Novel new energy electric vehicle thermal management controller

Abstract

The invention discloses a novel new energy electric vehicle thermal management controller, and relates to the technical field of vehicle thermal management, the controller adopts an integrated design, and a main control module, a PDU unit, a compressor driving controller, a PTC driving controller, a DC-DC, a low-voltage brushless electronic fan controller and a low-voltage brushless water pump controller are integrated in the same control box body; and an integrated control unit is formed by connecting an internal communication bus and a hard wire. Wherein the PDU provides high-voltage power distribution, the master control module achieves centralized control over all driving parts through a CAN / LIN bus and a hard wire, data are collected in real time in cooperation with a multi-path sensor, collaborative thermal management can be conducted on a cockpit HVAC air conditioning system, a power battery system, an electric drive and electric control system, a hydrogen reactor heat dissipation system and a heat recovery system, and the safety of the cockpit HVAC air conditioning system, the power battery system, the electric drive and electric control system, the hydrogen reactor heat dissipation system and the heat recovery system can be improved. Through high integration, the wire harness length and the installation space are reduced, the control response speed is increased, pure electric and hydrogen fuel cell vehicle models are compatible, intelligence and high efficiency of whole vehicle thermal management are achieved, and energy consumption and the fault rate are reduced.

Description

Technical Field

[0001] This invention relates to a novel thermal management controller for new energy electric vehicles. Background Technology

[0002] The automotive industry is developing rapidly, especially with the rapid development of new energy vehicles, which places higher demands on vehicle economy and safety. For example, the air conditioning systems of new energy vehicles differ significantly from those of traditional gasoline vehicles in terms of driving force and heat source. Their air conditioning compressors are electric compressors, and the systems cannot rely on engine preheating; they require PTC heaters or heat pump air conditioning systems, among other new technologies. Therefore, the thermal management system of new energy vehicles is more complex than that of traditional gasoline vehicles, and its importance to the entire vehicle is increasingly enhanced.

[0003] The thermal management system of new energy vehicles mainly includes three parts: air conditioning thermal management system, motor and electronic control cooling system, and battery thermal management system. It not only needs to provide a comfortable temperature for the passenger compartment, but also needs to provide thermal management for the power battery, electric drive and electronic control system of the whole vehicle to avoid performance or safety problems. It involves the comfort, safety and range of the whole vehicle and is a key subsystem technology of new energy vehicles.

[0004] Meanwhile, since the power batteries of new energy vehicles have strict requirements for the operating temperature, the thermal management system has a crucial impact on the performance, safety, lifespan and usage cost of the power batteries. The performance of the thermal management system of new energy vehicles will directly affect the overall performance of the vehicle. Adopting an integrated multi-in-one control system is conducive to the rational use of vehicle space, lightweight vehicle design, optimization of vehicle cost, and improvement of after-sales maintenance. Summary of the Invention

[0005] This invention provides a novel thermal management controller for new energy electric vehicles, which solves the problems of existing thermal management systems where the control modules are single-function, each component has its own control system, the structure is difficult to arrange, the high and low voltage wiring harnesses are messy, and after-sales maintenance is not conducive to maintenance.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a novel thermal management controller for new energy electric vehicles, comprising a main control module, a PDU unit, a compressor drive controller, a PTC drive controller, a DC-DC converter, a low-voltage brushless electronic fan controller, and a low-voltage brushless water pump controller integrated within the same control box. Each component is connected via a communication bus and hardwired connections to form an integrated thermal management control system. The PDU unit is connected to the compressor drive controller, PTC drive controller, and DC-DC converter via high-voltage lines, providing stable high-voltage DC power to the other five drive / control units besides the main control module. The main control module is connected to the compressor drive controller, PTC drive controller, DC-DC converter, low-voltage brushless electronic fan controller, and low-voltage brushless water pump controller via a CAN2 communication bus, and to a valve assembly consisting of an electronic expansion valve, a four-way valve, a three-way valve, a proportional valve, and a solenoid valve via a LIN communication bus. It is also connected to the solenoid valve assembly, a servo motor, and multiple sensors via hardwired connections. The DC-DC converter is connected to the low-voltage brushless electronic fan controller and low-voltage brushless water pump controller via low-voltage lines, providing low-voltage operating power.

[0007] Preferably, the PDU unit integrates a filter circuit, a pre-charging circuit, and a power distribution circuit. The input terminal of the filter circuit is connected to the high-voltage power supply of the vehicle, and the output terminal is connected to the power distribution circuit via the pre-charging circuit. The power distribution circuit is connected to the power input terminal of the compressor drive controller, the power input terminal of the PTC drive controller, and the DC-DC high-voltage power supply via three independent high-voltage output lines.

