An integrated battery environmental chamber thermal management testing system

Abstract

This invention discloses an integrated battery environmental chamber thermal management testing system. The system comprises: a temperature chamber system including a first compressor, a first gas-liquid separator, an environmental chamber evaporator, an environmental chamber condenser, a fan-heated electric heater, a heat exchanger, a first circulating water heat exchanger, and control valves and measuring elements on the pipelines; a direct cooling and heating system including a second gas-liquid separator, a second compressor, an evaporator, a battery pack, a heat exchanger, a second circulating water heat exchanger, and control valves and measuring elements on the pipelines; a liquid cooling system including a water-heated electric heater, a liquid-cooled circulating pump, a first mass flow controller, and control valves and measuring elements on the pipelines; and a circulating water system including a circulating water tank, a circulating water pump, a second mass flow controller, a third mass flow controller, a fourth mass flow controller, a second circulating water heat exchanger, and control valves and measuring elements on the pipelines. This system is adaptable to the testing of various battery packs, improving equipment utilization efficiency.

Description

Technical Field

[0001] This invention relates to the field of battery testing technology, specifically to an integrated battery environmental chamber thermal management testing system. Background Technology

[0002] In the field of battery R&D and performance testing, environmental chambers are core equipment for simulating the operating temperature environment of batteries. However, for thermal management testing of different types of battery packs (such as direct cooling and liquid cooling), auxiliary equipment such as direct cooling units and liquid cooling units are often required. For most R&D centers and laboratories, the power consumption of environmental testing equipment is very high, leading to increased testing costs. Reducing the energy consumption of environmental testing equipment under various operating conditions and improving energy utilization efficiency are of great significance. However, existing battery environmental chamber testing systems have the following prominent problems, which seriously restrict testing efficiency and energy utilization:

[0003] 1) High energy consumption and low energy utilization efficiency: During operation, the environmental chamber, direct cooling machine and liquid cooling machine need to dissipate heat to the environment through the cooling system. A large amount of electrical energy is converted into useless heat energy and lost, resulting in huge energy consumption and increased costs during the testing process. At the same time, the redundant design of independent heat dissipation of each device further reduces the overall energy utilization efficiency.

[0004] 2) Poor adaptability and cumbersome equipment replacement: Different cooling types (direct cooling / liquid cooling) of battery packs require different thermal management equipment (direct cooling machine / liquid cooling machine). Frequent equipment replacement is required during testing, which is not only complicated and time-consuming, but also increases the cost of equipment procurement and maintenance.

[0005] 3) System redundancy and bloated cooling architecture: The environmental chamber, direct cooler, and liquid cooler are each equipped with independent cooling systems, resulting in a dispersed test system structure and complex piping, which not only occupies laboratory space but also increases the difficulty of system debugging and troubleshooting.

[0006] The aforementioned problems make it difficult for existing battery environmental chamber testing systems to meet the requirements of efficient, energy-saving, and universal testing. There is an urgent need for an integrated, low-energy-consumption testing solution that is compatible with multiple types of battery packs. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention discloses an integrated battery environmental chamber thermal management testing system to solve the problems mentioned in the background section.

[0008] To achieve the above objectives, the present invention provides the following technical solution: an integrated battery environmental chamber thermal management testing system, comprising a temperature chamber system, a direct cooling and heating system, a liquid cooling system, and a circulating water system. Each system is interconnected via pipelines, control valves, and measuring elements to form an integrated testing architecture. The temperature chamber system is used to control the test environment temperature. The direct cooling and heating system and the liquid cooling system are adapted to the thermal management requirements of battery packs with different cooling types. The circulating water system is connected to the temperature chamber system and the direct cooling and heating system via pipelines, providing a heat transfer carrier for each system.

[0009] Preferably, the temperature chamber system includes a first compressor, a first gas-liquid separator, an environmental chamber evaporator, and an environmental chamber condenser connected in sequence by pipelines. A fan-heated electric heater, a heat exchanger, and a first circulating water heat exchanger are connected in series on the pipelines, and an expansion valve, a solenoid valve, and multiple temperature sensors and pressure transmitters are provided. The outlet pipeline of the first compressor branches off and connects to the first circulating water heat exchanger and the heat exchanger respectively. The outlet of the heat exchanger merges with the inlet pipeline of the expansion valve to realize the switching of refrigerant between different heat exchange paths, thereby completing the cooling or heating cycle.

[0010] Preferably, the direct cooling and heating system includes a second gas-liquid separator, a second compressor, an evaporator, a battery pack, and a second circulating water heat exchanger connected in sequence by pipelines. The pipelines are equipped with an expansion valve, a solenoid valve, and multiple temperature sensors and pressure transmitters. The outlet pipeline of the second compressor is connected to the heat exchanger, and the other end of the heat exchanger is connected to the temperature chamber system pipeline. At the same time, the second circulating water heat exchanger is connected to the circulating water system through pipelines, so that the refrigerant can selectively exchange heat with the refrigerant or circulating water of the temperature chamber system, thereby realizing the direct cooling or direct heating control of the battery pack.

[0011] Preferably, the liquid cooling system includes a water-heated electric heater, a liquid cooling circulation pump, and a first mass flow controller connected in sequence via pipelines. The pipelines are equipped with solenoid valves, multiple temperature sensors, and pressure transmitters. The outlet pipeline of the liquid cooling circulation pump is connected to the coolant channel of the evaporator. The refrigerant channel of the evaporator is connected to the inlet and outlet pipelines of the second compressor of the direct cooling and heating system via a solenoid valve. The water-heated electric heater is connected in series in the pipeline between the evaporator and the battery pack, so that the coolant can be cooled by heat exchange in the evaporator or heated by the water-heated electric heater before flowing to the battery pack, thus meeting the liquid cooling or liquid heating requirements of the battery pack.

