pressure in the air compressor's storage tank is greater than the second pressure threshold.
[0040] In some embodiments of the present invention, the on / off state of the vehicle operating condition control electronic thermostat and the conduction direction of the three-way solenoid valve include: When the vehicle is in cold start, idling, no-load, or medium-low load condition, turn off the electronic thermostat. When the vehicle is under high load or high temperature conditions, the electronic thermostat is turned on and the three-way solenoid valve is controlled to open the channel to the radiator and close the channel to the first heat exchanger. When the vehicle is operating in an extremely cold environment, the electronic thermostat is activated, and the three-way solenoid valve is used to close the channel to the radiator and open the channel to the first heat exchanger.
[0041] It should be noted that: When the vehicle is operating under cold start, idling, no-load, or low-to-medium load conditions, the electronic thermostat is turned off to keep the air compressor coolant in internal circulation, preventing over-cooling. When the vehicle is operating under high load or high-temperature conditions, the electronic thermostat is turned on, and the three-way solenoid valve is opened to the radiator while closing the channel to the first heat exchanger. This allows the low-temperature coolant to pre-cool the air compressor intake air, reducing the compression ratio and improving volumetric efficiency. When the vehicle is operating in extremely cold conditions, the electronic thermostat is turned on, and the three-way solenoid valve is closed to the radiator while opening the channel to the first heat exchanger. This uses the high-temperature coolant from the air compressor as a heat source to heat the engine intake manifold through the heat exchanger.
[0042] In some embodiments of the present invention, the method further includes: With the electronic thermostat turned on, the channel from the three-way solenoid valve to the radiator open, and the channel to the first heat exchanger closed, the opening degree of the electronic thermostat is adjusted based on the temperature of the air compressor outlet.
[0043] It should be noted that when the air compressor coolant is cooled by the radiator, the ECU controller can also adjust the opening of the electronic thermostat according to the temperature of the air compressor outlet to ensure heat dissipation efficiency.
[0044] This invention can improve energy utilization efficiency, extend equipment life, and achieve adaptive thermal management under all operating conditions.
[0045] This invention employs an independent water-cooled circulation system, establishing a separate coolant circulation loop between the engine and the air compressor, connected to the air compressor's internal cooling chamber and the engine cooling system via pipelines. An electronic thermostat is added to this loop for precise control of the coolant flow.
[0046] The electronic thermostat's intelligent control logic is as follows: When the air compressor outlet temperature exceeds a preset threshold (e.g., 100°C), the electronic thermostat turns on, and coolant flows into the engine's main cooling system for heat dissipation; when the temperature drops to a set hysteresis value (e.g., 90°C), the electronic thermostat turns off, and the coolant remains within the air compressor's small circulation loop to prevent overcooling; the control strategy can dynamically adjust the opening and closing thresholds based on PID algorithms or MAP lookup tables, combined with parameters such as engine speed, load, and ambient temperature.
[0047] Waste heat recovery and intake precooling coupling device: using the high-temperature coolant of the air compressor as a heat source to heat the engine intake manifold or cab heating system through a plate heat exchanger; or using the low-temperature coolant in the opposite direction to precool the air compressor intake, reduce the compression ratio and improve volumetric efficiency.
[0048] Rapid warm-up strategy in low-temperature environments: During the cold start phase, the control system prioritizes retaining the heat generated by the air compressor in the local circulation to assist the engine in warming up quickly, shortening the warm-up time, and improving combustion efficiency and emission performance.
[0049] Integrated Intelligent Control Unit (ECU): Designed with a dedicated control module, it collects signals such as air compressor inlet and outlet water temperature and pressure, engine speed, and air tank pressure, comprehensively judges the current operating conditions, executes the optimal thermal management strategy, and supports Over-the-Air Technology (OTA) upgrades and fault diagnosis functions.
[0050] The water-cooled circulation system in this invention is independently set up. It can use the waste heat of the air compressor to heat the engine intake air or the cab. The air compressor temperature can be controlled by controlling the coolant circuit. It can comprehensively judge the current operating conditions and execute the optimal thermal management strategy.
[0051] This invention can reduce the operating temperature of the air compressor by 10–20°C, improve continuous air pumping efficiency by more than 8%, reduce the extra oil consumption of the engine caused by the air compressor drive by about 3–5%, shorten the engine cold start warm-up time by more than 20%, improve low temperature start performance, extend the air compressor lubricating oil replacement cycle and the service life of key components, reduce maintenance costs, improve the air supply stability of the vehicle braking system, and enhance driving safety.
