Thermal management system and method based on dynamic switching of multiple power sources

Abstract

The invention provides a thermal management system and method based on multi-power-source dynamic switching, and belongs to the technical field of multi-heat-source comprehensive utilization. The invention discloses a thermal management system and method based on multi-power-source dynamic switching. The thermal management system comprises a thermal management execution module, a multi-power-source module, a sensing module and a control module. The multi-power-source module comprises a main power source and an auxiliary power source, and the main power source and the auxiliary power source are both connected with the heat management execution module to provide power; the sensing module is used for collecting operation parameters and external environment parameters of the thermal management system; the control module is electrically connected with the sensing module, the multi-power-source module and the heat management execution module and used for controlling switching of the main power source and the auxiliary power source and the operation state of the heat management execution module according to parameters collected by the sensing module. Through dynamic switching of multiple power sources, thermal management requirements under different working conditions can be met, the energy efficiency and reliability of the thermal management system are improved, and the influence of a single power source fault on system operation is reduced.

Description

Technical Field

[0001] This invention belongs to the field of multi-heat source integrated utilization technology, and relates to thermal management, particularly a thermal management system and method based on dynamic switching of multiple power sources. Background Technology

[0002] In modern industrial production, transportation (such as automobiles and ships), and electronic equipment, thermal management systems play a crucial role, and their performance directly affects the operating efficiency, reliability, and service life of equipment. Traditional thermal management systems typically use a single power source to power the actuators (such as water pumps and fans). For example, automotive thermal management systems often use an engine or a single electric motor as the power source.

[0003] However, thermal management systems powered by a single power source have several limitations. Firstly, thermal management requirements vary significantly depending on the operating conditions of the equipment. A single power source struggles to adapt to the power output demands under different conditions, resulting in low system efficiency. For instance, a car needs rapid heating during low-temperature starts and powerful cooling during high-speed driving. A single power source may lack sufficient power to meet high-load cooling demands, while wasting power during low-load insulation. Secondly, if the single power source fails, the entire thermal management system will malfunction, potentially leading to overheating damage or a sharp decline in performance, resulting in low reliability. Furthermore, in certain scenarios, such as the low-temperature range requirements of new energy vehicles, a thermal management system driven by a single motor power source consumes a large amount of battery power for heating, severely impacting the vehicle's range.

[0004] To address the aforementioned issues, there is an urgent need for a thermal management system and method that can dynamically adjust power supply according to different operating conditions to improve energy efficiency and reliability. Summary of the Invention

[0005] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a thermal management system and method based on dynamic switching of multiple power sources. The technical problem to be solved by this invention is to achieve optimal power supply under different operating conditions through dynamic switching and coordinated operation of the main power source and auxiliary power source, thereby improving system energy efficiency and reliability.

[0006] The objective of this invention can be achieved through the following technical solutions: A thermal management system based on dynamic switching of multiple power sources is characterized by comprising: The thermal management execution module, as the core execution unit for heat regulation, integrates specialized components such as water pumps, fans, heaters, and heat exchangers to accurately achieve efficient heat transfer, directional exchange, or adaptive adjustment. Through a real-time feedback adjustment mechanism, it stably achieves the preset target thermal management effect (such as temperature control accuracy ±2℃). The multi-power source module includes a core active power source and at least one functionally complementary auxiliary power source. Both the active power source and the auxiliary power source are stably connected to the thermal management execution module through a high-strength wear-resistant power transmission line with a power transmission efficiency of not less than 95%. This module provides continuous and load-matching power for the operation of each component of the thermal management execution module. The sensing module includes multiple high-precision sensors (temperature sensor accuracy ±0.5℃, flow sensor accuracy ±2%) distributed at key nodes of the system. The sensor response time is ≤100ms. It is used to collect the operating parameters of key nodes of the thermal management system and the external environmental parameters of the system in real time and synchronously, ensuring the comprehensiveness, timeliness and accuracy of parameter collection. The control module uses a high-performance microcontroller unit (MCU) as the core control unit with an operating frequency of no less than 1GHz. It is electrically connected to the sensing module, the multi-power source module, and the thermal management execution module via a CAN bus (communication rate 500kbps) or an industrial wireless LoRa module (transmission distance ≥1km). It is used to receive parameters collected by the sensing module in real time, perform logical analysis based on the preset multi-condition control strategy to determine whether power source switching is required, and accurately send switching commands to the multi-power source module. At the same time, it synchronously regulates the operating status of the thermal management execution module with a control delay of ≤50ms.

[0007] Furthermore, the thermal management execution module includes a high-pressure water pump with a rated operating pressure of 1.2-2.0 MPa, a variable frequency centrifugal fan with a speed range of 500-3000 rpm, a positive temperature coefficient (PTC) heater with a power density ≥2000 W / L, and a stainless steel plate heat exchanger with a heat transfer coefficient ≥3000 W / (m²·K). The high-pressure water pump is driven by a brushless DC motor with a flow rate adjustment range of 5-50 L / min, used to drive the coolant to circulate efficiently in a preset closed loop, ensuring heat transfer efficiency. The variable frequency fan supports stepless speed regulation and can dynamically adjust the speed according to the temperature difference between the inlet and outlet of the heat exchanger, used to enhance the convective heat transfer effect of the heat exchanger, with a heat transfer gain of 30%-80%. The PTC heater has a start-up response time of ≤2s when the ambient temperature is ≤-10℃, and a heating power adjustment range of 0-10kW, used to rapidly heat the coolant or heat exchange air under low-temperature conditions. The plate heat exchanger adopts a multi-channel cross-flow design with a leakage rate ≤1×10⁻ 6 Pa·m³ / s, which can efficiently realize heat exchange between coolant and different media such as air and high and low temperature coolant.

