Quick charging wire harness heat dissipation method and device, direct current quick charging system and vehicle

Abstract

The invention discloses a fast charging wire harness heat dissipation method and device, a direct current fast charging system and a vehicle. The fast-charging wire harness heat dissipation method comprises the following steps: acquiring a surface temperature field of a fast-charging wire harness in real time through a distributed temperature sensing array based on a cable digital twin model of heat-fluid-solid coupling; obtaining the heat accumulation rate of the fast charging wire harness according to the surface temperature field; the temperature of the wire harness is predicted based on a transfer function matrix between the temperature change rate and the cooling efficiency and the heat accumulation rate, and different heat dissipation control strategies are triggered in a graded mode; wherein the heat dissipation control strategy comprises a liquid cooling mode and / or an air cooling mode; in the heat dissipation control strategy, the flow of the cooling liquid is optimized based on an improved model prediction control algorithm.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, and in particular to a method, apparatus, DC fast charging system, and vehicle for heat dissipation of fast charging harness. Background Technology

[0002] With the development of vehicle technology (especially new energy vehicles), the popularity of new energy vehicles is increasing, and they have good application prospects. The charging issue of new energy vehicles has always been a major concern. To alleviate range anxiety, fast charging can reduce charging time to half an hour or even less. However, fast charging generates a large current, which leads to a high temperature rise in the wiring harness, thus requiring heat dissipation for the fast charging harness.

[0003] In existing technologies, a pre-set, fixed trigger threshold is relied upon. For example, the cooling system is only activated when the temperature at the monitoring point exceeds a single threshold of 85°C. This reactive mechanism is ineffective for heat dissipation in fast charging harnesses, leading to problems such as excessively high harness temperatures that limit the charging rate. Summary of the Invention

[0004] This invention provides a method, apparatus, DC fast charging system, and vehicle for heat dissipation of fast charging harnesses, so as to improve the heat dissipation effect of fast charging harnesses.

[0005] According to one aspect of the present invention, a method for heat dissipation of a fast charging harness is provided. The vehicle includes a DC charging socket, a liquid-cooled cable, a distributed temperature sensor array, a liquid-cooled connector plug, a connector socket, and a heat pump system. The distributed temperature sensor array is distributed on the DC charging socket and the liquid-cooled connector plug. Coolant in the liquid-cooled connector plug and the liquid-cooled cable circulates through the heat pump system. The heat pump system includes a liquid water pump and a fan.

[0006] The heat dissipation method for the fast charging harness includes:

[0007] Based on a digital twin model of the cable based on thermal-fluid-structure interaction, and by acquiring the surface temperature field of the fast charging harness in real time through a distributed temperature sensing array;

[0008] The heat accumulation rate of the fast charging harness is obtained based on the surface temperature field.

[0009] Based on the transfer function matrix between the temperature change rate and cooling efficiency, and the heat accumulation rate, the harness temperature is predicted, and different heat dissipation control strategies are triggered in stages; wherein, the heat dissipation control strategies include liquid cooling mode and / or air cooling mode.

[0010] In the heat dissipation control strategy, the coolant flow rate is optimized based on an improved model predictive control algorithm.

[0011] Optionally, the heat dissipation control strategy includes:

[0012] When the predicted wire harness temperature exceeds the high temperature threshold, the cooling pump system is adjusted to increase the coolant flow rate and improve heat dissipation performance.

[0013] When the predicted wire harness temperature exceeds the ultra-high temperature threshold, the fan of the cooling pump system is activated to improve the heat dissipation of the water tank.

[0014] When the predicted harness temperature exceeds the derating threshold, the high-voltage battery charging current is limited to reduce heat generation; wherein the high temperature threshold is less than the ultra-high temperature threshold, and the ultra-high temperature threshold is less than the derating threshold.

[0015] Optionally, when predicting the harness temperature based on the transfer function matrix between the temperature change rate and cooling efficiency, and the heat accumulation rate, and triggering different heat dissipation control strategies in stages, the method further includes:

[0016] Based on the information sent by the various components of the vehicle, a fault handling strategy is executed; wherein, the fault handling strategy includes: when the cooling pump system fails, reducing the charging current to the rated current of the cable; when the thermal management system and the charging pile fail, shutting down the charging process.