[0052] Combination Figure 3This invention establishes an independent coolant circulation loop inside the air compressor, with engine coolant entering the compressor's internal cooling chamber through pipelines. An electronic thermostat is added to the air compressor outlet, using a water temperature sensor to collect the outlet water temperature. The ECU (Electronic Control Unit) then controls the thermostat's activation and deactivation. When the outlet temperature is below a set hysteresis value of 82°C, the ECU controls the thermostat to close, maintaining coolant within the compressor's small circulation loop to prevent over-cooling. When the outlet temperature exceeds a preset threshold of 85°C, the ECU controls the thermostat to activate (fully activated at 95°C), at which point coolant flows into the vehicle's main cooling system. This design effectively decouples the thermal load interference between the engine and the air compressor, avoiding temperature fluctuations and control delays caused by sharing a cooling loop.
[0053] The high-temperature coolant entering the vehicle's main cooling system serves as a heat source. A three-way electronic valve is installed between the electronic thermostat and the radiator in the coolant passage. The ECU collects the ambient temperature via a temperature sensor. When the ambient temperature is below -15°C, the ECU controller controls the three-way solenoid valve to open the upper passage, allowing the high-temperature coolant to pass through plate heat exchanger A, heating the engine intake manifold, increasing the intake air temperature, shortening warm-up time, improving fuel atomization and combustion stability, and enhancing starting performance and power output under extremely cold conditions. When the ambient temperature is above 30°C, the ECU controller controls the three-way solenoid valve to open the lower passage, allowing the high-temperature coolant to first be cooled by the radiator, and then pre-cool the air compressor intake air using the low-temperature coolant through plate heat exchanger B, reducing the compression ratio and improving volumetric efficiency.
[0054] Combination Figure 4 As you can see, this invention features a dedicated ECU control module that integrates multi-dimensional sensor signals such as air compressor inlet and outlet coolant temperature, engine speed, air tank pressure, and ambient temperature. Based on a working condition identification model (e.g., idling, acceleration, high load, extreme cold environment), it dynamically adjusts the cooling strategy to achieve optimal decision-making regarding cooling flow and heat energy distribution, ensuring the air compressor always operates within its optimal temperature range, balancing efficiency and reliability. The specific adjustment strategy is shown in the table below:
[0055] The intelligent thermal management control system and method for air compressors provided by this invention have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this invention. Therefore, the content of this specification should not be construed as a limitation of this invention.
Claims
1. An intelligent thermal management control system for an air compressor, the air compressor comprising a water outlet and an air inlet pipe, characterized in that, The system includes: An electronic thermostat is installed at the water outlet of the air compressor; The three-way solenoid valve has an input end connected to an electronic thermostat, a first output end connected to one end of a first heat exchanger, and a second output end connected to one end of a radiator. The first heat exchanger is connected at one end to the engine intake manifold at the other end. The radiator is connected at one end to one end of the second heat exchanger. The second heat exchanger is connected at one end to the air compressor intake pipe; The ECU controller communicates with the electronic thermostat and the three-way solenoid valve. The ECU controller is used to control the on / off state of the electronic thermostat and the conduction direction of the three-way solenoid valve based on the vehicle's operating conditions, so that the coolant circulation path of the air compressor is the first path, the second path, or the third path. With the electronic thermostat off, the coolant circulation path of the air compressor is the first path, and the coolant circulates inside the air compressor. When the electronic thermostat is turned on and the input end of the three-way solenoid valve is connected to the first output end, the coolant circulation path of the air compressor is the second path. The coolant of the air compressor flows to the first heat exchanger through the three-way solenoid valve and heats the engine intake manifold through the first heat exchanger. With the electronic thermostat turned on and the input and second output terminals of the three-way solenoid valve connected, the coolant circulation path of the air compressor is the third path. The coolant of the air compressor flows to the radiator through the three-way solenoid valve, is cooled by the radiator, and then flows to the second heat exchanger to cool the air compressor intake pipe.
2. The intelligent thermal management control system for the air compressor according to claim 1, characterized in that, The system also includes: A pressure sensor is used to acquire the pressure in the air compressor's storage tank and transmit it to the ECU controller; Temperature sensors are used to acquire the temperature of the air compressor outlet and the ambient temperature and transmit them to the ECU controller.
3. The intelligent thermal management control system for the air compressor according to claim 2, characterized in that, The vehicle operating conditions are determined based on the pressure in the air compressor's storage tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed.