[0008] Furthermore, the primary power source is a high-efficiency permanent magnet synchronous motor with a rated power of 5-20kW and a rated efficiency of ≥94%. This motor features high energy efficiency, fast start-up response (≤100ms), and operating noise ≤60dB. The auxiliary power source includes a traditional internal combustion engine with a rated power of 10-30kW and a thermal efficiency of ≥40% and a small emergency backup motor with a rated power of 3-8kW. The permanent magnet synchronous motor is electrically connected to the vehicle's high-voltage power battery pack (voltage 200-400V) via a high-temperature resistant and flame-retardant power cable, with voltage fluctuations controlled within ±5% to ensure stable power supply. The engine is connected to the vehicle's fuel supply system, lubrication system, cooling system, and exhaust system to form a complete and independent power unit, with a low-temperature start-up success rate of ≥99.5% (at -20℃). The backup motor is connected to an independent 12V / 24V low-voltage lead-acid battery or lithium battery backup power supply, with a full-charge range of ≥2 hours, specifically for emergency power supply in case of failure of the primary power source and the main and auxiliary power sources.

[0009] Furthermore, the operating parameters collected by the sensing module specifically include: the temperature of the coolant at key heat exchange nodes such as the water pump outlet, heat exchanger inlet and outlet, and heater inlet and outlet (measurement range -40℃ to 150℃); the real-time flow rate in the coolant circulation loop (measurement range 0-100L / min); the stator and rotor temperatures of the main power source motor (measurement range -40℃ to 200℃); the engine block temperature (measurement range -40℃ to 150℃) and exhaust manifold temperature (measurement range -40℃ to 500℃); and the voltage of each power battery cell (measurement range 2.5-4.2). The system's temperature and module average temperature (measurement range -20℃ to 60℃), as well as the real-time operating power of various components such as water pumps, fans, and heaters in the thermal management execution module (measurement accuracy ±1%); the external environmental parameters include the real-time temperature (measurement range -40℃ to 85℃), relative humidity (measurement range 0-100%RH, accuracy ±5%RH) of the system's environment, and the altitude of the current location (measurement range -500m to 8000m, accuracy ±10m), where the altitude parameter is used to correct the influence of air density on the convective heat transfer efficiency of the heat exchanger, with a correction error ≤3%.

[0010] Furthermore, the multi-condition control strategy preset within the control module includes: When the load rate of the main power source exceeds the preset threshold (e.g., 80%) and continues for a preset time (e.g., 30 seconds), or when the operating temperature of the main power source exceeds the safe temperature threshold (e.g., 120℃ for permanent magnet synchronous motors, 100℃ for engine cylinders), the control module first sends a pre-start signal to the auxiliary power source (pre-start delay of 2-3 seconds to complete preheating and self-check), and then controls the start of the auxiliary power source. The auxiliary power source provides power to the thermal management execution module in a coordinated manner, with the main power source bearing 60%-70% and the auxiliary power source bearing 30%-40%, effectively sharing the load. When the main power source experiences a speed fluctuation exceeding ±10%, a power drop of ≥30%, or a motor stall, the control module uses its built-in fault diagnosis unit to identify and confirm the fault within 50ms. It then immediately sends a switching command to the power source switching module, with a switching time of ≤500ms, and controls the switch to the auxiliary power source. The auxiliary power source then provides sufficient power to the thermal management execution module to ensure continuous system operation and prevent thermal management interruption. When the external ambient temperature is lower than the preset low temperature threshold (e.g., -10℃) and the thermal management requirement is heating (target temperature ≥20℃), the control module prioritizes starting the auxiliary power source connected to the engine. It collects the cylinder block waste heat and exhaust waste heat generated during engine operation through the waste heat recovery heat exchanger and introduces it into the thermal management system through the waste heat recovery loop. The waste heat utilization rate is ≥60%, which reduces energy consumption by 40%-60% compared to the pure electric heating mode and improves thermal management efficiency. When the thermal management requirement is low (e.g., only maintaining the basic insulation of the equipment, with a target temperature fluctuation range of ±2℃), and the load rate of the main power source is lower than the preset low load threshold (e.g., 30%), the control module gradually reduces the output power of the auxiliary power source at a rate of 10% per second. When the power drops below 10%, the auxiliary power source is shut off, and only the main power source provides power to the thermal management execution module, reducing power redundancy and waste, and lowering system energy consumption.

[0011] Furthermore, it includes a power source switching module, which is rigidly connected to the power output shaft of the main power source, the power output shaft of the auxiliary power source, and the command output interface of the control module. It adopts an IP67-level waterproof and dustproof design to adapt to harsh working environments. After accurately receiving the switching command from the control module, it controls the oil and air circuits via mechanical clutch transmission or an electromagnetic directional valve to switch the power transmission between the main and auxiliary power sources and the thermal management execution module. The switching response time is ≤100ms. The power source switching module uses a wear-resistant dry clutch (service life ≥100,000 switching cycles) or a fast-response electromagnetic directional valve (action time ≤50ms). The power interruption time during switching is ≤50ms, ensuring a smooth power transmission transition without significant impact.

