Control box, integrated module and vehicle thermal management system

Abstract

According to the control box, the integrated module and the vehicle thermal management system, control over at least part of execution components in a refrigerant system and control over at least part of execution components in a cooling liquid system are integrated in the control box, and the control box is electrically connected with an upper computer in a whole vehicle; signals sent by the upper computer are transmitted to the execution components through the control box so as to drive the execution components to act. In this way, the number of control ports on the upper computer in the whole vehicle can be reduced, and the structure of the control end of the whole vehicle is optimized; moreover, in the embodiment of the invention, the agent side execution component and the liquid side execution component which are controlled by the control box are integrally designed to form an integrated module, so that the system structure is more compact, the occupied space is small, and the space layout of the whole vehicle can be optimized.

Description

Technical Field

[0001] This application relates to the field of fluid control technology, specifically to a control box, an integrated module, and a vehicle thermal management system. Background Technology

[0002] The thermal management system includes components such as compressors, water pumps, and various valves. To meet the system's functional requirements, there are a large number of valves, which are usually distributed. Since each valve corresponds to a control and drive system, the vehicle end needs multiple connectors and wiring harnesses to connect to it, and the vehicle control needs to assign multiple IDs to deal with it, which consumes communication resources. Summary of the Invention

[0003] The purpose of this application is to provide a control box that can reduce the number of control ports in a vehicle. Another purpose of this application is to provide an integrated module and a vehicle thermal management system that include the above-mentioned control box.

[0004] This application provides a control box for a vehicle thermal management system, the vehicle thermal management system including a refrigerant system and a coolant system, the control box including a housing, the housing integrating a first control module and a second control module, the first control module being used to control the operation of at least one actuator in the refrigerant system;

[0005] The second control module is used to control the operation of at least one actuator in the coolant system.

[0006] This application provides an integrated module for a vehicle thermal management system, comprising at least:

[0007] The coolant system includes a water pump, a heater, and at least one water valve;

[0008] The compressor and at least one electrically controlled valve in the refrigerant system;

[0009] It also includes the control box described above, wherein the first control module is capable of controlling the operation of the compressor and the electronically controlled valve; and the second control module is capable of controlling the operation of the water pump, the heater and the water valve.

[0010] This application provides a vehicle thermal management system, including:

[0011] The integrated module described in any of the above items;

[0012] The compressor, the evaporator, and the condenser are capable of forming a refrigerant circulation loop;

[0013] The battery device, wherein the coolant system is capable of exchanging heat with the battery device.

[0014] In this embodiment, the control of at least some of the actuators in the refrigerant system and the control of at least some of the actuators in the coolant system are integrated into a central control box. The control box is electrically connected to a host computer in the vehicle. Signals sent by the host computer are transmitted to each actuator via the control box to drive them to perform actions. This reduces the number of control ports required on the host computer in the vehicle and optimizes the overall vehicle control structure.

[0015] Furthermore, in this embodiment, the agent-side execution component and the liquid-side execution component controlled by the control box are integrated into an integrated module, making the system structure more compact, occupying less space, and optimizing the overall vehicle space layout.

[0016] The vehicle thermal management system in this application has the aforementioned integrated module and control box, and therefore also has the aforementioned technical effects of the control box and integrated module. Attached Figure Description

[0017] Figure 1 This is a structural block diagram of a vehicle thermal management system according to an embodiment of this application;

[0018] Figure 2 This is a diagram showing the electrical connection relationship between the control box and each execution component in the embodiments of this application;

[0019] Figure 3 This is a schematic diagram of the integrated module in an embodiment of this application;

[0020] Figure 4 for Figure 3 A structural diagram of the middle block and the control box, in which the top wall of the housing in the control box is hidden;

[0021] Figure 5 for Figure 3 The structure shown is a bottom view, with the frame removed;

[0022] Figure 6 for Figure 3 A schematic diagram of the structure shown from another direction;

[0023] Figure 7 for Figure 3 A schematic diagram of the middle frame.