[0012] Preferably, the circulating water system includes a circulating water tank and a circulating water pump connected by pipelines. The outlet pipeline of the circulating water pump branches off and connects to multiple mass flow controllers. Each mass flow controller is connected to the circulating water channel of the first circulating water heat exchanger and the second circulating water heat exchanger through pipelines. The pipelines are equipped with solenoid valves, multiple temperature sensors, and pressure transmitters. After the circulating water is output by the circulating water pump, the flow rate is regulated by the mass flow controllers and enters the first circulating water heat exchanger and the second circulating water heat exchanger to exchange heat with the refrigerant, thereby realizing the transfer and balance of heat in each system.

[0013] Preferably, the system can realize eight working modes, including direct cooling of the battery pack in the temperature chamber, direct cooling of the battery pack in the temperature chamber, direct cooling of the battery pack in the temperature chamber, direct cooling of the battery pack in the temperature chamber, liquid cooling of the battery pack in the temperature chamber, liquid cooling of the battery pack in the temperature chamber, liquid cooling of the battery pack in the temperature chamber, liquid cooling of the battery pack in the temperature chamber, and liquid cooling of the battery pack in the temperature chamber. By switching the on / off state of the control valves on each system pipeline, the flow path of the refrigerant and coolant is changed, thereby realizing the switching of different working modes.

[0014] Preferably, in either the direct cooling / heating mode of the battery pack for cooling or the direct cooling / cooling mode of the battery pack for heating, the temperature box system and the direct cooling / heating system establish a refrigerant circulation loop through a heat exchanger, prioritizing heat exchange between the refrigerants. Excess heat is transferred through the first and second circulating water heat exchangers of the circulating water system. In the liquid cooling / heating mode of the battery pack for heating, the pipes of the liquid cooling system are connected to the evaporator and heat exchanger of the direct cooling / heating system, and excess heat is transferred to the temperature box system through the refrigerant of the direct cooling / heating system, achieving energy recovery and utilization.

[0015] Preferably, the temperature sensor and pressure transmitter are installed at the pipeline nodes of each system to collect temperature and pressure signals in the pipeline in real time; the controller adjusts the speed of the first compressor and the second compressor, the opening degree of each expansion valve and the flow parameters of each mass flow controller according to the collected signals to achieve precise control of cooling capacity, heating capacity and refrigerant subcooling and superheating.

[0016] Preferably, the air-heated electric heater is connected in series in the connecting pipe between the environmental chamber condenser and the environmental chamber, and is linked with the temperature sensor through an independent control switch to help meet the heating demand; the refrigerant channel inlet of the heat exchanger is branched to the outlet of the first compressor, and the outlet merges with the inlet pipe of the expansion valve to form a switchable heat exchange loop, so that the refrigerant can selectively flow through the heat exchanger to exchange heat with the direct cooling and heating system.

[0017] Compared with existing technologies, the advantages of this invention are as follows: By efficiently integrating the temperature chamber system, liquid cooling system, and direct cooling system, this invention can adapt to the testing of various battery packs and saves equipment costs. Coupling the temperature chamber system with the battery thermal management system through a heat exchanger enables efficient utilization of the thermal energy of each system under different operating modes, saving energy consumption of the testing system. Connecting the cooling systems of each subsystem in parallel improves equipment utilization efficiency. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0019] In the attached diagram:

[0020] Figure 1 This is a diagram of an integrated battery environmental chamber thermal management test system according to an embodiment of the present invention;

[0021] Figure 2 This is a schematic diagram of the refrigerant flow in a direct-cooling battery pack of an incubator according to an embodiment of the present invention;

[0022] Figure 3 This is a schematic diagram of the refrigerant flow in a direct-cooling heating battery pack of an embodiment of the present invention;

[0023] Figure 4 This is a schematic diagram of the refrigerant flow in a direct cooling and heating system of a battery pack in a temperature chamber according to an embodiment of the present invention.

[0024] Figure 5 This is a schematic diagram of the refrigerant flow in a direct cooling battery pack for heating in an incubator according to an embodiment of the present invention.

[0025] Figure 6 This is a schematic diagram of the refrigerant and coolant flow in a liquid-cooled battery pack for incubator refrigeration according to an embodiment of the present invention;

[0026] Figure 7 This is a schematic diagram of the flow of refrigerant and coolant in a liquid-cooled heating battery pack in an embodiment of the present invention.

[0027] Figure 8 This is a schematic diagram of the refrigerant and coolant flow in a liquid-cooled heating system for a battery pack used in a temperature chamber according to an embodiment of the present invention.

[0028] Figure 9 This is a schematic diagram of the flow of refrigerant and coolant in a liquid-cooled battery pack for heating in an incubator according to an embodiment of the present invention.