[0012] A thermal management method based on dynamic switching of multiple power sources, applied to a thermal management system based on dynamic switching of multiple power sources, is characterized by including the following steps: S1. System initialization: The control module first performs a comprehensive self-check on the sensing module, multi-power source module, thermal management execution module, and power source switching module (self-check time ≤ 5 seconds). After reading the status codes of each module through the CAN bus and confirming that there are no fault codes, the control module starts the main power source at 50% of the rated power to drive the thermal management execution module into the initial operating state (initial coolant circulation flow rate 10L / min, initial fan speed 1000rpm). S2. Each sensor in the sensing module collects the operating parameters of the thermal management system and external environmental parameters in real time according to a preset sampling frequency (10Hz). After the collected data is converted by the built-in 16-bit analog-to-digital converter (ADC) unit of the sensor, it is transmitted to the signal receiving unit of the control module in real time in the form of data messages via the CAN bus, with a data transmission success rate of ≥99.9%. S3. The data analysis unit of the control module performs preprocessing on the received parameters, such as Kalman filtering for noise reduction, temperature drift calibration, and outlier removal. The processed parameters are compared with preset thresholds, and then combined with multi-condition control strategies to perform logical operations to analyze and determine whether a power source switch is needed. S4. If it is determined that a power source switch is required, the instruction generation unit of the control module sends a precise switch instruction containing information such as power source type, switching sequence, and power allocation ratio to the power source switch module. The power source switch module executes the switch operation according to the preset process of instruction verification - power cut-off - mechanism action - power connection - status feedback, so as to realize the switch or coordinated operation between the main power source and the auxiliary power source. If it is determined that a power source switch is not required, the current power source operation status is maintained, and the control module refreshes the operation status information of each module through the bus every 1 second. S5. Based on the real-time parameters collected by the sensing module, the control module uses a proportional-integral-derivative (PID) control algorithm to synchronously adjust the operating parameters of each component of the thermal management execution module (such as water pump speed, fan frequency, and heater power), with an adjustment accuracy of ±5%, so that the actual operating parameters of the thermal management system stably approach and achieve the target thermal management effect. S6. Repeat steps S2-S5 to achieve continuous dynamic operation of the thermal management system and real-time dynamic switching of the power source through a closed-loop control mechanism of acquisition-analysis-control-feedback. The entire closed-loop control cycle is ≤200ms.

[0013] Furthermore, in step S3, when the control module analyzes and processes the parameters, it also includes a dual mechanism of threshold interval comparison and linear trend prediction to detect parameter anomalies, with an anomaly detection response time ≤100ms. When anomalies are detected, such as the parameters collected by the sensing module exceeding the normal range by ±10%, the sudden change amplitude within 1 second ≥5%, or the three consecutive sampling values ​​exceeding the threshold, the control module immediately drives the audible and visual alarm device (the buzzer emits a continuous 2kHz beep, and the red alarm light flashes at a frequency of 1Hz) through the IO interface to issue an alarm signal. At the same time, it calls the built-in emergency strategy library to start the corresponding auxiliary power source and thermal management execution module emergency operation mode (such as starting the backup motor, maximizing the fan speed, and cutting off unnecessary heating loads) according to the anomaly type (such as excessively high temperature, excessively low flow, or power source failure), ensuring that the system's basic thermal management function is not interrupted.

[0014] Furthermore, in step S4, when switching between the active power source and the auxiliary power source for coordinated operation, the control module uses a gradient loading method to control the output power of the auxiliary power source. That is, the power of the auxiliary power source is gradually increased according to a preset gradient of 10% increase per second of rated power, while the power of the active power source is synchronously reduced at the same gradient, so that the fluctuation range of the total power output is controlled within ±5%, achieving a smooth transition, effectively avoiding mechanical damage to the system transmission components and execution modules caused by power shock, and extending the service life of the equipment.

[0015] Furthermore, including step S7, the storage unit of the control module (capacity ≥16GB, supporting data retention for more than 10 years after power failure) records in real time the specific time (accurate to milliseconds) of each power source switch, the reason for triggering the switch (such as excessive load, excessive temperature, fault code), the operating parameters of each key component before and after the switch (temperature, flow rate, power, speed), and thermal management effect parameters (deviation between target temperature and actual temperature, heat exchange efficiency), forming a structured operation log; this log can be exported as a CSV file through a USB 2.0 interface or Bluetooth 4.2 module for fault diagnosis, performance evaluation, and iterative optimization of control strategies based on big data analysis during daily system maintenance.

[0016] Compared with the prior art, the thermal management system and method based on dynamic switching of multiple power sources of the present invention have the following advantages: 1. Improved energy efficiency: By dynamically switching and coordinating multiple power sources, it adapts to the thermal management needs under different operating conditions, avoiding the problem of insufficient power from a single power source at high loads and energy waste at low loads, thus significantly improving system energy efficiency; 2. Enhanced reliability: The main and auxiliary power sources are redundantly designed. When the main power source fails, the auxiliary power source can quickly take over, ensuring the continuous operation of the thermal management system and reducing the risk of equipment damage. 3. Wide adaptability: The main and auxiliary power source types can be flexibly configured according to different application scenarios (such as new energy vehicles and industrial equipment) to meet diverse thermal management needs; 4. High level of intelligence: The sensing module collects data in real time, and the control module automatically switches the power source and adjusts the execution module based on preset strategies without manual intervention. At the same time, the operation log provides data support for system optimization. Attached Figure Description

[0017] Figure 1 This is a diagram illustrating the overall architecture of the thermal management system and method based on dynamic switching of multiple power sources according to the present invention. Figure 2 This is a control architecture framework diagram of the thermal management system and method based on dynamic switching of multiple power sources in this invention; Figure 3 This is a flowchart illustrating the workflow of the thermal management system and method based on dynamic switching of multiple power sources according to the present invention. Detailed Implementation

[0018] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings to further illustrate the technical solutions of the present invention. However, the present invention is not limited to these embodiments.