[0017] Optionally, after predicting the harness temperature based on the transfer function matrix between the temperature change rate and cooling efficiency, and the heat accumulation rate, and triggering different heat dissipation control strategies in stages, the method further includes:

[0018] The failure life of the insulation material is calculated in real time based on the number of times the vehicle is fast-charged and the surface temperature field during the fast-charging process.

[0019] Optionally, before the cable digital twin model based on thermal-fluid-structure interaction and before acquiring the surface temperature field of the fast charging harness in real time through a distributed temperature sensing array, the method further includes:

[0020] The aging factor of the cable insulation layer is incorporated into the cable digital twin model based on thermal-fluid-structure interaction as a determinant of the surface temperature field.

[0021] Optionally, in the heat dissipation control strategy, optimizing the coolant flow rate based on an improved model predictive control algorithm includes:

[0022] The theoretical heat load is calculated based on real-time current values ​​and ambient temperature.

[0023] Based on the theoretical heat load, target temperature change, radiator system power, and radiator motor speed, a multi-objective optimization algorithm is used to determine the coolant flow rate.

[0024] Optionally, the multi-objective optimization algorithm is the NSGA-II genetic algorithm.

[0025] Optionally, when implementing the heat dissipation control strategy, the method further includes:

[0026] When the coolant flow rate deviation exceeds the set deviation value and the duration exceeds the set time, the control water tank switches to the backup hydraulic circuit.

[0027] Optionally, when implementing the heat dissipation control strategy, the method further includes:

[0028] If the ambient temperature is lower than the set ambient temperature threshold, the heater will be activated to maintain the coolant temperature above the freezing point.

[0029] According to another aspect of the present invention, a fast charging harness heat dissipation device is provided. The vehicle includes a DC charging socket, a liquid-cooled cable, a distributed temperature sensor array, a liquid-cooled connector plug, a connector socket, and a heat pump system. The distributed temperature sensor array is distributed on the DC charging socket and the liquid-cooled connector plug. The coolant in the liquid-cooled connector plug and the liquid-cooled cable circulates through the heat pump system. The heat pump system includes a liquid water pump and a fan.

[0030] The fast charging harness heat dissipation device includes:

[0031] The surface temperature field acquisition module is used to acquire the surface temperature field of the fast charging harness in real time through a distributed temperature sensing array based on a cable digital twin model of thermal-fluid-solid coupling.

[0032] A thermal accumulation rate acquisition module is used to obtain the thermal accumulation rate of the fast charging harness based on the surface temperature field.

[0033] A graded control module is used to predict the wire harness temperature based on the transfer function matrix between the temperature change rate and cooling efficiency, as well as the heat accumulation rate, and to trigger different heat dissipation control strategies in a graded manner; wherein, the heat dissipation control strategies include multiple modes such as liquid cooling and / or air cooling.

[0034] The cooling flow optimization module is used to optimize the coolant flow rate based on an improved model predictive control algorithm in the heat dissipation control strategy.

[0035] According to another aspect of the present invention, a DC fast charging system is provided, comprising: a DC charging socket, a liquid-cooled cable, a distributed temperature sensor array, a liquid-cooled connector plug, a connector socket, a heat pump system, and a thermal management system;

[0036] The distributed temperature sensor array is distributed on the DC charging socket and the liquid-cooled connector plug; the coolant in the liquid-cooled connector plug and the liquid-cooled cable is circulated through the heat pump system; the heat pump system includes a liquid water pump and a fan.

[0037] The thermal management system performs the fast charging harness heat dissipation method as described in any embodiment of the present invention.

[0038] According to another aspect of the present invention, a vehicle is provided, including a DC fast charging system as described in any embodiment of the present invention.

[0039] The heat dissipation method for fast charging harnesses provided in this invention can predict the heat generated by the fast charging harness during fast charging and adopt a hierarchical control strategy based on the prediction structure. On the one hand, it can improve the heat dissipation effect of the fast charging harness and improve the problem of the fast charging harness being too hot and limiting the charging rate. On the other hand, through precise heat dissipation control, it is beneficial to reduce the energy consumption generated during vehicle fast charging, thereby reducing charging costs and improving customer experience.