[0029] The diagram labels are as follows: 101, First compressor; 102, First gas-liquid separator; 103, Ambient chamber evaporator; 104, Ambient chamber condenser; 105, Electric fan heater; 106, First expansion valve; 107, First pressure transmitter; 108, First temperature sensor; 109, Second pressure transmitter; 110, Second temperature sensor; 111, Heat exchanger; 112, First solenoid valve; 113, Second solenoid valve; 114, Second expansion valve; 115, Third solenoid valve; 116, Third expansion valve; 117, Fourteenth temperature sensor; 118, Fourteenth pressure transmitter; 119. 15th Temperature Sensor; 120. 15th Pressure Transmitter; 201. 2nd Gas-Liquid Separator; 202. 2nd Compressor; 203. 4th Expansion Valve; 204. 4th Solenoid Valve; 205. 5th Solenoid Valve; 206. 6th Solenoid Valve; 207. 7th Solenoid Valve; 208. 8th Solenoid Valve; 209. 9th Solenoid Valve; 210. Evaporator; 211. 3rd Pressure Transmitter; 212. 3rd Temperature Sensor; 213. Battery Pack; 214. 4th Pressure Transmitter; 215. 4th Temperature Sensor; 216. 10th Solenoid Valve; 217. 5th Expansion Valve; 218. 11th Solenoid Valve; 219. Solenoid valve; 220. Fifth temperature sensor; 221. Fifth pressure transmitter; 222. Thirteenth solenoid valve; 223. Sixth temperature sensor; 224. Sixth pressure transmitter; 225. Seventh temperature sensor; 226. Seventh pressure transmitter; 301. Water heater; 302. Eighth pressure transmitter; 303. Eighth temperature sensor; 304. Fourteenth solenoid valve; 305. Fifteenth solenoid valve; 306. Ninth temperature sensor; 307. Ninth pressure transmitter; 308. Liquid-cooled circulating pump; 309. First mass flow controller; 310. 311. Tenth temperature sensor; 312. Tenth pressure transmitter; 313. Eleventh temperature sensor; 314. Eleventh pressure transmitter; 405. Circulating water tank; 406. Circulating water pump; 407. Second mass flow controller; 408. Sixteenth solenoid valve; 409. Third mass flow controller; 410. First circulating water heat exchanger; 411. Twelfth pressure transmitter; 412. Twelfth temperature sensor; 413. Seventeenth solenoid valve; 414. Fourth mass flow controller; 415. Thirteenth pressure transmitter; 416. Thirteenth temperature sensor; 417. Second circulating water heat exchanger. Detailed Implementation

[0030] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0031] Example: Figure 1As shown, an integrated battery environmental chamber thermal management testing system includes a temperature chamber system, a direct cooling and heating system, a liquid cooling system, and a circulating water system. These systems are interconnected through pipelines, control valves, and measuring elements to form an integrated testing architecture. The system can achieve eight operating modes: temperature chamber cooling with direct cooling of the battery pack, temperature chamber heating with direct cooling and heating of the battery pack, temperature chamber cooling with direct cooling and heating of the battery pack, temperature chamber heating with direct cooling and cooling of the battery pack, temperature chamber cooling with liquid cooling of the battery pack, temperature chamber heating with liquid cooling and heating of the battery pack, and temperature chamber heating with liquid cooling and cooling of the battery pack. Switching between different operating modes is achieved by changing the on / off state of the control valves on the pipelines of each system, thereby altering the flow paths of the refrigerant and coolant.

[0032] The temperature chamber system is used to control the test environment temperature. The temperature chamber system includes a first compressor 101, a first gas-liquid separator 102, an environmental chamber evaporator 103, and an environmental chamber condenser 104 connected in sequence by pipelines. A fan-heated electric heater, a heat exchanger, and a first circulating water heat exchanger are connected in series on the pipelines. An expansion valve, a solenoid valve, and multiple temperature sensors and pressure transmitters are also provided. The outlet pipeline of the first compressor branches off and connects to the first circulating water heat exchanger and the first heat exchanger. The outlet of the heat exchanger merges with the inlet pipeline of the expansion valve to realize the switching of refrigerant between different heat exchange paths, thereby completing the cooling or heating cycle.

[0033] The direct cooling / heating system and the liquid cooling system are adapted to the thermal management requirements of battery packs with different cooling types. The direct cooling / heating system includes a second gas-liquid separator 201, a second compressor 202, an evaporator 210, a battery pack 213, and a second circulating water heat exchanger 413, which are connected in sequence by pipelines. The pipelines are equipped with expansion valves, solenoid valves, and multiple temperature sensors and pressure transmitters. The outlet pipeline of the second compressor is connected to the heat exchanger, and the other end of the heat exchanger is connected to the temperature chamber system pipeline. At the same time, the second circulating water heat exchanger 413 is connected to the circulating water system through pipelines, so that the refrigerant can selectively exchange heat with the refrigerant or circulating water of the temperature chamber system to achieve electric... The direct cooling or direct heating control of the battery pack 213; the liquid cooling system includes a water-heated electric heater 301, a liquid cooling circulation pump 308 and a first mass flow controller 309 connected in sequence by pipelines. The pipelines are equipped with solenoid valves and multiple temperature sensors and pressure transmitters; the outlet pipeline of the liquid cooling circulation pump is connected to the coolant channel of the evaporator, and the refrigerant channel of the evaporator is connected to the inlet and outlet pipelines of the second compressor of the direct cooling and heating system through a solenoid valve. The water-heated electric heater is connected in series in the pipeline between the evaporator and the battery pack, so that the coolant can be cooled by heat exchange in the evaporator or heated by the water-heated electric heater before flowing to the battery pack, meeting the liquid cooling or liquid heating requirements of the battery pack.