[0008] Preferably, the main control module is configured with two CAN communication interfaces and one LIN communication interface. The two CAN communication interfaces include CAN1 and CAN2. The CAN1 communication interface is connected to the vehicle's VCU and BMS components via the CAN bus to realize vehicle communication information interaction. The CAN2 communication interface is connected to the communication terminals of the compressor drive controller, PTC drive controller, DC-DC controller, low-voltage brushless electric fan controller, and low-voltage brushless water pump controller via the CAN bus, respectively, for sending control commands to each drive / control unit and receiving operating status data fed back by each unit. The LIN communication port is connected to the communication terminals of each valve body in the valve group component via the LIN bus to realize the control of the valve group component. At the same time, the main control module is connected to the control terminal and feedback terminal of the servo motor, the signal output terminals of multiple PT sensors, the signal output terminals of multiple temperature sensors, and the digital feedback signal output terminals via hard wiring. It is also connected to the relevant controlled electrical components via the PWM signal output terminal and the high and low level signal output terminals.

[0009] Preferably, the power input terminal of the compressor drive controller is connected to the high-voltage output terminal of the PDU unit, the communication terminal is connected to the CAN2 communication interface of the main control module, and the drive output terminal is connected to the power input terminal of the automotive electric compressor. The compressor drive controller receives control commands sent by the main control module through CAN2 to control the start and stop of the electric compressor and adjust its speed. At the same time, it detects the compressor operating parameters, has fault protection, fault detection and fault diagnosis functions, and feeds back the compressor operating status to the main control module through CAN2.

[0010] Preferably, the power input terminal of the low-voltage brushless electronic fan controller is connected to the DC-DC low-voltage output terminal, the communication terminal is connected to the CAN2 communication interface of the main control module, and the drive output terminal is connected to the power input terminal of the low-voltage heat dissipation electronic fan. The low-voltage brushless electronic fan controller receives control commands sent by the main control module through CAN2, controls the operation of the low-voltage heat dissipation electronic fan, detects the operating status of the electronic fan, has fault detection, fault diagnosis and fault handling functions, and feeds back the operating status of the electronic fan to the main control module through CAN2.

[0011] Preferably, the bottom of the control box is equipped with a cooling plate heat dissipation device. The heat dissipation device can dissipate heat through the return gas temperature of the refrigerant, the condensed liquid refrigerant, or the low-temperature liquid. The heat dissipation status is automatically determined according to the current operating environment of the system.

[0012] Compared with the prior art, the beneficial effects of the present invention are: This invention integrates the main control module, PDU unit, and five drive / control units into a single enclosure through a "seven-in-one" integrated design. The internal wiring uses short-distance buses and hardwired connections, reducing the length of external wiring harnesses by more than 60% and lowering the risk of EMC interference. The control command transmission path is shortened, and the response time is improved to ≤50ms, enabling more precise dynamic temperature control. It also saves 50% of installation space, making it suitable for the compact layout requirements of commercial vehicles. Attached Figure Description

[0013] Figure 1 A schematic diagram of the electrical system framework for the invention; Figure 2 This is a schematic diagram of the electrical principle framework of the present invention; Figure 3 This is a framework diagram of the control system of the present invention; Figure 4 This is the electrical schematic diagram of the main control module of the present invention. Detailed Implementation

[0014] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0015] This invention provides a novel thermal management controller for new energy electric vehicles, comprising a main control module, a PDU unit, a compressor drive controller, a PTC drive controller, a DC-DC converter, a low-voltage brushless electronic fan controller, and a low-voltage brushless water pump controller integrated within the same control box. All components are connected via a communication bus and hardwired connections to form an integrated thermal management control system. The PDU unit is connected to the compressor drive controller, PTC drive controller, and DC-DC converter via high-voltage lines, providing stable high-voltage DC power to the other five drive / control units besides the main control module. The main control module is connected to the compressor drive controller, PTC drive controller, DC-DC converter, low-voltage brushless electronic fan controller, and low-voltage brushless water pump controller via a CAN2 communication bus, and to a valve assembly consisting of an electronic expansion valve, a four-way valve, a three-way valve, a proportional valve, and a solenoid valve via a LIN communication bus. It is also connected via hardwired connections to a solenoid valve assembly, a servo motor, and multiple sensors. The DC-DC converter... The controller is connected to the low-voltage brushless electronic fan controller and the low-voltage brushless water pump controller via low-voltage lines to provide low-voltage power. A cooling plate heat dissipation device is installed at the bottom of the control box. This heat dissipation device is connected to the system's refrigerant circuit or cryogenic liquid circuit. The heat dissipation status is automatically determined according to the current operating environment of the system. The controller is used for centralized thermal management control of the driver's cabin HVAC air conditioning system, power battery system, electric drive and control system, hydrogen reactor heat dissipation system (hydrogen fuel cell), and heat recovery system of new energy electric vehicles.