[0019] like Figure 1 - Figure 3 As shown, the thermal management system based on dynamic switching of multiple power sources includes: The thermal management execution module, as the core execution unit for thermal regulation, integrates specialized components (water pumps, fans, heaters, and heat exchangers) adapted to different operating conditions. The selection of core components matches the maximum heat load requirements of the system (e.g., heater power matches the maximum heating requirements at -20℃). This is used to accurately achieve efficient heat transfer, directional exchange, or adaptive adjustment. Through a real-time feedback adjustment mechanism of parameter acquisition, deviation calculation, and execution adjustment, it stably achieves the preset target thermal management effect (e.g., temperature control accuracy of electronic equipment ±2℃, cabin temperature control accuracy ±1℃). The multi-power source module includes a core active power source that matches normal operating conditions and at least one complementary auxiliary power source that adapts to extreme / emergency operating conditions. The active power source is selected to meet more than 80% of the system's power requirements under normal operating conditions, while the auxiliary power source covers peak loads and emergency fault scenarios. Both the active and auxiliary power sources are stably connected to the thermal management execution module through high-strength wear-resistant power transmission lines (the mechanical transmission uses an alloy steel drive shaft, and the electric transmission uses a copper core cable). The power transmission efficiency is not less than 95%, which is used to provide continuous and adaptable power that matches the dynamic load requirements for the operation of each component of the thermal management execution module, avoiding insufficient power or redundant waste. The sensing module includes multiple high-precision sensors (temperature sensor accuracy ±0.5℃, flow sensor accuracy ±2%) distributed across key system nodes, ensuring full coverage and redundant backup of critical parameters. The temperature sensors utilize PT1000 platinum resistance thermometers (excellent low-temperature stability), while the flow sensors employ electromagnetic measurement principles (compatible with various coolant media). The sensors have a response time ≤100ms and support electromagnetic interference resistance (EMC Class 3 electromagnetic compatibility). They are used for real-time, synchronous acquisition of operating parameters from key nodes of the thermal management system and external environmental parameters. The acquired data undergoes hardware filtering and preprocessing before transmission, ensuring the comprehensiveness, timeliness, and accuracy of parameter acquisition. The control module adopts a main controller + dedicated functional sub-module architecture, with a high-performance microcontroller unit (MCU) with an operation frequency of no less than 1GHz as the core control unit, and is equipped with a data acquisition sub-module, an instruction output sub-module, and a communication sub-module. It is electrically connected to the sensing module, the multi-power source module, and the thermal management execution module via a CAN bus (communication rate 500kbps, suitable for short-range scenarios such as vehicle-mounted systems) or an industrial wireless LoRa module (transmission distance ≥1km, suitable for long-range scenarios in non-vehicle-mounted systems). The communication process uses CRC check to ensure data integrity. It is used to receive parameters collected by the sensing module in real time, perform logical analysis based on the preset multi-condition control strategy to determine whether power source switching is required, and send precise switching instructions containing execution timing and power parameters to the multi-power source module and the power source switching module. At the same time, it synchronously regulates the operating status of the thermal management execution module, with a control delay of ≤50ms to ensure timely response. Furthermore, the thermal management execution module includes a high-pressure water pump with a rated operating pressure of 1.2-2.0 MPa, a variable frequency centrifugal fan with a speed range of 500-3000 rpm, a positive temperature coefficient (PTC) heater with a power density ≥2000 W / L, and a stainless steel plate heat exchanger with a heat transfer coefficient ≥3000 W / (m²·K). The high-pressure water pump is driven by a brushless DC motor with a flow rate adjustment range of 5-50 L / min, used to drive the coolant to circulate efficiently in a preset closed loop, ensuring heat transfer efficiency. The variable frequency fan supports stepless speed regulation and can dynamically adjust the speed according to the temperature difference between the inlet and outlet of the heat exchanger, used to enhance the convective heat transfer effect of the heat exchanger, with a heat transfer gain of 30%-80%. The PTC heater has a start-up response time of ≤2s when the ambient temperature is ≤-10℃, and a heating power adjustment range of 0-10kW, used to rapidly heat the coolant or heat exchange air under low-temperature conditions. The plate heat exchanger adopts a multi-channel cross-flow design with a leakage rate ≤1×10⁻ 6 Pa·m³ / s, which can efficiently realize heat exchange between coolant and different media such as air and high and low temperature coolant.

[0020] Furthermore, the main power source is a high-efficiency permanent magnet synchronous motor with a rated power of 5-20kW and a rated efficiency of ≥94%. This motor features high energy efficiency, fast start-up response (≤100ms), and operating noise of ≤60dB. The auxiliary power sources include a traditional internal combustion engine with a rated power of 10-30kW and a thermal efficiency of ≥40% and a small emergency backup motor with a rated power of 3-8kW. The permanent magnet synchronous motor is electrically connected to the vehicle's high-voltage power battery pack (voltage 200-400V) via a high-temperature resistant and flame-retardant power cable, with voltage fluctuations controlled within ±5% to ensure stable power supply. The engine is connected to the vehicle's fuel supply system, lubrication system, cooling system, and exhaust system to form a complete and independent power unit, with a low-temperature start-up success rate of ≥99.5% (at -20℃). The backup motor is connected to an independent 12V / 24V low-voltage lead-acid battery or lithium battery backup power supply, with a range of ≥2 hours when fully charged, specifically for emergency power supply in case of failure of the main power source and the main and auxiliary power sources.

[0021] Furthermore, the operating parameters collected by the sensing module specifically include: the temperature of the coolant at key heat exchange nodes such as the water pump outlet, heat exchanger inlet and outlet, and heater inlet and outlet (measurement range -40℃ to 150℃); the real-time flow rate in the coolant circulation loop (measurement range 0-100L / min); the stator and rotor temperatures of the main power source motor (measurement range -40℃ to 200℃); the engine block temperature (measurement range -40℃ to 150℃) and exhaust manifold temperature (measurement range -40℃ to 500℃); and the voltage of each power battery cell (measurement range 2.5-4.2). The system's temperature includes the average temperature of the module (measurement range -20℃ to 60℃), and the real-time operating power of components such as water pumps, fans, and heaters in the thermal management execution module (measurement accuracy ±1%). External environmental parameters include the real-time temperature of the system's environment (measurement range -40℃ to 85℃), relative humidity (measurement range 0-100%RH, accuracy ±5%RH), and altitude of the current location (measurement range -500m to 8000m, accuracy ±10m). The altitude parameter is used to correct the influence of air density on the convective heat transfer efficiency of the heat exchanger, with a correction error ≤3%.