[0034] The circulating water system is connected to the temperature box system and the direct cooling and heating system through pipelines, providing a heat transfer medium for each system. The circulating water system includes a circulating water tank 401 and a circulating water pump 402 connected by pipelines. The outlet pipeline of the circulating water pump branches and connects to multiple mass flow controllers. Each mass flow controller is connected to the circulating water channel of the first circulating water heat exchanger 413 through pipelines. The pipelines are equipped with solenoid valves and multiple temperature sensors and pressure transmitters. After the circulating water is output by the circulating water pump, the flow rate is regulated by the second mass flow controller 403, and the water enters the first circulating water heat exchanger 406 and the second circulating water heat exchanger 413 to exchange heat with the refrigerant, thereby realizing the heat transfer and balance of each system.

[0035] Furthermore, in either the direct cooling / heating mode of the battery pack for cooling or the direct cooling / cooling mode of the battery pack for heating, the temperature box system and the direct cooling / heating system establish a refrigerant circulation loop through a heat exchanger, prioritizing heat exchange between the refrigerants. The remaining heat is transferred through the first and second circulating water heat exchangers 413 of the circulating water system. In the liquid cooling / heating mode of the battery pack for heating, the pipelines of the liquid cooling system are connected to the evaporator and heat exchanger of the direct cooling / heating system, and excess heat is transferred to the temperature box system through the refrigerant of the direct cooling / heating system, achieving energy recovery and utilization.

[0036] Furthermore, temperature sensors and pressure transmitters are installed at the pipeline nodes of each system to collect temperature and pressure signals in the pipeline in real time. Based on the collected signals, the controller adjusts the speed of the first compressor and the second compressor, the opening degree of each expansion valve, and the flow parameters of each mass flow controller to achieve precise control of cooling capacity, heating capacity, and refrigerant subcooling and superheating.

[0037] Furthermore, the air-heated electric heater is connected in series in the connecting pipe between the environmental chamber condenser and the environmental chamber, and is linked with the temperature sensor through an independent control switch to help meet the heating demand; the refrigerant channel inlet of the heat exchanger is connected to the branch pipe of the first compressor outlet, and the outlet merges with the expansion valve inlet pipe to form a switchable heat exchange loop, so that the refrigerant can selectively flow through the heat exchanger to exchange heat with the direct cooling and heating system.

[0038] The temperature sensors include a first temperature sensor 108, a second temperature sensor 110, a third temperature sensor 212, a fourth temperature sensor 215, a fifth temperature sensor 220, a sixth temperature sensor 223, a seventh temperature sensor 225, an eighth temperature sensor 303, a ninth temperature sensor 306, a tenth temperature sensor 310, an eleventh temperature sensor 312, a twelfth temperature sensor 408, a thirteenth temperature sensor 412, a fourteenth temperature sensor 117, and a fifteenth temperature sensor 119.

[0039] The pressure transmitters include a first pressure transmitter 107, a second pressure transmitter 109, a third pressure transmitter 211, a fourth pressure transmitter 214, a fifth pressure transmitter 221, a sixth pressure transmitter 224, a seventh pressure transmitter 226, an eighth pressure transmitter 302, a ninth pressure transmitter 307, a tenth pressure transmitter 311, an eleventh pressure transmitter 313, a twelfth pressure transmitter 407, a thirteenth pressure transmitter 411, a fourteenth pressure transmitter 118, and a fifteenth pressure transmitter 120.

[0040] The solenoid valves include a first solenoid valve 112, a second solenoid valve 113, a third solenoid valve 115, a fourth solenoid valve 204, a fifth solenoid valve 205, a sixth solenoid valve 206, a seventh solenoid valve 207, an eighth solenoid valve 208, a ninth solenoid valve 209, a tenth solenoid valve 216, an eleventh solenoid valve 218, a twelfth solenoid valve 219, a thirteenth solenoid valve 222, a fourteenth solenoid valve 304, a fifteenth solenoid valve 305, a sixteenth solenoid valve 404, and a seventeenth solenoid valve 409.

[0041] The expansion valve includes a first expansion valve 106, a second expansion valve 114, a third expansion valve 116, a fourth expansion valve 203, and a fifth expansion valve 217.

[0042] Figure 2 This is a schematic diagram of the refrigerant flow in a direct-cooling battery pack of a temperature chamber according to an embodiment of the present invention. In the temperature chamber system, the refrigerant flow direction is: first compressor 101 > first circulating water heat exchanger 406 > first expansion valve 106 > ambient chamber evaporator 103 > first gas-liquid separator 102 > first compressor 101. The heat transfer direction is: ambient chamber > ambient chamber evaporator 103 > refrigerant > first circulating water heat exchanger 406 > circulating water. The refrigerant in the ambient chamber evaporator 103 absorbs heat from the ambient chamber, lowering its temperature. The heat absorbed by the refrigerant is transferred to the circulating water through the first circulating water heat exchanger 406.

[0043] The cooling capacity of the chamber is adjusted by regulating the speed of the first compressor 101 and the opening degree of the first expansion valve 106 through the feedback signals of the fourteenth temperature sensor 117 and the fourteenth pressure transmitter 118.

[0044] In the battery pack direct cooling system, the refrigerant flow direction is: second compressor 202 > second circulating water heat exchanger 413 > fourth expansion valve 203 > battery pack 213 > second gas-liquid separator 201 > second compressor 202. The heat transfer direction is: battery pack 213 > refrigerant > second circulating water heat exchanger 413 > circulating water.

[0045] The cooling capacity of the battery pack 213 is adjusted by regulating the speed of the second compressor 202 and the opening degree of the fourth expansion valve 203 through the feedback signals of the fourth pressure transmitter 214 and the fourth temperature sensor 215.