[0024] in Figures 1 to 7 The one-to-one correspondence between the reference numerals and components in the attached drawings is as follows:

[0025] 200 Control box; 210 Housing; 201 Connection port; 220 Circuit board; 11 Compressor; 12 Electrically controlled valve; 121 First solenoid directional valve; 122 Second solenoid directional valve; 123 Third solenoid directional valve; 124 Fourth solenoid directional valve; 125 Fifth solenoid directional valve; 126 First electronic expansion valve; 127 Second electronic expansion valve; 128 Third electronic expansion valve; 13 Gas-liquid separator; 14 Condenser; 15 Evaporator; 16 Heat exchanger; 17 Heat exchanger; 300 Block; 301 First interface; 302 Second interface; 303 Third interface; 304 Third interface; 305 Fifth interface; 306 Sixth interface;

[0026] 211 First water pump; 212 Second water pump; 221 First water valve; 222 Second water valve; 223 Third water valve; 22a Cable; 23 Heater; 24 Battery; 25 Motor and electronic control components; 26 Radiator; 27 Water tank; 28 Flow channel plate; 281 Interface;

[0027] 100 Frame; 101 Recess; 102 Support column; 103 Column. Detailed Implementation

[0028] To enable those skilled in the art to better understand the technical solutions of this application, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0029] Please refer to Figures 1 to 7 , Figure 1 This is a structural block diagram of a vehicle thermal management system according to an embodiment of this application; Figure 2 This is a diagram showing the electrical connection relationship between the control box and each execution component in the embodiments of this application; Figure 3 This is a schematic diagram of the integrated module in an embodiment of this application; Figure 4 for Figure 3 A structural diagram of the middle block and the control box, in which the top wall of the housing in the control box is hidden; Figure 5 for Figure 3 The structure shown is a bottom view, with the frame removed; Figure 6 for Figure 3 A schematic diagram of the structure shown from another direction; Figure 7 for Figure 3 A schematic diagram of the middle frame.

[0030] This application provides a vehicle thermal management system, including a refrigerant system and a coolant system. The coolant system can exchange heat with the battery device in the vehicle thermal management system. The battery device includes a battery 24 and an electric motor control component 25. The refrigerant system includes a compressor 11, an evaporator 15, a condenser 14, a gas-liquid separator 13, and various electrically controlled valves 12. The electrically controlled valves 12 include components requiring electric control, such as four-way reversing valves, directional valves, and throttle valves. The throttle valve can be an electronic expansion valve. The type, number, and location of the electrically controlled valves 12 can be set according to the specific requirements of the system. Figure 1 The example shown is an arrangement of three electronic expansion valves and five solenoid directional valves. The three electronic expansion valves are named as follows: first electronic expansion valve 126, second electronic expansion valve 127, and third electronic expansion valve 128. Figure 1 The five solenoid directional valves are: first solenoid directional valve 121, second solenoid directional valve 122, third solenoid directional valve 123, fourth solenoid directional valve 124 and fifth solenoid directional valve 125.

[0031] This application defines components in a system that require control signals as actuators. Some actuators may include a drive unit and an actuating mechanism. The drive unit receives control signals to drive the actuating mechanism. Taking an electrically controlled valve as an example, the electrically controlled valve is an actuator. The drive unit of the electrically controlled valve may include components such as a rotor and a stator. The actuating mechanism of the electrically controlled valve is a valve mechanism including a valve stem. The rotor receives control signals and can drive the valve stem to reciprocate between the open and closed valve positions. Furthermore, taking a water pump as an example, the water pump includes a motor and an impeller. The motor is the drive unit, and the impeller is the actuating mechanism. The motor receives control signals and can drive the impeller to rotate.

[0032] In this embodiment of the application, the actuators in the refrigerant system are defined as refrigerant-side actuators, such as compressor 11 and various electronically controlled valves 12.

[0033] In the refrigerant system, components such as compressor 11, evaporator 15, and condenser 14 can form a refrigerant circulation loop through pipelines. The refrigerant can circulate in the refrigerant circulation loop, and in this process, the cooling and heating functions are achieved through changes in the physical state of the refrigerant.

[0034] Some refrigerant systems also include a heat exchanger 17.