[0022] Furthermore, the multi-condition control strategies preset within the control module include: When the load rate of the main power source exceeds the preset threshold (e.g., 80%) and continues for a preset time (e.g., 30 seconds), or when the operating temperature of the main power source exceeds the safe temperature threshold (e.g., 120℃ for permanent magnet synchronous motors, 100℃ for engine cylinders), the control module first sends a pre-start signal to the auxiliary power source (pre-start delay of 2-3 seconds to complete preheating and self-check), and then controls the start of the auxiliary power source. The auxiliary power source provides power to the thermal management execution module in a coordinated manner, with the main power source bearing 60%-70% and the auxiliary power source bearing 30%-40%, effectively sharing the load. When the main power source experiences a speed fluctuation exceeding ±10%, a power drop of ≥30%, or a motor stall, the control module uses its built-in fault diagnosis unit to identify and confirm the fault within 50ms. It then immediately sends a switching command to the power source switching module, with a switching time of ≤500ms, and controls the switch to the auxiliary power source. The auxiliary power source then provides sufficient power to the thermal management execution module to ensure continuous system operation and prevent thermal management interruption. When the external ambient temperature is lower than the preset low temperature threshold (e.g., -10℃) and the thermal management requirement is heating (target temperature ≥20℃), the control module prioritizes starting the auxiliary power source connected to the engine. It collects the cylinder block waste heat and exhaust waste heat generated during engine operation through the waste heat recovery heat exchanger and introduces it into the thermal management system through the waste heat recovery loop. The waste heat utilization rate is ≥60%, which reduces energy consumption by 40%-60% compared to the pure electric heating mode and improves thermal management efficiency. When the thermal management requirement is low (e.g., only maintaining the basic insulation of the equipment, with a target temperature fluctuation range of ±2℃), and the load rate of the main power source is lower than the preset low load threshold (e.g., 30%), the control module gradually reduces the output power of the auxiliary power source at a rate of 10% per second. When the power drops below 10%, the auxiliary power source is shut off, and only the main power source provides power to the thermal management execution module, reducing power redundancy and waste, and lowering system energy consumption.

[0023] Furthermore, it includes a power source switching module, which is rigidly connected to the power output shaft of the main power source, the power output shaft of the auxiliary power source, and the command output interface of the control module. It adopts an IP67-level waterproof and dustproof design to adapt to harsh working environments. After accurately receiving the switching command from the control module, it controls the oil and air circuits through mechanical clutch transmission or electromagnetic reversing valve to realize the switching of power transmission between the main power source, the auxiliary power source, and the thermal management execution module. The switching response time is ≤100ms. The power source switching module adopts a dry clutch with excellent wear resistance (service life ≥100,000 switching cycles) or an electromagnetic reversing valve with fast response speed (action time ≤50ms). The power interruption time during the switching process is ≤50ms, ensuring a smooth transition of power transmission without obvious shock.

[0024] Preferably, the thermal management method based on dynamic switching of multiple power sources, applied to a thermal management system based on dynamic switching of multiple power sources, is characterized by including the following steps: S1. System initialization: The control module first performs a comprehensive self-check on the sensing module, multi-power source module, thermal management execution module, and power source switching module (self-check time ≤ 5 seconds). After reading the status codes of each module through the CAN bus and confirming that there are no fault codes, the control module starts the main power source at 50% of the rated power to drive the thermal management execution module into the initial operating state (initial coolant circulation flow rate 10L / min, initial fan speed 1000rpm). S2. Each sensor in the sensing module collects the operating parameters of the thermal management system and external environmental parameters in real time according to a preset sampling frequency (10Hz). After the collected data is converted by the built-in 16-bit analog-to-digital converter (ADC) unit of the sensor, it is transmitted to the signal receiving unit of the control module in real time in the form of data messages via the CAN bus, with a data transmission success rate of ≥99.9%. S3. The data analysis unit of the control module performs preprocessing on the received parameters, such as Kalman filtering for noise reduction, temperature drift calibration, and outlier removal. The processed parameters are compared with preset thresholds, and then combined with multi-condition control strategies to perform logical operations to analyze and determine whether a power source switch is needed. S4. If it is determined that a power source switch is required, the instruction generation unit of the control module sends a precise switch instruction containing information such as power source type, switching sequence, and power allocation ratio to the power source switch module. The power source switch module executes the switch operation according to the preset process of instruction verification - power cut-off - mechanism action - power connection - status feedback, so as to realize the switch or coordinated operation between the main power source and the auxiliary power source. If it is determined that a power source switch is not required, the current power source operation status is maintained, and the control module refreshes the operation status information of each module through the bus every 1 second. S5. Based on the real-time parameters collected by the sensing module, the control module uses a proportional-integral-derivative (PID) control algorithm to synchronously adjust the operating parameters of each component of the thermal management execution module (such as water pump speed, fan frequency, and heater power), with an adjustment accuracy of ±5%, so that the actual operating parameters of the thermal management system stably approach and achieve the target thermal management effect. S6. Repeat steps S2-S5 to achieve continuous dynamic operation of the thermal management system and real-time dynamic switching of the power source through a closed-loop control mechanism of acquisition-analysis-control-feedback. The entire closed-loop control cycle is ≤200ms.