[0040] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0041] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0042] Figure 1 This is a schematic diagram of the structure of a DC fast charging system provided in an embodiment of the present invention;

[0043] Figure 2 A flowchart illustrating a heat dissipation method for a fast charging harness provided in an embodiment of the present invention;

[0044] Figure 3 A flowchart illustrating another fast charging harness heat dissipation method provided in an embodiment of the present invention;

[0045] Figure 4 This is a schematic diagram of a fast charging harness heat dissipation device provided in an embodiment of the present invention. Detailed Implementation

[0046] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0047] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0048] This invention provides a method for heat dissipation of fast charging harnesses. The method is performed by a fast charging harness heat dissipation device, which can be integrated into the vehicle's thermal management system, such as a battery management system (BMS).

[0049] To better understand the heat dissipation method for fast charging harnesses provided in the embodiments of the present invention, the relevant structure of the DC fast charging system and the heat dissipation principle of the fast charging harness will be explained first.

[0050] Figure 1 This is a schematic diagram of a DC fast charging system provided in an embodiment of the present invention. See also... Figure 1 The DC fast charging system includes a DC charging socket 1, a liquid-cooled cable 2, a distributed temperature sensor array 3, a liquid-cooled connector plug 4, a connector socket 5, and a heat pump system 6; wherein, the distributed temperature sensor array 3 is distributed on the DC charging socket 1 and the liquid-cooled connector plug 4; the coolant in the liquid-cooled connector plug 4 and the liquid-cooled cable 2 is circulated through the heat pump system 6; the heat pump system 6 includes a water pump ( Figure 1 (Not shown in the image) and fan 62. Exemplarily, the distributed temperature sensing array 3 includes temperature sensors 31, 32, 33, and 34, wherein temperature sensors 31 and 32 are disposed on the DC charging socket 1, and temperature sensors 33 and 34 are disposed on the liquid cooling connector plug 4.

[0051] Optionally, the liquid-cooled connector plug 4 is also provided with a thermally conductive insulating sheet 41, through which the coolant can dissipate heat.

[0052] Furthermore, the DC fast charging system also includes a high-voltage battery 7, which includes a thermal management system 71 and a battery disconnect unit (BDU) 72. The connector socket 5 charges the high-voltage battery 7 through the BDU. The thermal management system 7 may be, for example, a battery management system (BMS) used to implement the heat dissipation method for the fast charging harness provided in any embodiment of the present invention.

[0053] The heat dissipation path in the fast charging harness is as follows: During charging, the heat generated by the connector socket 5 is transferred to the liquid-cooled connector plug 4, and the heat from the liquid-cooled connector plug 4 is transferred to the thermally conductive insulating sheet 41; the liquid-cooled cable 2 is also cooled by the coolant in the heat pump system 6. It should be noted that the heat pump system 6 only operates during fast charging. During slow charging, the liquid-cooled cable 2 can still dissipate heat through the coolant, but the coolant is generally not flowing at this time.

[0054] The heat dissipation path of the heat pump system 6 is as follows: When the vehicle is fast charging, the BMS controls the heat pump system 6 to work. At this time, the water pump in the heat pump system 6 delivers the coolant sequentially to the liquid cooling connector plug 4, the liquid cooling cable 2, and the DC charging socket 1, and then returns to the heat pump system 6.

[0055] Figure 2 This is a schematic flowchart illustrating a heat dissipation method for a fast charging cable harness according to an embodiment of the present invention. See also... Figure 2 The heat dissipation method for this fast charging harness includes the following steps:

[0056] S110, a cable digital twin model based on thermal-fluid-solid coupling, and real-time acquisition of the surface temperature field of the fast charging harness through a distributed temperature sensing array;

[0057] S120. The heat accumulation rate of the fast charging harness is obtained based on the surface temperature field.

[0058] S130. Based on the transfer function matrix between the temperature change rate and cooling efficiency, and the heat accumulation rate, the harness temperature is predicted, and different heat dissipation control strategies are triggered in stages; wherein, the heat dissipation control strategies include liquid cooling mode and / or air cooling mode.

[0059] S140. In the heat dissipation control strategy, the coolant flow rate is optimized based on the improved model predictive control algorithm.