[0035] In this embodiment, the coolant system includes components such as a water pump, water valve, heater 23, heat exchanger 16, flow channel plate 28, radiator 26, and water tank 27. Similarly, in this application, the actuators in the coolant system are defined as liquid-side actuators; the aforementioned components requiring control signals, such as the water pump, water valve, heater 23, and heat exchanger 16, are all liquid-side actuators. Likewise, the components in the coolant system are connected by pipelines to form a coolant circulation loop, where the coolant and refrigerant exchange heat as they flow through the heat exchanger 16. When the coolant flows through the battery 24 and the motor control component 25, it can carry away the heat generated by the battery 24 and the motor control component 25. Alternatively, the coolant can also heat components such as the battery 24 when the ambient temperature is low.

[0036] The working principles of the refrigerant system and coolant system of the vehicle thermal management system are not detailed in this application; please refer to existing materials.

[0037] This application provides an integrated module for integrating some or all of the refrigerant-side actuators and some or all of the liquid-side actuators together. Specifically, the integrated module includes at least one refrigerant-side actuator and at least one liquid-side actuator. The integrated module includes a compressor 11 and at least one electrically controlled valve 12 in a refrigerant system, and also includes a water pump, a heater 23, and at least one water valve in a coolant system. Figure 1 The diagram shows two water pumps, designated as first pump 211 and second pump 212; and three water valves, designated as first valve 221, second valve 222, and third valve 223. The number of water valves and pumps is not limited to those described herein and depends on the specific system.

[0038] The control of both the agent-side and liquid-side actuators in the integrated module is integrated into the control box 200. The control box 200 is also part of the integrated module.

[0039] Please refer to Figure 3 In this embodiment, the control box 200 includes a housing 210. The housing 210 integrates a first control module and a second control module. The first control module controls the operation of at least one actuator in the refrigerant system. Figure 1 and Figure 2 As shown, the compressor 11 and each electronically controlled valve 12 in the refrigerant system are integrated into an integrated module, and their actions are controlled by the first control module. The second control module is used to control the action of at least one actuator in the coolant system, from... Figure 1 and Figure 2As shown, the water pump, water valve, and heater 23 in the coolant system are integrated into an integrated module, and their actions are controlled by a second control module. As mentioned above, the control box 200 is part of the integrated module. The first control module of the control box 200 is used to control the actions of the liquid-side actuators in the integrated module, and the second control module is used to control the actions of the liquid-side actuators in the integrated module.

[0040] In other words, in this embodiment, the control of at least some of the actuators in the refrigerant system and the control of at least some of the actuators in the coolant system are integrated into the central control box 200. The control box 200 is electrically connected to the host computer in the vehicle. Signals sent by the host computer are transmitted to each actuator via the control box 200 to drive the actuators to perform their actions. This reduces the number of control ports occupied on the host computer in the vehicle and optimizes the overall vehicle control structure.

[0041] Furthermore, in this embodiment, the agent-side execution component and the liquid-side execution component controlled by the control box 200 are integrated into an integrated module, making the system structure more compact, occupying less space, and optimizing the overall vehicle space layout.

[0042] In this embodiment, the first control module includes a plurality of first control units, each first control unit corresponding to one actuating component in the refrigerant system; that is, one first control unit controls one refrigerant-side actuating component. For the control box 200 applied in an integrated module, one first control unit controls one refrigerant-side actuating component in the integrated module. The number of first control units depends on the refrigerant-side actuating components comprising the integrated module. For example, when the integrated module includes a compressor 11 and at least one electrically controlled valve 12, the first control module has first control units corresponding one-to-one with the compressor 11 and the electrically controlled valve 12. Figure 1 When there are 8 electrically controlled valves 12 (five solenoid directional valves and three electronic expansion valves), the number of first control units in the first control module is 9, one of which is a compressor control unit, and the other 8 are valve control units. The valve control units correspond one-to-one with the electrically controlled valves 12. Of course, the number of agent-side actuators in the integrated module is not limited to the above description.