[0046] The flow rate of circulating water in the first circulating water heat exchanger 406 is controlled by the third mass flow controller 405 through the feedback signals of the fifth pressure transmitter 221 and the fifth temperature sensor 220, and the flow rate of circulating water in the second circulating water heat exchanger 413 is controlled by the fourth mass flow controller 410 through the feedback signals of the first pressure transmitter 107 and the first temperature sensor 108, thereby achieving the regulation of refrigerant subcooling.

[0047] In this embodiment, the valves involved in the control include, but are not limited to: the first expansion valve 106, the second solenoid valve 113, the third solenoid valve 115, the fourth expansion valve 203, the seventh solenoid valve 207, the ninth solenoid valve 209, the twelfth solenoid valve 219, the sixteenth solenoid valve 404, and the seventeenth solenoid valve 409.

[0048] Figure 3 This is a schematic diagram of the refrigerant flow in a direct-cooling heating battery pack of an embodiment of the present invention. In the heating system, the refrigerant flow direction is: first compressor 101 > ambient chamber condenser 104 > third expansion valve 116 > first circulating water heat exchanger 406 > first gas-liquid separator 102 > first compressor 101. The heat flow direction is: circulating water > first circulating water heat exchanger 406 > refrigerant > ambient chamber condenser 104 > ambient chamber. The refrigerant in the first circulating water heat exchanger 406 absorbs heat from the circulating water and transfers the heat to the ambient chamber through the ambient chamber condenser 104. A fan-heated electric heater 105 can be further used to meet greater heat demand.

[0049] The superheat of the refrigerant is adjusted by the feedback signals from the first pressure transmitter 107 and the first temperature sensor 108.

[0050] In the battery pack direct cooling system, the refrigerant flow direction is: second compressor 202 > battery pack 213 > fifth expansion valve 217 > second circulating water heat exchanger 413 > second gas-liquid separator 201 > second compressor 202. The heat flow direction is: circulating water > second circulating water heat exchanger 413 > refrigerant > battery pack.

[0051] The superheat of the refrigerant is adjusted by the feedback signals from the fifth temperature sensor 220 and the fifth pressure transmitter 221.

[0052] In this embodiment, the valves involved in the control include, but are not limited to: the third expansion valve 116, the sixth solenoid valve 206, the fifth expansion valve 217, the twelfth solenoid valve 219, the eighth solenoid valve 208, the eleventh solenoid valve 218, the sixteenth solenoid valve 404, and the seventeenth solenoid valve 409.

[0053] Figure 4This is a schematic diagram of the refrigerant flow in a direct-cooling heating system for a battery pack in a temperature chamber according to an embodiment of the present invention. In the temperature chamber system, the refrigerant flow direction is: first compressor 101 > heat exchanger 111 and first circulating water heat exchanger 406 > first expansion valve 106 > ambient chamber evaporator 103 > first gas-liquid separator 102 > first compressor 101. The heat transfer direction is: ambient chamber > ambient chamber evaporator 103 > refrigerant > heat exchanger 111 and first circulating water heat exchanger 406. Heat is preferentially transferred to the direct-cooling system of the battery pack through heat exchanger 111, and secondarily transferred to the circulating water through the first circulating water heat exchanger 406.

[0054] The subcooling and superheat of the refrigerant are controlled by the feedback signals from the first pressure transmitter 107, the first temperature sensor 108, the second pressure transmitter 109, the second temperature sensor 110, the fourteenth temperature sensor 117, and the fourteenth pressure transmitter 118.

[0055] In the direct cooling system of the battery pack, the refrigerant flow direction is as follows: second compressor 202 > battery pack 213 > fifth expansion valve 217 > heat exchanger 111 and second circulating water heat exchanger 413 > second gas-liquid separator 201 > second compressor 202.

[0056] In the incubator system, the high-pressure gaseous refrigerant from the outlet of the first compressor 101 exchanges heat with the low-pressure liquid refrigerant from the outlet of the fifth expansion valve 217 in the battery pack direct cooling system in heat exchanger 111. The heat exchange process takes place primarily in heat exchanger 111, followed by the first circulating water heat exchanger 406 and the second circulating water heat exchanger 413, which improves the energy utilization efficiency of the entire system and reduces energy consumption.

[0057] The subcooling and superheat of the refrigerant are controlled by the feedback signals from the fourth pressure transmitter 214, the fourth temperature sensor 215, the fifth temperature sensor 220, the fifth pressure transmitter 221, the sixth temperature sensor 223, and the sixth pressure transmitter 224.

[0058] In this embodiment, the valves involved in the control include, but are not limited to: first expansion valve 106, first solenoid valve 112, second solenoid valve 113, third solenoid valve 115, sixth solenoid valve 206, eighth solenoid valve 208, fifth expansion valve 217, twelfth solenoid valve 219, thirteenth solenoid valve 222, sixteenth solenoid valve 404, and seventeenth solenoid valve 409.

[0059] Figure 5 This is a schematic diagram of the refrigerant flow in a direct cooling battery pack heating system according to an embodiment of the present invention. The refrigerant flow direction in the heating system is as follows: first compressor 101 > ambient chamber condenser 104 > third expansion valve 116 > heat exchanger 111 and first circulating water heat exchanger 406 > first gas-liquid separator 102 > first compressor 101.

[0060] The subcooling and superheating of the refrigerant are controlled by feedback signals from the first pressure transmitter 107, the first temperature sensor 108, the second pressure transmitter 109, the second temperature sensor 110, the fifteenth temperature sensor 119, and the fifteenth pressure transmitter 120. This allows for the further activation of the fan-heated electric heater 105 to provide greater heating capacity.