[0060] In the thermal-fluid-solid coupling cable digital twin model, "heat" refers to the heat generation and conduction processes such as Joule heating of conductors, interfacial contact thermal resistance, and material thermal conductivity; "fluid" refers to the flow processes that carry away heat through convection, such as the velocity and pressure fields of coolant or air; and "solid" refers to the geometry, material properties, and thermal stress deformation of solid components such as metal conductors, insulation layers, and sheaths. These three elements exchange temperature-heat flow-velocity data in real time through conjugate heat transfer boundaries, forming a thermal-fluid-solid coupling. The digital twin model digitizes the real object, allowing the virtual copy to synchronize, predict, and optimize with the physical entity in real time. This coupled model is mapped online using the digital twin, and combined with real-time temperature data acquired from various parts of the fast-charging harness by a distributed temperature sensing array, temperature field visualization and heat dissipation optimization are achieved.

[0061] Among them, the heat accumulation rate is the accumulation of heat over time. The faster the heat accumulation rate, the faster the fast charging harness heats up. Therefore, the heat accumulation rate can be used to predict the temperature of the harness. When the heat accumulation rate of the harness is high, a more robust heat dissipation strategy is required for the fast charging harness.

[0062] The transfer function matrix between temperature change rate and cooling efficiency establishes the functional relationship between the temperature change rate of the fast charging harness and the cooling efficiency of the heat pump system, refining the numerical relationship between the two. Specifically, the temperature change rate and the heat accumulation rate are positively correlated, and the two can be converted between each other.

[0063] For example, the graded heat dissipation control strategy includes: a first-level strategy, which adjusts the cooling pump system to increase the coolant flow rate and improve heat dissipation performance when the predicted wiring harness temperature exceeds the high-temperature threshold; a second-level strategy, which adjusts the cooling pump system to start the fan when the predicted wiring harness temperature exceeds the ultra-high temperature threshold to improve water tank heat dissipation; and a third-level strategy, which limits the high-voltage battery charging current and reduces heat generation when the predicted wiring harness temperature exceeds the derating threshold; wherein the high-temperature threshold is less than the ultra-high temperature threshold, and the ultra-high temperature threshold is less than the derating threshold.

[0064] Furthermore, for different heat dissipation strategies, the coolant flow rate of the cooling pump system is fine-tuned according to the improved model predictive control algorithm to improve control accuracy.

[0065] The heat dissipation method for fast charging harnesses provided in this invention can predict the heat generated by the fast charging harness during fast charging and adopt a hierarchical control strategy based on the prediction structure. On the one hand, it can improve the heat dissipation effect of the fast charging harness and improve the problem of the fast charging harness being too hot and limiting the charging rate. On the other hand, through precise heat dissipation control, it is beneficial to reduce the energy consumption generated during vehicle fast charging, thereby reducing charging costs and improving customer experience.

[0066] Based on the above embodiments, optionally, when predicting the wire harness temperature based on the transfer function matrix between the temperature change rate and cooling efficiency and the heat accumulation rate in S130, and triggering different heat dissipation control strategies in stages, the following steps are also included:

[0067] Based on information sent by various vehicle components, a fault handling strategy is executed. This strategy includes: reducing the charging current to the cable's rated current when the cooling pump system malfunctions; and shutting down the charging process when the thermal management system or charging station malfunctions.

[0068] The embodiments of the present invention improve safety during fast charging by providing fault handling strategies.

[0069] Figure 3 This is a schematic flowchart illustrating another fast-charging harness heat dissipation method provided in an embodiment of the present invention. See also... Figure 3 Based on the above embodiments, optionally, after S130, predicting the harness temperature based on the transfer function matrix between the temperature change rate and cooling efficiency, and the heat accumulation rate, and triggering different heat dissipation control strategies in stages, the method further includes:

[0070] S150: Calculate the failure life of the insulation material in real time based on the number of times the vehicle is fast charged and the surface temperature field during the fast charging process.

[0071] Specifically, based on the failure life of the insulation material, it can be determined whether the component needs to be replaced, thereby improving the vehicle's safety performance.

[0072] Based on the above embodiments, optionally, before S110, the cable digital twin model based on thermal-fluid-structure interaction, and the real-time acquisition of the surface temperature field of the fast charging harness through a distributed temperature sensing array, the following method is further included:

[0073] The aging factor of cable insulation is incorporated into the cable digital twin model based on thermal-fluid-structure interaction as a determinant of the surface temperature field.

[0074] Among them, the aging factor of cable insulation layer has a certain impact on thermal-fluid-structure coupling. By incorporating the aging factor of cable insulation layer into the digital twin model of cable based on thermal-fluid-structure coupling as a determinant of the surface temperature field, the accuracy of the model can be improved.