[0043] Similarly, the second control module includes several second control units, each of which corresponds to one actuator in the coolant system. That is, one second control unit controls one liquid-side actuator. When the control box 200 is used in an integrated module, one second control unit controls one liquid-side actuator in the integrated module. The number of second control units depends on the liquid-side actuators that make up the integrated module. For example, when the integrated module includes a water pump, heater 23, and water valve, the second control module has second control units corresponding to each of the water pump, heater 23, and water valve. That is, the second control module includes a water pump control unit, a heater control unit, and a water valve control unit, and the number of each control unit depends on the number of water pumps, heaters 23, and water valves. Figure 1 The diagram shows a specific example of two water pumps, one heater 23, and three water valves. Accordingly, the second control module includes three water pump control units, one heater control unit, and three water valve control units.

[0044] Specifically, the water pump includes a motor and an impeller. The water pump control unit sends a control signal to the motor, and the motor controls the impeller to rotate according to the control signal.

[0045] In this embodiment, the water valve control unit corresponds one-to-one with the water valve, and the water valve control unit controls the corresponding water valve to be open or closed.

[0046] In this embodiment, the first control unit or the second control unit in the control box 200 is configured to correspond one-to-one with the execution component, which facilitates setup and subsequent maintenance.

[0047] Please refer to Figure 4 It is understood that in this embodiment of the application, the control box 200 includes a circuit board 220, and the first control module and the second control module are integrated on the circuit board 220. This results in a high degree of integration of the control box 200, which is beneficial to reducing the size of the control box 200.

[0048] In this embodiment, the first control module and the execution component it controls are electrically connected via wired, wireless, Bluetooth, Wi-Fi, or 5G communication. Similarly, the second control module and the execution component it controls are electrically connected via wired, wireless, Bluetooth, Wi-Fi, or 5G communication. Figure 3The diagram illustrates the electrical connection between the control box 200 and each actuator via cables 22a. Specifically, the power supply terminals of each actuator are connected to the connection port 201 of the control box 200 via cables. The connection port 201 on the control box 200 can be a single main port, where the cables from each actuator converge and are electrically connected to the second control module. This connection method requires only one connection port 201 on the housing 210, resulting in a simple structure and high cable connection efficiency to the control box 200. Of course, the number and structure of connection ports on the control box 200 are not limited to those described herein.

[0049] To facilitate the installation of the integrated module, the integrated module may include a rack 100, and the components in the integrated module are directly or indirectly supported by the rack 100 to form a whole.

[0050] Regarding the arrangement of the execution components in the integrated module, this article also provides a specific embodiment.

[0051] The integrated module in this embodiment also includes a block 300, which has N mounting holes inside. Figure 4 (Not shown in the diagram), each mounting hole has a valve mechanism fixed inside. The housing 210 is located above the housing, and the valve mechanism extends into the housing. The housing 210 has a drive unit corresponding to each valve mechanism. The first control module sends control signals to each drive unit to control the action of each valve mechanism. An electrically controlled valve includes one valve mechanism and one drive unit. Where N is greater than or equal to 2.

[0052] Please combine Figure 4 Understand the above content, Figure 4 The top cover of the housing 210 in the control box 200 has been removed. Figure 4 As shown, eight valve mechanisms are fixed inside the block 300. The upper part of each valve mechanism extends into the housing 210 and passes through the circuit board 220 on the side away from the block 300. These eight valve mechanisms can be the valve mechanisms of the first electromagnetic directional valve 121, the second electromagnetic directional valve 122, the third electromagnetic directional valve 123, the fourth electromagnetic directional valve 124, the fifth electromagnetic directional valve 125, the first electronic expansion valve 126, the second electronic expansion valve 127, and the third electronic expansion valve 128 mentioned above, or they can be valve mechanisms of other electrically controlled valves. The drive unit corresponding to the valve mechanism is located below the circuit board 220 and is obscured by the circuit board 220. Figure 4 Not displayed.

[0053] The surface of block 300 also has interfaces for connection to external refrigerant piping, wherein Figure 4The diagram shows six interfaces on both sides of the block 300: interface 301, interface 302, interface 303, interface 304, interface 305, and interface 306. Other interfaces may also be provided on other sides of the block 300 to meet the operational needs of the valve mechanism located inside the block 300. In this embodiment, the housing 210 of the control box 200 is fixedly connected to the block 300.