[0025] Furthermore, in step S3, when the control module analyzes and processes the parameters, it also includes a dual mechanism of threshold range comparison and linear trend prediction to detect parameter anomalies, with an anomaly detection response time ≤100ms. When anomalies are detected, such as the parameters collected by the sensing module exceeding the normal range by ±10%, the sudden change amplitude within 1 second ≥5%, or the three consecutive sampling values ​​exceeding the threshold, the control module immediately drives the audible and visual alarm device (the buzzer emits a continuous 2kHz beep, and the red alarm light flashes at a frequency of 1Hz) through the IO interface to issue an alarm signal. At the same time, it calls the built-in emergency strategy library to start the corresponding auxiliary power source and thermal management execution module emergency operation mode (such as starting the backup motor, maximizing the fan speed, and cutting off unnecessary heating loads) according to the anomaly type (such as excessively high temperature, excessively low flow, or power source failure), ensuring that the system's basic thermal management function is not interrupted.

[0026] Furthermore, in step S4, when switching between the active power source and the auxiliary power source for coordinated operation, the control module uses a gradient loading method to control the output power of the auxiliary power source. That is, the power of the auxiliary power source is gradually increased according to a preset gradient of 10% increase per second of rated power, while the power of the active power source is reduced synchronously at the same gradient, so that the fluctuation range of the total power output is controlled within ±5%, achieving a smooth transition, effectively avoiding mechanical damage to the system transmission components and execution modules caused by power shock, and extending the service life of the equipment.

[0027] Furthermore, including step S7, the storage unit of the control module (capacity ≥16GB, supporting data retention for more than 10 years after power failure) records in real time the specific time (accurate to milliseconds) of each power source switch, the reason for triggering the switch (such as excessive load, excessive temperature, fault code), the operating parameters of each key component before and after the switch (temperature, flow rate, power, speed), and thermal management effect parameters (deviation between target temperature and actual temperature, heat exchange efficiency), forming a structured operation log; this log can be exported as a CSV file through a USB 2.0 interface or Bluetooth 4.2 module for fault diagnosis, performance evaluation, and iterative optimization of control strategies based on big data analysis during daily system maintenance.

[0028] The working principle of this invention: This system uses a closed-loop control mechanism of perception-decision-execution-feedback as its core. Through the coordinated operation of the perception module, control module, multi-power source and switching module, thermal management execution module, and log and emergency support module, it achieves precise heat regulation and dynamic power source adaptation. In operation, the system first enters an initialization state. The control module completes a comprehensive self-check of the perception module, multi-power source module, thermal management execution module, and power source switching module within 5 seconds. It reads the status codes of each module via the CAN bus. After confirming no faults, it controls the main power source to start at 50% of its rated power, driving the thermal management execution module into its initial operating state. At this time, the initial coolant circulation flow rate is 10L / min, and the initial fan speed is 1000rpm. The perception module deploys high-precision sensors according to the principle of full coverage of key nodes and redundant backup. These sensors collect two types of core parameters in real time at a preset sampling frequency of 10Hz. One type of parameter is operational parameters, which track the temperature and flow rate of water pumps, heat exchangers, and heaters in the heat flow path, monitor the temperature and power of power sources (motors, engines), and the operating status of actuators such as water pumps and fans, achieving full perception of the system's internal status. The other type is environmental parameters, which collect ambient temperature, humidity, and altitude. The altitude parameter is corrected using an altitude-air density correlation model to adjust the heat exchanger efficiency calculation, eliminating environmental interference with a correction error ≤3%. The collected data is processed by hardware filtering and 16-bit ADC conversion before being transmitted to the control module via CAN bus or industrial wireless LoRa module. CRC verification is used during communication to ensure data integrity, with a transmission success rate ≥99.9%, providing accurate data support for subsequent decision-making. The control module adopts a main controller + functional sub-module architecture. After receiving data from the sensing module, it first performs preprocessing such as Kalman filtering for noise reduction, temperature drift calibration, and outlier removal, and then performs logical operations based on preset multi-condition control strategies to achieve power source switching and thermal regulation decisions.Regarding power source switching decisions, when the load rate of the main power source is ≥80% for 30 seconds, or the operating temperature exceeds the safety threshold (e.g., 120℃ for permanent magnet synchronous motors, 100℃ for engine blocks), the control module first sends a 2-3 second pre-start signal to the auxiliary power source. After completing preheating and self-check, the main power source supplies power in a coordinated manner, with the auxiliary power source handling 60%-70% and the auxiliary power source handling 30%-40%. When faults such as main power source speed fluctuation ±10%, power drop ≥30%, or motor stall are detected, the built-in fault diagnosis unit will complete the process within 50ms. Upon successful fault identification and confirmation, a switching command is immediately triggered, switching to auxiliary power source for independent power supply within 500ms. When the ambient temperature is ≤-10℃ and the thermal management requirement is heating (target temperature ≥20℃), the engine auxiliary power source is prioritized for startup. Waste heat is collected from the cylinder block and exhaust through a waste heat recovery heat exchanger, achieving a waste heat utilization rate of ≥60%, resulting in energy savings of 40%–60% compared to pure electric heating. When the main power source load rate is ≤30% and the thermal demand is low, the auxiliary power source power is gradually reduced at a rate of 10% per second, shutting down once it drops below 10%, with only the main power source providing power. Regarding thermal regulation decisions, the control module employs a PID algorithm, dynamically adjusting the operating parameters of each component in the thermal management execution module based on the deviation between the sensed parameters and the target value (e.g., electronic equipment temperature control accuracy ±2℃, cabin temperature control accuracy ±1℃), with an adjustment accuracy of ±5%. Meanwhile, the control module also detects parameter anomalies through a dual mechanism of threshold range comparison and linear trend prediction, with an anomaly detection response time of ≤100ms. When a parameter is detected to exceed the normal range by ±10%, the sudden change within 1 second is ≥5%, or the threshold is exceeded three times consecutively, the audible and visual alarm device is immediately activated to issue an alarm signal, and the corresponding emergency mode is initiated by calling the emergency strategy library to ensure that the system's basic thermal management functions are not interrupted. In addition, the control module's storage unit records the specific time, triggering reason, parameters before and after the switch, and thermal management effect of each power source switch in real time, forming a structured operation log, which can be exported via USB 2.0 interface or Bluetooth 4.2 module for fault diagnosis and strategy optimization. The multi-power source module and switching module constitute a precise power adaptation unit. The main power source is a high-efficiency permanent magnet synchronous motor with a rated power of 5-20kW and a rated efficiency of ≥94%, which is compatible with more than 80% of normal operating conditions. It features high energy efficiency, fast start-up response (≤100ms), and operating noise ≤60dB. It is connected to the vehicle's high-voltage power battery pack through a high-temperature resistant and flame-retardant power cable, and the voltage fluctuation is controlled within ±5%. The auxiliary power sources include a traditional internal combustion engine with a rated power of 10-30kW and a thermal efficiency of ≥40% and a small emergency backup motor with a rated power of 3-8kW. The engine is connected to the vehicle's fuel supply system, lubrication system, etc., and has a low-temperature start-up success rate of ≥99.5% in an environment of -20℃. The backup motor is connected to an independent low-voltage backup power supply, with a full charge range of ≥2h, and is specifically used for emergency power supply.The power source switching module adopts an IP67-rated waterproof and dustproof design, achieving power on / off switching via a dry clutch (service life ≥ 100,000 switching cycles) or an electromagnetic reversing valve (action time ≤ 50ms), with a switching response time ≤ 100ms. During coordinated operation switching, a gradient loading strategy is employed, adjusting the main and auxiliary power source power at a 10% rated power gradient per second, with total power fluctuation ≤ ±5%. In emergency switching, the power interruption time is ≤ 50ms, preventing damage to components from power shocks. The thermal management execution module integrates four core components, precisely executing heat transfer, exchange, and heating according to the control module's instructions. The high-pressure water pump is driven by a brushless DC motor with a rated working pressure of 1.2-2.0MPa and a flow rate adjustment range of 5-50L / min. It drives the coolant to circulate efficiently in a preset closed-loop circuit, providing a carrier for heat transfer. The variable frequency fan has a speed range of 500-3000rpm and supports stepless speed regulation. The speed can be dynamically adjusted according to the temperature difference between the inlet and outlet of the heat exchanger, and the heat transfer gain reaches 30%-80%. The PTC heater has a power density of ≥2000W / L and a start-up response time of ≤2s when the ambient temperature is ≤-10℃. The heating power adjustment range is 0-10kW, which meets the requirements of low-temperature heating. The stainless steel plate heat exchanger adopts a multi-channel cross-flow design with a heat transfer coefficient of ≥3000W / (m²・K) and a leakage rate of ≤1×10⁻. 6 With a capacity of Pa·m³ / s, the system efficiently facilitates heat exchange between multiple media. It operates continuously and dynamically through a closed-loop control mechanism of data acquisition, analysis, control, and feedback, with a total control cycle of ≤200ms. The sensing module provides real-time feedback on the control effect, while the control module continuously optimizes decision commands based on the feedback data. Multiple power sources and the execution module synchronously adjust their operating states, ultimately achieving dynamic matching between power sources and heat demand. This avoids overload of the main power source and reduces power waste under low load conditions, achieving the dual goals of efficient control and energy-saving reliability.