[0075] Based on the above embodiments, optionally, in S140, the heat dissipation control strategy optimizes the coolant flow rate based on an improved model predictive control algorithm, including:

[0076] The theoretical heat load is calculated based on real-time current values ​​and ambient temperature.

[0077] Based on the theoretical heat load, target temperature change, radiator system power, and radiator motor speed, a multi-objective optimization algorithm is used to determine the coolant flow rate.

[0078] The theoretical heat load refers to the heat generated by the action of electric current. For example, the calculation time for the theoretical heat load is Q = α·I. 2 ·R+β·(Ta-25), where α and β are material compensation coefficients, I is the real-time current value, and Ta is the ambient temperature.

[0079] Multi-objective optimization algorithms consider multiple objectives simultaneously, selecting a compromise solution. Specifically, the optimization objectives may include the change in target temperature, the power of the radiator system, and the speed of the radiator motor. For example, the coolant flow rate v = argmin(ω1·ΔT + ω2·Ppump), where ω1 is the initial speed of the radiator motor, ω2 is the adjusted speed, ΔT is the temperature reduction of the fast charging harness, Ppump is the power of the radiator system, and argmin represents the values ​​of ΔT, ω2, and Ppump that minimize the coolant flow rate v. This configuration optimizes the coolant flow rate.

[0080] Based on the above embodiments, optionally, the multi-objective optimization algorithm is the NSGA-II genetic algorithm. The NSGA-II genetic algorithm uses the pattern of genetic algorithms (i.e., selection-crossover-mutation) to stratify the population according to which species are better and more dispersed, evolving generation after generation, and finally giving a uniformly distributed optimal compromise curve. The NSGA-II genetic algorithm has the beneficial effect of not requiring repeated weight adjustments and providing all optimal results with a single algorithm.

[0081] Based on the above embodiments, optionally, when implementing the heat dissipation control strategy, it further includes:

[0082] When the coolant flow rate deviation exceeds the set deviation value and the duration exceeds the set time, the control water tank switches to the backup hydraulic circuit.

[0083] Excessive coolant flow deviation, such as a difference between the actual and target coolant flow rates exceeding a set deviation, can lead to insufficient coolant flow. This, in turn, results in inadequate heat dissipation in the fast-charging harness, potentially causing issues like limited charging speed and component burnout. Typically, coolant pipeline problems such as a sudden drop in water pump efficiency, filter blockage, or stuck electric valves can cause excessive coolant flow deviation. Therefore, switching the water tank to the backup hydraulic circuit can mitigate this problem.

[0084] Based on the above embodiments, optionally, when implementing the heat dissipation control strategy, it further includes:

[0085] If the ambient temperature is lower than the set ambient temperature threshold, the heater will be activated to maintain the coolant temperature above the freezing point.

[0086] Low ambient temperatures can cause coolant to become viscous, reducing its flow rate and volume, thus affecting its heat dissipation effect on the fast charging harness. Maintaining the coolant temperature above freezing by activating a heater (e.g., a PTC heater) ensures good coolant flow and effective heat dissipation.

[0087] In the above embodiments, optionally, the method of heat dissipation through the heat pump system is a conventional mode, wherein the control method for controlling the coolant flow rate is PID control, namely proportional-integral-derivative control, which improves both response speed and response accuracy.

[0088] Based on the above embodiments, optionally, the embodiments of the present invention also include an emergency mode, wherein, in the emergency mode, a thermoelectric cooler (TEC) and a phase-change material (PCM) are used for synergistic cooling. The TEC acts as the active cooling component in the synergistic cooling process, while the PCM acts as a temperature buffer. The combination of the two enables a rapid response time of <0.3s, and their complementary weaknesses result in a faster, more uniform, and more energy-efficient cooling effect.

[0089] In summary, this invention implements a predictive-compensation-self-healing method for heat dissipation control of fast charging harnesses. Prediction refers to predicting the temperature rise of the fast charging harness, specifically by predicting the harness temperature based on the transfer function matrix between the temperature change rate and cooling efficiency, as well as the heat accumulation rate. This prediction stage is equivalent to feedforward compensation of the heat load. For example, a Markov decision process can be used. Compensation refers to the process of heat dissipation for the fast charging harness, specifically by optimizing the coolant flow rate based on an improved model predictive control algorithm in the heat dissipation control strategy. This compensation stage is equivalent to dynamic parameter adjustment. For example, Lyapunov optimization can be used. Self-healing refers to fault-tolerant control, specifically through fault handling strategies. For example, fuzzy Petri nets can be used.