[0061] In the battery pack direct cooling system, the refrigerant flow direction is: second compressor 202 > heat exchanger 111 and second circulating water heat exchanger 413 > fourth expansion valve 203 > battery pack 213 > second gas-liquid separator 201 > second compressor 202. The heat transfer direction is: battery pack 213 > refrigerant > heat exchanger 111 and second circulating water heat exchanger. Heat is preferentially transferred to the temperature chamber system through heat exchanger 111, and secondly transferred to the circulating water through the second circulating water heat exchanger 413. In the battery pack direct cooling system, the high-pressure gaseous refrigerant at the outlet of the second compressor 202 and the low-pressure liquid refrigerant at the outlet of the third expansion valve 116 in the temperature chamber system exchange heat in heat exchanger 111.

[0062] The subcooling and superheat of the refrigerant are controlled by the feedback signals from the fourth pressure transmitter 214, the fourth temperature sensor 215, the fifth temperature sensor 220, the fifth pressure transmitter 221, the sixth temperature sensor 223, and the sixth pressure transmitter 224.

[0063] In this embodiment, the valves involved in the control include, but are not limited to: the third expansion valve 116, the first solenoid valve 112, the second solenoid valve 113, the seventh solenoid valve 207, the ninth solenoid valve 209, the fourth expansion valve 203, the eleventh solenoid valve 218, the twelfth solenoid valve 219, the thirteenth solenoid valve 222, the sixteenth solenoid valve 404, and the seventeenth solenoid valve 409.

[0064] Figure 6 This is a schematic diagram of the refrigerant and coolant flow in a liquid-cooled refrigeration system of a battery pack for a temperature chamber according to an embodiment of the present invention. In the temperature chamber system, the refrigerant flow direction is: first compressor 101 > first circulating water heat exchanger 406 > first expansion valve 106 > ambient chamber evaporator 103 > first gas-liquid separator 102 > first compressor 101. The heat transfer direction is: ambient chamber > ambient chamber evaporator 103 > refrigerant > first circulating water heat exchanger 406 > circulating water.

[0065] The subcooling and superheat of the refrigerant are controlled by the feedback signals from the first pressure transmitter 107, the first temperature sensor 108, the second pressure transmitter 109, the second temperature sensor 110, the fourteenth temperature sensor 117, and the fourteenth pressure transmitter 118.

[0066] In a liquid cooling system, the cooling of the coolant requires the cooling capacity provided by a direct cooling system. The battery environment chamber thermal management test system proposed in this invention combines the functions of a direct cooler and a liquid cooler. The direct cooling system in the direct cooler can directly meet the cooling requirements of the liquid cooling system, eliminating the need to design a separate direct cooling system and saving equipment costs.

[0067] In the liquid cooling system, the refrigerant flow direction is: second compressor 202 > second circulating water heat exchanger 413 > fourth expansion valve 203 > evaporator 210 > second gas-liquid separator 201 > second compressor 202. The coolant flow direction is: liquid cooling circulating pump 308 > first mass flow controller 309 > evaporator 210 > battery pack 213 > liquid cooling circulating pump 308. The heat transfer direction is: battery pack 213 > coolant > evaporator 210 > refrigerant > second circulating water heat exchanger 413 > circulating water.

[0068] The cooling capacity of the cooling system is controlled by adjusting the speed of the second compressor 202 according to the set temperature of the coolant.

[0069] In this embodiment, the valves involved in the control include, but are not limited to: the first expansion valve 106, the second solenoid valve 113, the third solenoid valve 115, the fourth expansion valve 203, the fifth solenoid valve 205, the ninth solenoid valve 209, the twelfth solenoid valve 219, the eleventh solenoid valve 218, the sixteenth solenoid valve 404, and the seventeenth solenoid valve 409.

[0070] Figure 7 This is a schematic diagram of the refrigerant and coolant flow in a liquid-cooled heating battery pack of an embodiment of the present invention. In the heating system, the refrigerant flow direction is: first compressor 101 > ambient chamber condenser 104 > third expansion valve 116 > heat exchanger 111 and first circulating water heat exchanger 406 > first gas-liquid separator 102 > first compressor 101. The low-pressure liquid refrigerant after the third expansion valve 116 preferentially absorbs heat in the heat exchanger 111, and secondarily absorbs heat in the first circulating water heat exchanger 406. The electric fan heater 105 can be further activated to meet a greater heating capacity.

[0071] The subcooling and superheat of the refrigerant are controlled by the feedback signals from the first pressure transmitter 107, the first temperature sensor 108, the second pressure transmitter 109, the second temperature sensor 110, the fifteenth temperature sensor 119, and the fifteenth pressure transmitter 120.

[0072] In the liquid cooling system, the coolant flow direction is: liquid cooling circulation pump 308 > first mass flow controller 309 > evaporator 210 > water-heated electric heater 301 > battery pack 213 > liquid cooling circulation pump 308. The water-heated electric heater 301 can heat the coolant to the set temperature to meet the heating requirements of the battery pack 213. Excess heat can be transferred to the temperature chamber system through the direct cooling system, making full use of the waste heat of the test system and reducing unnecessary energy consumption.

[0073] In the liquid cooling system, the refrigerant flow direction is: second compressor 202 > heat exchanger 111 > fourth expansion valve 203 > evaporator 210 > second gas-liquid separator 201 > second compressor 202. The heat transfer direction is: coolant > evaporator 210 > refrigerant for battery pack direct cooling system > heat exchanger 111 > refrigerant for temperature chamber system.