[0054] In this embodiment, multiple electrically controlled valves 12 of the refrigerant system are installed in a single block 300, resulting in a high degree of integration, reduced overall weight of the integrated module, and the elimination of cable connections, leading to a more compact and simpler structure. The block 300 can be a single, integrated structure, or it can be composed of several smaller blocks joined together by welding or other methods.

[0055] Block 300 is not limited to the cuboid structure shown in the figure; its shape can be reasonably selected according to the actual product. Block 300 is a one-piece structure (in this article, "one-piece" means not assembled by welding, bonding, or other splicing methods), which can minimize the leakage points of block 300. Of course, block 1 can also be composed of two or more parts joined together by welding or other methods, such as two cubes, two cuboids, or one cube and one cuboid combined. Alternatively, it can be composed of two or more regular or irregular parts, all of which should fall within the scope of the block in this application, because compared to multiple pipeline connection designs, this can still reduce the overall leakage points.

[0056] The block 300 can be supported on the frame 100, and the control box 200 is located above the block 300, supporting and fixing the block 300. Considering the connection between the block 300 and other related components, the block 300 can be supported on the frame 100 by the support column 102.

[0057] The integrated module in this embodiment also includes a heat exchanger 16, which is located on the side of the block 300 opposite to the control box 200. The heat exchanger 16 can be fixed to the block 300 or directly supported and fixed to the frame 100. This allows for convenient connection of related components and a more compact installation.

[0058] In this embodiment, the compressor 11 is relatively heavy and can be directly placed on the base of the frame 100. To improve the installation stability of the compressor 11, a recess 101 adapted to the bottom shell of the compressor 11 can also be provided on the base. When the bottom shell of the compressor 11 is arc-shaped, the shape of the recess 101 is also arc-shaped. The compressor 11 is positioned below the block 300, and part of the compressor 11 can be located below the block 300 to make full use of the space below the block 300.

[0059] In this embodiment, the integrated module also includes a flow channel plate 28 and a water tank 27 connected in the coolant system. The flow channel plate 28 and the water tank 27 can be integrally installed, resulting in a simple structure and small footprint. Alternatively, the flow channel plate 28 and the water tank 27 can be connected via pipelines, simplifying their manufacturing process and increasing installation flexibility. The flow channel plate 28 has multiple internal channels for guiding coolant flow. The external surface of the flow channel plate 28 has multiple connection interfaces 281. A water pump and a water valve are directly mounted on the upper surface of the flow channel plate 28. The water pump primarily provides flow power to the corresponding flow channels, while the water valve controls the connection or disconnection of the corresponding channels within the flow channel plate 28 to configure the required flow path for the system.

[0060] In this embodiment, the water pump and water valve are directly mounted and fixed on the flow channel plate 28, and can be arranged along the height direction with the flow channel plate 28, reducing the occupation of the vehicle's horizontal space. Furthermore, the connection ports of the water pump and water valve can be directly connected to the openings on the flow channel plate 28, eliminating the need for intermediate pipelines, resulting in a more compact structure and smaller space occupation.

[0061] In this embodiment, the heater 23 in the coolant system is located on the side of the flow channel plate 28 opposite to the water pump. The heater 23 can be directly fixed to the flow channel plate 28, or it can be directly supported on the frame 100. The installation of the heater 23 makes full use of the space below the flow channel plate 28, resulting in a compact integrated module structure.

[0062] The frame 100 may also be provided with columns 103 for positioning or connecting and fixing related components. In summary, all water pumps, heaters, water valves, compressors, blocks, control boxes, flow channels, and water tanks are integrated onto the frame 100. This allows for pre-assembly of these components onto the frame 100, and direct connection of the assembled structure to the vehicle or operating environment, making installation quick and convenient.

[0063] Furthermore, in this embodiment, the gas-liquid separator 13 can be located on the side of the water tank 27 away from the flow channel plate 28, making full use of the back space of the water tank 27.

[0064] The water inlet of water tank 27 faces upwards. Water tank 27, control box 200, and block 300 can be roughly rectangular in shape. The length directions of control box 200 and block 300 are roughly parallel to the central axis of compressor 11. The length direction of water tank 27 and the central axis of compressor 11 can have an angle, for example, they can be roughly perpendicular.