[0016] The aforementioned PDU unit integrates a filter circuit, a pre-charging circuit, and a power distribution circuit. The input of the filter circuit is connected to the vehicle's high-voltage power supply, and the output is connected to the power distribution circuit via the pre-charging circuit. The power distribution circuit is connected to the power input of the compressor drive controller, the power input of the PTC drive controller, and the DC-DC high-voltage power supply via three independent high-voltage output lines.

[0017] The aforementioned main control module is equipped with two CAN communication interfaces and one LIN communication interface. The two CAN communication interfaces include CAN1 and CAN2. The CAN1 communication interface connects to the vehicle's VCU and BMS components via the CAN bus to realize vehicle communication information exchange. The CAN2 communication interface connects to the compressor drive controller, PTC drive controller, DC-DC controller, low-voltage brushless electric fan controller, and low-voltage brushless water pump controller via the CAN bus to send control commands to each drive / control unit and receive operating status data from each unit. The LIN communication port connects to the communication terminals of each valve body in the valve group via the LIN bus to realize the control of the valve group. At the same time, the main control module connects to the control and feedback terminals of the servo motor, the signal output terminals of multiple PT sensors, the signal output terminals of multiple temperature sensors, and the digital feedback signal output terminals via hard wiring. It also connects to the relevant controlled electrical components via PWM signal output terminals and high / low level signal output terminals.

[0018] The power input terminal of the compressor drive controller is connected to the high-voltage output terminal of the PDU unit, the communication terminal is connected to the CAN2 communication interface of the main control module, and the drive output terminal is connected to the power input terminal of the automotive electric compressor. The compressor drive controller receives control commands sent by the main control module through CAN2 to control the start and stop of the electric compressor and speed adjustment. At the same time, it detects the compressor operating parameters, has fault protection, fault detection and fault diagnosis functions, and feeds back the compressor operating status to the main control module through CAN2.

[0019] The power input terminal of the aforementioned low-voltage brushless electronic fan controller is connected to the DC-DC low-voltage output terminal, the communication terminal is connected to the CAN2 communication interface of the main control module, and the drive output terminal is connected to the power input terminal of the low-voltage heat dissipation electronic fan. The low-voltage brushless electronic fan controller receives control commands sent by the main control module through CAN2, controls the operation of the low-voltage heat dissipation electronic fan, detects the operating status of the electronic fan, has fault detection, fault diagnosis and fault handling functions, and feeds back the operating status of the electronic fan to the main control module through CAN2.

[0020] In this embodiment of the seven-in-one controller, the main control module has a CAN1 communication port and a LIN communication port as external communication ports. CAN1 is mainly responsible for communicating with the entire vehicle and other components of the vehicle. The LIN communication port is mainly responsible for controlling electrical components with LIN communication capabilities, including the electronic expansion valve assembly, the four-way valve assembly, the three-way valve assembly, and the proportional valve assembly. The CAN2 communication interface interacts with the compressor drive controller, the PTC drive controller, the DC-DC converter, the low-voltage electric fan drive controller, and the low-voltage electric water pump drive controller, controlling the corresponding components through CAN communication and simultaneously reading and parsing the corresponding data information fed back by each component on the CAN bus. The main control module can also control via hardwired connection. The system controls solenoid valve components and servo motors, detects feedback signals from servo motors, and detects system pressure signals, temperature signals, and digital feedback signals from multiple PT sensors and temperature sensors. Based on the detected signals and the analysis of relevant signals from various components on the CAN and LIN buses, it performs corresponding logic processing and can control related electrical components via PWM control signals or high / low level control signals. The PDU unit integrates filtering circuits, pre-charging circuits, and power distribution circuits, providing a stable high-voltage DC power supply to the compressor drive controller, PTC drive controller, and DC-DC converter, while meeting EMC requirements. The compressor drive controller primarily receives communication from the main control module. The main control module receives communication commands from the main control module to drive the electric compressor, monitors its operation, and performs fault detection, diagnosis, and handling. It also feeds back the compressor's operating status to the main control module via the CAN bus. The PTC drive controller primarily receives communication commands from the main control module, drives the PTC, and monitors its operation, performing fault detection, diagnosis, and handling. The DC-DC converter inverts high-voltage DC power into low-voltage regulated DC power, providing a stable DC power supply to low-voltage electric fans and water bottles. It also performs fault detection, diagnosis, and handling, and communicates with the main control module via the CAN bus. The main control module communicates with and receives control commands from the main control module, and provides feedback on the DC-DC converter's operating status to the main control module. The low-voltage electric fan drive controller mainly receives communication commands from the main control module, controls the operation of the low-voltage electric fan, and monitors the operating status of the electric fan. It has functions such as fault detection, fault diagnosis, and fault handling, and also provides feedback on the electric fan's operating status to the main control module via the CAN bus. The low-pressure water pump drive controller receives communication commands from the main control module, controls the operation of the low-pressure electric water pump, and monitors the operating status of the electric water pump. It has functions such as fault detection, fault diagnosis, and fault handling, and also provides feedback on the electric water pump's operating status to the main control module via the CAN bus.The entire control system is integrated into a single control cabinet. The bottom of the controller is equipped with a cooling plate for heat dissipation. This cooling system can dissipate heat through the return gas temperature of the refrigerant, through the condensed liquid refrigerant, or through cryogenic liquids. The heat dissipation status can be determined based on the current operating environment of the system, ensuring the safety and reliability of the entire control system.