[0074] In this embodiment, the valves involved in the control include, but are not limited to: first solenoid valve 112, second solenoid valve 113, third expansion valve 116, fourth expansion valve 203, fifth solenoid valve 205, ninth solenoid valve 209, eleventh solenoid valve 218, thirteenth solenoid valve 222, sixteenth solenoid valve 404, and seventeenth solenoid valve 409.

[0075] Figure 8 This is a schematic diagram of the refrigerant and coolant flow in a liquid-cooled heating system for a battery pack in a temperature chamber according to an embodiment of the present invention. In the temperature chamber system, the refrigerant flow direction is: first compressor 101 > first circulating water heat exchanger 406 > first expansion valve 106 > ambient chamber evaporator 103 > first gas-liquid separator 102 > first compressor 101. The heat transfer direction is: ambient chamber > ambient chamber evaporator 103 > refrigerant > first circulating water heat exchanger 406 > circulating water.

[0076] The subcooling and superheat of the refrigerant are controlled by the feedback signals from the first pressure transmitter 107, the first temperature sensor 108, the second pressure transmitter 109, the second temperature sensor 110, the fourteenth temperature sensor 117, and the fourteenth pressure transmitter 118.

[0077] In the liquid cooling system, the coolant flow direction is: liquid cooling circulation pump 308 > first mass flow controller 309 > evaporator 210 > water-heated electric heater 301 > battery pack 213 > liquid cooling circulation pump 308. The water-heated electric heater 301 can heat the coolant to the set temperature to meet the heating requirements of the battery pack.

[0078] In this embodiment, the valves involved in the control include, but are not limited to: the first expansion valve 106, the first solenoid valve 112, the second solenoid valve 113, and the fourteenth solenoid valve 304.

[0079] Figure 9This is a schematic diagram of the refrigerant and coolant flow in a liquid-cooled battery pack for heating in an embodiment of the present invention. In the incubator system, the refrigerant flow direction is: first compressor 101 > ambient chamber condenser 104 > third expansion valve 116 > heat exchanger 111 and first circulating water heat exchanger 406 > first gas-liquid separator 102 > first compressor 101. The low-pressure liquid refrigerant after the third expansion valve 116 preferentially absorbs heat in heat exchanger 111, and secondarily absorbs heat in first circulating water heat exchanger 406. The electric fan heater 105 can be further activated to meet a greater heating capacity.

[0080] The subcooling and superheat of the refrigerant are controlled by the feedback signals from the first pressure transmitter 107, the first temperature sensor 108, the second pressure transmitter 109, the second temperature sensor 110, the fourteenth temperature sensor 117, and the fourteenth pressure transmitter 118.

[0081] In the liquid cooling system, the refrigerant flow direction is: second compressor 202 > heat exchanger 111 and second circulating water heat exchanger 413 > fourth expansion valve 203 > evaporator 210 > second gas-liquid separator 201 > second compressor 202. The coolant flow direction is: liquid cooling circulation pump 308 > first mass flow controller 309 > evaporator 210 > battery pack 213 > liquid cooling circulation pump 308.

[0082] The heat transfer direction is: battery pack 213 > coolant > evaporator 210 > refrigerant for the direct cooling system of the battery pack > heat exchanger 111 and the second circulating water heat exchanger 413. The heat exchange process preferentially occurs in heat exchanger 111, where the high-pressure gaseous refrigerant after the second compressor 202 exchanges heat with the low-pressure liquid refrigerant after the third expansion valve 116. The remaining heat exchange takes place in the first circulating water heat exchanger 406 and the second circulating water heat exchanger 413.

[0083] The cooling capacity of the cooling system is controlled by adjusting the speed of the second compressor 202 according to the set temperature of the coolant.

[0084] In this embodiment, the valves involved in the control include, but are not limited to: first solenoid valve 112, second solenoid valve 113, third expansion valve 116, fourth expansion valve 203, fifth solenoid valve 205, ninth solenoid valve 209, twelfth solenoid valve 219, eleventh solenoid valve 218, thirteenth solenoid valve 222, sixteenth solenoid valve 404, and seventeenth solenoid valve 409.

[0085] This invention establishes a universal thermal management architecture that covers the testing needs of battery packs with multiple cooling types through deep integration of a temperature chamber system, a direct cooling / heating system, a liquid cooling system, and a circulating water system. The various systems, through the coordinated operation of pipelines, control valves, and measuring elements, enable flexible switching between eight operating modes. It also covers the cooling and heating combinations of the temperature chamber and the battery pack's direct / liquid cooling, and achieves heat balance with the circulating water system via heat exchanger coupling, thus solving the problems of "high energy consumption, equipment redundancy, and poor adaptability" in traditional testing systems.

[0086] On the one hand, the system integrates environmental chamber temperature control and direct / liquid cooling thermal management functions into the same architecture, avoiding the equipment redundancy and cost waste caused by separate configuration of environmental chamber, direct cooler, and liquid cooler in traditional solutions. It adapts to the testing needs of battery packs with different cooling types and significantly improves equipment utilization efficiency. On the other hand, by prioritizing direct heat exchange of refrigerant between systems through heat exchangers, balancing residual heat in the circulating water system, and energy recovery and utilization in the liquid cooling heating mode of the battery pack heated by the temperature chamber, the system significantly reduces energy loss during testing and improves overall energy utilization efficiency.

[0087] Each embodiment verifies the system's precise control over cooling capacity, heating capacity, and refrigerant subcooling / superheating through specific refrigerant / coolant flow directions, valve control logic, and sensor feedback adjustments, ensuring the stability of the test environment and the accuracy of battery pack thermal management testing. This achieves integrated, low-energy-consumption, and highly adaptable battery environment compartment thermal management testing.