[0029] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A thermal management system based on dynamic switching of multiple power sources, characterized in that, include: The thermal management execution module, as the core execution unit for thermal regulation, is used to accurately achieve efficient heat transfer, directional exchange, or adaptive adjustment in order to stably achieve the preset target thermal management effect. The multi-power source module includes a core active power source and at least one complementary auxiliary power source. Both the active power source and the auxiliary power source are stably connected to the thermal management execution module through power transmission lines, and are used to provide continuous and adaptable power for the operation of each component of the thermal management execution module. The sensing module includes multiple distributed high-precision sensors, which are used to collect the operating parameters of key nodes of the thermal management system and the external environmental parameters of the system in real time and synchronously, ensuring the comprehensiveness and timeliness of parameter collection. The control module, as the core control unit of the system, is electrically connected to the sensing module, the multi-power source module, and the thermal management execution module via wired or wireless means. It is used to receive parameters collected by the sensing module in real time, analyze and determine whether power source switching is required based on the preset multi-condition control strategy, and send switching commands to the multi-power source module in a precise manner. At the same time, it synchronously regulates the operating status of the thermal management execution module.

2. The thermal management system based on dynamic switching of multiple power sources according to claim 1, characterized in that, The thermal management execution module includes a high-pressure water pump, a variable frequency fan, a PTC heater, and a plate heat exchanger. The high-pressure water pump drives the coolant to circulate efficiently in a preset loop, ensuring heat transfer efficiency. The variable frequency fan can adjust its speed according to heat exchange requirements to enhance the convective heat exchange effect of the heat exchanger. The PTC heater is used to rapidly heat the coolant or heat exchange air under low-temperature conditions. The plate heat exchanger, through a multi-channel design, is used to efficiently achieve heat exchange between different media.

3. The thermal management system based on dynamic switching of multiple power sources according to claim 1, characterized in that, The primary power source is a high-efficiency permanent magnet synchronous motor, which features high energy efficiency and fast response. The auxiliary power source includes a traditional internal combustion engine and a small emergency backup motor. The permanent magnet synchronous motor is electrically connected to the vehicle's high-voltage power battery pack via a power cable to obtain stable power. The engine is connected in conjunction with the vehicle's fuel supply system, lubrication system, etc., to form a complete power unit. The backup motor is connected to an independent low-voltage backup power supply for emergency power supply.