4. The intelligent thermal management control system for the air compressor according to claim 3, characterized in that, When the ambient temperature is below the first temperature threshold, the vehicle operating condition is determined to be an extremely cold environment condition. When the ambient temperature is greater than the second temperature threshold, the vehicle operating condition is determined to be a high-temperature environment condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is less than the first speed threshold, and the temperature at the air compressor outlet is less than the third temperature threshold, the vehicle operating condition is determined to be a cold start condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the first speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's air tank is greater than the first pressure threshold, the vehicle's operating condition is determined to be the idling condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the second speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's storage tank is less than or equal to the second pressure threshold, the vehicle's operating condition is determined to be either an unloaded condition or a medium-low load condition. The vehicle is identified as being in a high-load condition when the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is greater than the second speed threshold, the temperature at the air compressor outlet is greater than the fourth temperature threshold, and the pressure in the air compressor's storage tank is greater than the second pressure threshold.
5. The intelligent thermal management control system for the air compressor according to claim 4, characterized in that, The on / off state of the electronic thermostat based on vehicle operating condition control and the conduction direction of the three-way solenoid valve include: When the vehicle is in cold start, idling, no-load, or medium-low load condition, turn off the electronic thermostat. When the vehicle is under high load or high temperature conditions, the electronic thermostat is turned on and the three-way solenoid valve is controlled to open the channel to the radiator and close the channel to the first heat exchanger. When the vehicle is operating in an extremely cold environment, the electronic thermostat is activated, and the three-way solenoid valve is used to close the channel to the radiator and open the channel to the first heat exchanger.
6. The intelligent thermal management control system for the air compressor according to claim 5, characterized in that, The ECU controller is also used to adjust the opening degree of the electronic thermostat based on the temperature of the air compressor outlet when the electronic thermostat is turned on, the channel from the three-way solenoid valve to the radiator is open, and the channel to the first heat exchanger is closed.
7. A method for intelligent thermal management control of an air compressor based on the intelligent thermal management control system of the air compressor according to any one of claims 1-6, characterized in that, Applied to ECU controllers, including: The pressure in the air compressor's air tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed are obtained. The vehicle operating conditions are determined based on the pressure in the air compressor's storage tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed. The on / off state of the electronic thermostat and the conduction direction of the three-way solenoid valve are controlled based on vehicle operating conditions.
8. The intelligent thermal management control method for an air compressor according to claim 7, characterized in that, The vehicle operating conditions are determined based on the pressure in the air compressor's storage tank, the temperature at the air compressor's outlet, the ambient temperature, and the engine speed, including: When the ambient temperature is below the first temperature threshold, the vehicle operating condition is determined to be an extremely cold environment condition. When the ambient temperature is greater than the second temperature threshold, the vehicle operating condition is determined to be a high-temperature environment condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is less than the first speed threshold, and the temperature at the air compressor outlet is less than the third temperature threshold, the vehicle operating condition is determined to be a cold start condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the first speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's air tank is greater than the first pressure threshold, the vehicle's operating condition is determined to be the idling condition. When the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is within the second speed range, the temperature of the air compressor outlet is less than or equal to the fourth temperature threshold, and the pressure in the air compressor's storage tank is less than or equal to the second pressure threshold, the vehicle's operating condition is determined to be either an unloaded condition or a medium-low load condition. The vehicle is identified as being in a high-load condition when the ambient temperature is greater than or equal to the first temperature threshold and less than or equal to the second temperature threshold, the engine speed is greater than the second speed threshold, the temperature at the air compressor outlet is greater than the fourth temperature threshold, and the pressure in the air compressor's storage tank is greater than the second pressure threshold.
9. The intelligent thermal management control method for an air compressor according to claim 8, characterized in that, The on / off state of the electronic thermostat based on vehicle operating condition control and the conduction direction of the three-way solenoid valve include: When the vehicle is in cold start, idling, no-load, or medium-low load condition, turn off the electronic thermostat. When the vehicle is under high load or high temperature conditions, the electronic thermostat is turned on and the three-way solenoid valve is controlled to open the channel to the radiator and close the channel to the first heat exchanger. When the vehicle is operating in an extremely cold environment, the electronic thermostat is activated, and the three-way solenoid valve is used to close the channel to the radiator and open the channel to the first heat exchanger.
10. The intelligent thermal management control method for an air compressor according to claim 9, characterized in that, The method further includes: With the electronic thermostat turned on, the channel from the three-way solenoid valve to the radiator open, and the channel to the first heat exchanger closed, the opening degree of the electronic thermostat is adjusted based on the temperature of the air compressor outlet.