[0065] The vehicle thermal management system provided in this application includes the aforementioned integrated module and control box 200. Therefore, the vehicle thermal management system also has the technical effects of the aforementioned integrated module and control box 200.

[0066] For other structures of vehicle thermal management systems, please refer to current technology; they will not be elaborated upon in this article.

[0067] The above are merely preferred embodiments of this application. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A control box for a vehicle thermal management system, characterized in that, The vehicle thermal management system includes a refrigerant system and a coolant system. The control box includes a housing, and a first control module and a second control module are integrated inside the housing. The first control module is used to control the operation of at least one actuator in the refrigerant system. The second control module is used to control the operation of at least one actuator in the coolant system.

2. The control box according to claim 1, characterized in that, The first control module includes a plurality of first control units, and each first control unit corresponds to and controls one of the actuators in the refrigerant system. Alternatively / and, the second control module includes a plurality of second control units, each of which corresponds to and controls an actuator in the coolant system.

3. The control box according to claim 2, characterized in that, The actuators of the coolant system include a water pump and at least one water valve. The water pump includes a motor and an impeller. The second control unit includes a water pump control unit and at least one water valve control unit. The water pump control unit sends a control signal to the motor, and the motor controls the impeller to rotate according to the control signal. The water valve control unit corresponds to each water valve to control the opening or closing of the corresponding water valve.

4. The control box according to claim 1, characterized in that, The control box includes a circuit board, and the first control module and the second control module are integrated on the circuit board.

5. The control box according to any one of claims 1 to 4, characterized in that, The first control module and the actuators in the refrigerant system it controls are electrically connected via wired, wireless, Bluetooth, Wi-Fi, or 5G communication. Alternatively / and, the second control module and the actuators in the coolant system it controls are electrically connected via wired, wireless, Bluetooth, Wi-Fi, or 5G communication.

6. The control box according to any one of claims 1 to 4, characterized in that, The housing has a connection port, and the cables of each actuator in the coolant system are electrically connected to the connection port to be electrically connected to the second control module.

7. An integrated module for a vehicle thermal management system, characterized in that, At least including: The coolant system includes a water pump, a heater, and at least one water valve; The compressor and at least one electrically controlled valve in the refrigerant system; It also includes the control box according to any one of claims 1 to 6, wherein the first control module is capable of controlling the operation of the compressor and the electronically controlled valve; and the second control module is capable of controlling the operation of the water pump, the heater and the water valve.

8. The integrated module according to claim 7, characterized in that, It also includes a block, which has N mounting holes inside. Each mounting hole has a valve mechanism fixed inside. The housing is located above the block, and the valve mechanism extends into the housing. The housing has a drive unit that corresponds to each valve mechanism. The first control module sends control signals to each drive unit to control the operation of each valve mechanism. The electric control valve includes the valve mechanism and the drive unit; where N is greater than or equal to 2.

9. The integrated module according to claim 8, characterized in that, It also includes a heat exchanger located on the side of the block away from the control box; Alternatively / and, the compressor is positioned below the block, with the compressor at least partially located below the block; Alternatively and / or, the electrically controlled valve includes a directional valve and an electronic expansion valve.

10. The integrated module according to any one of claims 7 to 9, characterized in that, It also includes a connected flow channel plate and a water tank. The flow channel plate is integrally formed with the water tank or connected by a pipeline. The flow channel plate has multiple channels inside to guide the flow of coolant. The flow channel plate has multiple connection interfaces on the outside. The water pump and each of the water valves are directly installed on the upper surface of the flow channel plate.

11. The integrated module according to claim 10, characterized in that, The heater is located on the side of the flow channel plate opposite to the side where the water pump is installed; Or / and, it also includes a gas-liquid separator for the refrigerant system, the gas-liquid separator being located on the side of the water tank opposite to the flow channel plate.

12. The integrated module according to claim 10, characterized in that, It also includes a frame, on which the water pump, the heater, the at least one water valve, the compressor, the control box, the flow channel plate and the water tank are integrated.

13. A vehicle thermal management system, characterized in that, include: The integrated module according to any one of claims 7 to 12; The compressor, the evaporator, and the condenser are capable of forming a refrigerant circulation loop; The battery device, wherein the coolant system is capable of exchanging heat with the battery device.

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