4. The thermal management system based on dynamic switching of multiple power sources according to claim 1, characterized in that, The operating parameters collected by the sensing module include the temperature of the coolant at the inlet and outlet and key heat exchange nodes, the real-time flow rate in the coolant circulation loop, the stator and rotor temperatures of the main power source motor, the engine block and exhaust manifold temperatures, the average temperature of the power battery cells and modules, and the real-time operating power of various components such as water pumps and fans in the thermal management execution module; the external environmental parameters include the real-time temperature, relative humidity and current altitude of the system's environment, where the altitude parameter is used to correct the heat exchange efficiency calculation.

5. The thermal management system based on dynamic switching of multiple power sources according to claim 1, characterized in that, The preset multi-condition control strategies within the control module include: When the load rate of the main power source exceeds the preset threshold and continues for a preset time, or when the operating temperature of the main power source exceeds the safe temperature threshold, the control module first sends a pre-start signal, and then controls the start of the auxiliary power source to work with the main power source to provide power to the thermal management execution module and share the load. When the main power source experiences abnormal speed or sudden power drop, the control module, after confirming the fault through the fault diagnosis unit, immediately switches to the auxiliary power source, which then provides sufficient power to the thermal management execution module to ensure continuous system operation. When the external ambient temperature is lower than the preset low temperature threshold and the thermal management requirement is heating, the control module prioritizes starting the auxiliary power source connected to the engine, making full use of the cylinder waste heat and exhaust waste heat generated during engine operation, and improving thermal management efficiency and reducing energy consumption through the waste heat recovery loop. When thermal management demand is low and the load rate of the main power source is below a preset low load threshold, the control module first gradually reduces the output power of the auxiliary power source, and then controls the auxiliary power source to shut down, so that only the main power source provides power to the thermal management execution module, thereby reducing power waste. The preset control strategies within the control module include: When the load rate of the main power source exceeds the preset threshold and continues for a preset time, or when the operating temperature of the main power source exceeds the safe temperature threshold, the control module controls the start of the auxiliary power source to work with the main power source to provide power to the thermal management execution module. When the main power source fails, the control module immediately switches to the auxiliary power source, which then provides power solely to the thermal management execution module. When the external ambient temperature is lower than the preset low temperature threshold and the thermal management requirement is heating, the control module prioritizes starting the auxiliary power source connected to the engine to improve thermal management efficiency by utilizing the engine's waste heat. When the thermal management demand is low and the load rate of the main power source is lower than the preset low load threshold, the control module controls the shutdown of the auxiliary power source, and only the main power source provides power to the thermal management execution module.

6. The thermal management system based on dynamic switching of multiple power sources according to claim 1, characterized in that, The system includes a power source switching module, which is connected to the power output terminals of the main power source, the auxiliary power source, and the command output terminal of the control module. This module accurately receives switching commands from the control module and then switches the power transmission between the main and auxiliary power sources and the thermal management execution module via mechanical or electromagnetic means. The power source switching module employs a wear-resistant dry clutch or a fast-response electromagnetic directional valve structure to ensure a smooth and reliable switching process.

7. A thermal management method based on dynamic switching of multiple power sources, applied to the thermal management system based on dynamic switching of multiple power sources as described in any one of claims 1-6, characterized in that, Includes the following steps: S1. System initialization: The control module first performs a self-check on each module. After confirming that there are no faults, it starts the main power source to provide initial power to the thermal management execution module, so that the thermal management system enters the preset initial operating state. S2. The sensors of the sensing module collect the operating parameters of the thermal management system and the external environment parameters in real time according to the preset sampling frequency, and transmit the collected parameters to the signal receiving unit of the control module in real time through the data bus. S3. The data analysis unit of the control module performs preprocessing such as filtering and calibration on the received parameters, and then analyzes and determines whether a power source switch is needed based on the preset control strategy. S4. If it is determined that a power source switch is required, the instruction generation unit of the control module sends a precise switch instruction to the power source switch module. The power source switch module executes the switch operation according to the preset process to realize the switch or coordinated operation between the main power source and the auxiliary power source. If it is determined that a power source switch is not required, the current power source operation status is maintained. S5. The control module adjusts the operating parameters of each component of the thermal management execution module synchronously based on the real-time parameters collected by the sensing module, so that the thermal management system can stably achieve the target thermal management effect. S6. Repeat steps S2-S5 to achieve continuous dynamic operation of the thermal management system and real-time dynamic switching of the power source through closed-loop control.

8. The thermal management system and method based on dynamic switching of multiple power sources according to claim 7, characterized in that, In step S3, when the control module analyzes and processes the parameters, it also includes detecting abnormalities in the parameters through threshold comparison and trend analysis. When the abnormality of the parameters collected by the sensing module is detected to be outside the normal range or due to sudden changes, the control module immediately issues an alarm signal through the audible and visual alarm device and starts the corresponding emergency operation mode of the auxiliary power source and thermal management execution module according to the preset emergency strategy to ensure the basic functions of the system.

9. The thermal management system and method based on dynamic switching of multiple power sources according to claim 7, characterized in that, In step S4, when switching between the active power source and the auxiliary power source, the control module uses a gradient loading method to control the output power of the auxiliary power source, that is, gradually increasing the power of the auxiliary power source according to a preset gradient, so that the total power output transitions smoothly and effectively avoids damage to system components caused by power shock.

10. The thermal management system and method based on dynamic switching of multiple power sources according to claim 7, characterized in that, Including step S7, the storage unit of the control module records in real time the specific time of each power source switch, the reason for triggering the switch, the operating parameters of each key component before and after the switch, and the thermal management effect parameters, forming a complete operation log; this log can be exported through the data interface for daily system maintenance and troubleshooting and iterative optimization of control strategies.

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