[0088] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An integrated battery environmental chamber thermal management testing system, characterized in that: The system includes a temperature chamber system, a direct cooling and heating system, a liquid cooling system, and a circulating water system. These systems are interconnected through pipelines, control valves, and measuring elements to form an integrated testing architecture. The temperature chamber system is used to control the test environment temperature. The direct cooling and heating system and the liquid cooling system are adapted to the thermal management requirements of different types of battery packs. The circulating water system is connected to the temperature chamber system and the direct cooling and heating system through pipelines to provide a heat transfer medium for each system. The temperature chamber system includes a first compressor, a first gas-liquid separator, an environmental chamber evaporator, and an environmental chamber condenser connected in sequence by pipelines. A fan-heated electric heater, a heat exchanger, and a first circulating water heat exchanger are connected in series on the pipelines, and an expansion valve, a solenoid valve, and multiple temperature sensors and pressure transmitters are provided. The outlet pipeline of the first compressor branches and connects to the first circulating water heat exchanger and the heat exchanger respectively. The outlet of the heat exchanger merges with the inlet pipeline of the expansion valve to realize the switching of refrigerant between different heat exchange paths, thereby completing the cooling or heating cycle. The direct cooling and heating system includes a second gas-liquid separator, a second compressor, an evaporator, a battery pack, and a second circulating water heat exchanger connected in sequence by pipelines. The pipelines are equipped with an expansion valve, a solenoid valve, and multiple temperature sensors and pressure transmitters. The outlet pipeline of the second compressor is connected to the heat exchanger, and the other end of the heat exchanger is connected to the temperature box system pipeline. At the same time, the second circulating water heat exchanger is connected to the circulating water system through pipelines, so that the refrigerant can selectively exchange heat with the refrigerant or circulating water of the temperature box system to realize the direct cooling or direct heating control of the battery pack. The system can achieve eight working modes, including direct cooling of the battery pack in the temperature chamber, direct cooling of the battery pack in the temperature chamber, direct cooling of the battery pack in the temperature chamber, direct cooling of the battery pack in the temperature chamber, liquid cooling of the battery pack in the temperature chamber, liquid cooling of the battery pack in the temperature chamber, liquid cooling of the battery pack in the temperature chamber, and liquid cooling of the battery pack in the temperature chamber. By switching the on / off state of the control valves on each system pipeline, the flow path of the refrigerant and coolant is changed, thereby realizing the switching of different working modes. In either the direct cooling / heating mode or the direct cooling / cooling mode of the battery pack in the incubator, the incubator system and the direct cooling / heating system establish a refrigerant circulation loop through a heat exchanger, prioritizing heat exchange between the refrigerants. Excess heat is transferred through the first and second circulating water heat exchangers of the circulating water system. In the liquid cooling / heating mode of the battery pack in the incubator, the pipes of the liquid cooling system are connected to the evaporator and heat exchanger of the direct cooling / heating system. Excess heat is transferred to the incubator system through the refrigerant of the direct cooling / heating system, achieving energy recovery and utilization.

2. The integrated battery environmental chamber thermal management testing system according to claim 1, characterized in that: The liquid cooling system includes a water-heated electric heater, a liquid cooling circulation pump, and a first mass flow controller connected in sequence via pipelines. The pipelines are equipped with solenoid valves, multiple temperature sensors, and pressure transmitters. The outlet pipeline of the liquid cooling circulation pump is connected to the coolant channel of the evaporator. The refrigerant channel of the evaporator is connected to the inlet and outlet pipelines of the second compressor of the direct cooling and heating system via a solenoid valve. The water-heated electric heater is connected in series in the pipeline between the evaporator and the battery pack, so that the coolant can be cooled by heat exchange in the evaporator or heated by the water-heated electric heater before flowing to the battery pack, thus meeting the liquid cooling or liquid heating requirements of the battery pack.

3. The integrated battery environmental chamber thermal management testing system according to claim 1, characterized in that: The circulating water system includes a circulating water tank and a circulating water pump connected by pipelines. The outlet pipeline of the circulating water pump branches and connects to multiple mass flow controllers. Each mass flow controller is connected to the circulating water channel of the first circulating water heat exchanger and the second circulating water heat exchanger through pipelines. The pipelines are equipped with solenoid valves, multiple temperature sensors, and pressure transmitters. After the circulating water is output by the circulating water pump, the flow rate is regulated by the mass flow controllers and enters the first circulating water heat exchanger and the second circulating water heat exchanger to exchange heat with the refrigerant, thereby realizing the transfer and balance of heat in each system.

4. The integrated battery environmental compartment thermal management testing system according to claim 1, characterized in that: The temperature sensor and pressure transmitter are installed at the pipeline nodes of each system to collect temperature and pressure signals in the pipeline in real time. The controller adjusts the speed of the first compressor and the second compressor, the opening degree of each expansion valve and the flow parameters of each mass flow controller according to the collected signals to achieve precise control of cooling capacity, heating capacity and refrigerant subcooling and superheating.

5. The integrated battery environmental compartment thermal management testing system according to claim 1, characterized in that: The air-heated electric heater is connected in series in the connecting pipe between the environmental chamber condenser and the environmental chamber, and is linked with the temperature sensor through an independent control switch to help meet the heating demand; the refrigerant channel inlet of the heat exchanger is connected to the branch pipe of the first compressor outlet, and the outlet merges with the expansion valve inlet pipe to form a switchable heat exchange loop, so that the refrigerant can selectively flow through the heat exchanger to exchange heat with the direct cooling and direct heating system.

Images