[0021] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A novel thermal management controller for new energy electric vehicles, comprising a main control module, a PDU unit, a compressor drive controller, a PTC drive controller, a DC-DC converter, a low-voltage brushless electronic fan controller, and a low-voltage brushless water pump controller integrated within the same control box. All components are connected via a communication bus and hardwired connections to form an integrated thermal management control system. The controller is characterized by: The PDU unit is connected to the compressor drive controller, PTC drive controller, and DC-DC converter via high-voltage lines, providing stable high-voltage DC power to the other five drive / control units besides the main control module. The main control module is connected to the compressor drive controller, PTC drive controller, DC-DC converter, low-voltage brushless electronic fan controller, and low-voltage brushless water pump controller via the CAN2 communication bus. It is also connected to the valve assembly consisting of electronic expansion valve, four-way valve, three-way valve, proportional valve, and solenoid valve via the LIN communication bus. Furthermore, it is connected to the solenoid valve assembly, servo motor, and multiple sensors via hardwired connections. The DC-DC converter is connected to the low-voltage brushless electronic fan controller and low-voltage brushless water pump controller via low-voltage lines, providing low-voltage operating power.

2. The novel thermal management controller for new energy electric vehicles according to claim 1, characterized in that: The PDU unit integrates a filter circuit, a pre-charging circuit, and a power distribution circuit. The input of the filter circuit is connected to the vehicle's high-voltage power supply, and the output is connected to the power distribution circuit via the pre-charging circuit. The power distribution circuit is connected to the power input of the compressor drive controller, the power input of the PTC drive controller, and the DC-DC high-voltage power supply via three independent high-voltage output lines.

3. The novel thermal management controller for new energy electric vehicles according to claim 1, characterized in that: The main control module is equipped with two CAN communication interfaces and one LIN communication interface. The two CAN communication interfaces are CAN1 and CAN2. The CAN1 communication interface is connected to the vehicle's VCU and BMS components via the CAN bus to realize vehicle communication information exchange. The CAN2 communication interface is connected to the compressor drive controller, PTC drive controller, DC-DC controller, low-voltage brushless electric fan controller, and low-voltage brushless water pump controller via the CAN bus to send control commands to each drive / control unit and receive operating status data from each unit. The LIN communication port is connected to the communication terminals of each valve body in the valve group via the LIN bus to realize the control of the valve group. At the same time, the main control module is connected to the control and feedback terminals of the servo motor, the signal output terminals of multiple PT sensors, the signal output terminals of multiple temperature sensors, and the digital feedback signal output terminals via hard wiring. It is also connected to the relevant controlled electrical components via PWM signal output terminals and high and low level signal output terminals.

4. A novel thermal management controller for new energy electric vehicles according to claim 1, characterized in that: The power input terminal of the compressor drive controller is connected to the high-voltage output terminal of the PDU unit, the communication terminal is connected to the CAN2 communication interface of the main control module, and the drive output terminal is connected to the power input terminal of the automotive electric compressor. The compressor drive controller receives control commands sent by the main control module via CAN2 to control the start and stop of the electric compressor and adjust its speed. It also detects the compressor's operating parameters, has fault protection, fault detection and fault diagnosis functions, and feeds back the compressor's operating status to the main control module via CAN2.

5. The control method for a vehicle air purification system according to claim 3, characterized in that: The power input terminal of the low-voltage brushless electronic fan controller is connected to the DC-DC low-voltage output terminal, the communication terminal is connected to the CAN2 communication interface of the main control module, and the drive output terminal is connected to the power input terminal of the low-voltage heat dissipation electronic fan. The low-voltage brushless electronic fan controller receives control commands sent by the main control module through CAN2, controls the operation of the low-voltage heat dissipation electronic fan, detects the operating status of the electronic fan, has fault detection, fault diagnosis and fault handling functions, and feeds back the operating status of the electronic fan to the main control module through CAN2.

6. The control method for a vehicle air purification system according to claim 1, characterized in that: The bottom of the control box is equipped with a cooling plate heat dissipation device. The heat dissipation device can dissipate heat through the return gas temperature of the refrigerant, the condensed liquid refrigerant, or the low-temperature liquid. The heat dissipation status is automatically determined according to the current operating environment of the system.

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