[0090] The embodiments of the present invention can achieve at least the following beneficial effects:

[0091] Firstly, temperature control accuracy has been improved; specifically, the standard deviation of surface temperature of fast charging cables has been reduced; under fast charging conditions, the maximum temperature has decreased significantly; and the temperature fluctuation range is lower.

[0092] Secondly, dynamic response performance is improved; specifically, the system response time is significantly shortened, resulting in a substantial improvement in response performance; the temperature overshoot during current step is reduced; and the prediction accuracy of the digital twin model is higher.

[0093] Thirdly, energy efficiency optimization; specifically, overall energy consumption reduction.

[0094] This invention also provides a heat dissipation device for fast charging harnesses. Figure 4 This is a schematic diagram of a fast charging cable harness heat dissipation device provided in an embodiment of the present invention. See also... Figure 4 The fast charging harness heat dissipation device includes:

[0095] The surface temperature field acquisition module 310 is used to acquire the surface temperature field of the fast charging harness in real time through a distributed temperature sensing array based on the cable digital twin model of thermal-fluid-solid coupling.

[0096] The thermal accumulation rate acquisition module 320 is used to obtain the thermal accumulation rate of the fast charging harness based on the surface temperature field.

[0097] The hierarchical control module 330 is used to predict the wire harness temperature based on the transfer function matrix between the temperature change rate and cooling efficiency, as well as the heat accumulation rate, and to trigger different heat dissipation control strategies in a hierarchical manner; wherein, the heat dissipation control strategies include multiple modes such as liquid cooling and / or air cooling.

[0098] The cooling flow optimization module 340 is used to optimize the coolant flow rate in the heat dissipation control strategy based on an improved model predictive control algorithm.

[0099] The fast charging harness heat dissipation device provided in the embodiments of the present invention can perform the fast charging harness heat dissipation method provided in any embodiment of the present invention, and has corresponding beneficial effects.

[0100] This invention also provides a vehicle that can be a new energy vehicle, a hybrid vehicle, or other vehicle that requires plug-in fast charging. The vehicle includes the DC fast charging system provided in any embodiment of this invention and has corresponding beneficial effects.

[0101] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this is not limited herein.

[0102] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A fast charging wire harness heat dissipation method, characterized in that, The vehicle comprises a direct current charging socket, a liquid cooling cable, a distributed temperature sensing array, a liquid cooling connector plug, a connector socket and a heat dissipation pump system; wherein the distributed temperature sensing array is distributed on the direct current charging socket and the liquid cooling connector plug; the cooling liquid in the liquid cooling connector plug and the liquid cooling cable is circulated through the heat dissipation pump system; the heat dissipation pump system comprises a liquid water pump and a fan; The fast charging wire harness heat dissipation method comprises: a cable digital twin model based on thermal-fluid-solid coupling, and real-time acquisition of a surface temperature field of the fast charging wire harness through the distributed temperature sensing array; obtaining a heat accumulation rate of the fast charging wire harness according to the surface temperature field; predicting the wire harness temperature based on a transfer function matrix between the temperature change rate and the cooling efficiency, and hierarchically triggering different heat dissipation control strategies; wherein the heat dissipation control strategies comprise a liquid cooling mode and / or an air cooling mode; in the heat dissipation control strategies, optimizing the cooling liquid flow based on an improved model predictive control algorithm.

2. The fast-charge wiring harness heat dissipation method of claim 1, wherein, The heat dissipation control strategies comprise: when the predicted wire harness temperature exceeds a high temperature threshold, regulating the heat dissipation pump system to increase the cooling liquid flow to improve the heat dissipation performance; when the predicted wire harness temperature exceeds an ultrahigh temperature threshold, regulating the fan of the heat dissipation pump system to start to improve the water tank heat dissipation; when the predicted wire harness temperature exceeds a derating threshold, limiting the high-voltage battery charging current to reduce the heat generation; wherein the high temperature threshold is less than the ultrahigh temperature threshold, and the ultrahigh temperature threshold is less than the derating threshold.

3. The fast-charge wiring harness heat dissipation method of claim 1, wherein, In the process of predicting the wire harness temperature based on the transfer function matrix between the temperature change rate and the cooling efficiency and the heat accumulation rate, and hierarchically triggering different heat dissipation control strategies, it also comprises: executing a fault handling strategy according to the information sent by each component of the vehicle; wherein the fault handling strategy comprises: when the heat dissipation pump system fails, reducing the charging current to charge at the rated current of the cable; when the thermal management system and the charging pile fail, shutting down the charging process.

4. The fast-charge wiring harness heat dissipation method of claim 1, wherein, After predicting the wire harness temperature based on the transfer function matrix between the temperature change rate and the cooling efficiency and the heat accumulation rate, and hierarchically triggering different heat dissipation control strategies, it also comprises: real-time calculation of the insulation material failure life according to the number of fast charging of the vehicle and the surface temperature field in the fast charging process.

5. The fast-charge wiring harness heat dissipation method of claim 4, wherein, Before the cable digital twin model based on thermal-fluid-solid coupling and real-time acquisition of the surface temperature field of the fast charging wire harness through the distributed temperature sensing array, it also comprises: including the cable insulation layer aging factor into the cable digital twin model based on thermal-fluid-solid coupling as a decisive factor of the surface temperature field.

6. The fast-charge wiring harness heat dissipation method of claim 1, wherein, The process of optimizing the cooling liquid flow based on the improved model predictive control algorithm in the heat dissipation control strategies comprises: calculating the theoretical heat load according to the real-time current value and the ambient temperature; determining the cooling liquid flow by using a multi-objective optimization algorithm according to the theoretical heat load, the target temperature change amount, the heat dissipation pump system power and the heat dissipation pump motor speed.

7. The fast-charge wiring harness heat dissipation method of claim 6, wherein, The multi-objective optimization algorithm is an NSGA-II genetic algorithm.

8. The fast-charge wiring harness heat dissipation method of any one of claims 1-7, wherein, When executing the heat dissipation control strategy, further comprising: When the cooling liquid flow deviation exceeds the set deviation value and the duration exceeds the set time, control the water tank to switch to the standby hydraulic circuit.

9. The fast-charge wiring harness heat dissipation method of any one of claims 1-7, wherein, When executing the heat dissipation control strategy, further comprising: If the ambient temperature is lower than the set ambient temperature threshold, start the heater to maintain the cooling liquid temperature above the freezing point.

10. A fast charging wire harness heat dissipation device, characterized in that, The vehicle comprises a DC charging socket, a liquid cooling cable, a distributed temperature sensing array, a liquid cooling connector plug, a connector socket and a heat dissipation pump system; wherein the distributed temperature sensing array is distributed on the DC charging socket and the liquid cooling connector plug; the cooling liquid in the liquid cooling connector plug and the liquid cooling cable is circulated through the heat dissipation pump system; the heat dissipation pump system comprises a liquid water pump and a fan; The fast charging wire harness heat dissipation device comprises: A surface temperature field acquisition module for acquiring the surface temperature field of the fast charging wire harness based on a heat-flow-solid coupled cable digital twin model and through a distributed temperature sensing array in real time; A heat accumulation rate acquisition module for obtaining the heat accumulation rate of the fast charging wire harness according to the surface temperature field; A hierarchical control module for predicting the wire harness temperature based on a transfer function matrix between the temperature change rate and the cooling efficiency and the heat accumulation rate, and hierarchically triggering different heat dissipation control strategies; wherein the heat dissipation control strategies include liquid cooling and / or air cooling multiple modes; A cooling flow optimization module for optimizing the cooling liquid flow based on an improved model predictive control algorithm in the heat dissipation control strategy.

11. A direct current fast charging system, characterized in that, Comprise: A DC charging socket, a liquid cooling cable, a distributed temperature sensing array, a liquid cooling connector plug, a connector socket, a heat dissipation pump system and a thermal management system; Wherein the distributed temperature sensing array is distributed on the DC charging socket and the liquid cooling connector plug; the cooling liquid in the liquid cooling connector plug and the liquid cooling cable is circulated through the heat dissipation pump system; the heat dissipation pump system comprises a liquid water pump and a fan; The thermal management system executes the fast charging wire harness heat dissipation method as claimed in any one of claims 1-9.

12. A vehicle characterized by comprising: Comprise the DC fast charging system as claimed in claim 11.

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