Integrated thermal management system and energy distribution management method for electric forklift

Abstract

The invention discloses an integrated thermal management system for an electric forklift and an energy distribution management method, relates to the technical field of thermal management, and aims to solve the problem that a thermal management system capable of accurately regulating and controlling a forklift battery and a cab simultaneously lacks in the prior art. Wherein the integrated heat management master control comprises a detection module, a priority level judgment module and a regulation and control module; the heat management device is electrically connected with the integrated heat management master control and comprises a heating and cooling device, the circulation loop is connected with the heat management device, a cab and a battery system and is provided with a driving device and a proportional regulation and control switch, and the integrated heat management master control obtains the states and conditions of the forklift, the battery system and the cab system. The priority level and the heat management regulation degree of the battery system and the cab system are judged, and the battery system and the cab system are regulated through a heating device, a heat dissipation device and the like. Two-way intelligent flow and waste heat recovery of heat between the battery and the cab can be achieved, extra energy consumption is greatly reduced, and the energy efficiency and endurance of the whole vehicle are improved.

Description

Technical Field

[0001] This invention belongs to the field of thermal management technology, specifically relating to an integrated thermal management system and energy distribution management method for electric forklifts. Background Technology

[0002] Electric forklifts are material handling equipment powered by batteries, converting chemical energy into electrical energy. They are mainly classified into four-way electric forklifts, electric pallet stackers, and manual electric lift stackers. Electric forklifts need to discharge during operation, and since batteries have internal resistance, they generate heat during discharge. To prevent overheating and ensure operator safety, forklifts are typically equipped with cooling components such as fans to dissipate heat from the batteries. Furthermore, excessively cold temperatures can also affect battery performance, leading to capacity degradation, inability to recharge, or extremely low charge / discharge rates. Therefore, battery thermal management is necessary.

[0003] To facilitate operators frequently getting out of the vehicle to accurately place goods, wrap pallets, or interact with the warehousing system, the cabs of existing electric forklifts are mostly open or semi-open. These cabs only provide basic rain and sun protection and are not very comfortable. The temperature of the cab determines the operator's comfort, but existing electric forklifts lack a system that can regulate the temperature of both the battery and the cab.

[0004] To address the aforementioned issues, the electric forklift thermal management system (patent number CN116968503A) proposes a solution, comprising: a battery cooling circulation loop, a battery heating circulation loop, a cab cooling circulation loop, a cab heating circulation loop, a control unit, and a thermal management control module. The battery cooling circulation loop includes a battery cooling sub-loop and a refrigerant sub-loop. The cab cooling circulation loop is connected in parallel with the refrigerant sub-loop, sharing an electric compressor and condenser. The cab heating circulation loop is connected in parallel with the battery heating circulation loop, sharing a heater and a second power unit. The control unit independently controls the on / off state of each loop. The thermal management control module controls the operation of the control unit and each loop based on the battery temperature data and / or externally input thermal management requests. This patent provides a thermal management system that simultaneously meets the thermal management needs of both the battery and the cab.

[0005] However, this patent's thermal management of the battery and cab lacks precise allocation and efficient adjustment strategies for different demands on the battery system and cab system under varying operating conditions. Current methods often employ simple solenoid valves for coarse control in a fixed flow mode, failing to achieve stepless, on-demand, and precise distribution of heat or cold between the battery and cab. This results in inefficient energy allocation, with oversupply leading to waste or undersupply affecting performance, failing to achieve optimal energy efficiency. Summary of the Invention

[0006] This invention discloses an integrated thermal management system and energy distribution management method for electric forklifts, aiming to solve the problem in the prior art of lacking a thermal management system that can simultaneously and precisely control the electric forklift battery and cab.

[0007] To solve the aforementioned technical problems, the invention adopts the following technical solution:

[0008] An integrated thermal management system for electric forklifts includes:

[0009] Integrated Thermal Management Control: The integrated thermal management control includes a detection module, a priority level judgment module, and a control module; the detection module is used to acquire the forklift status, the actual temperature of the battery system and the cab system, and whether there is a driver in the cab; the priority level judgment module determines the priority level of heating or cooling and the degree of thermal management control based on the detection results of the detection module; the control module controls the heating and cooling devices to perform thermal management control on the cab system and the battery system;

[0010] Thermal management device: includes a heating device and a heat dissipation device, wherein the integrated thermal management control unit is electrically connected to the heating device and the heat dissipation device;

[0011] Circulation loop: The heating device and the heat dissipation device are connected to the cab system and the battery system through the circulation loop. The circulation loop is equipped with a drive device and a proportional control switch. The drive device and the proportional control switch are connected to the integrated thermal management main control circuit.

[0012] By adopting this technical solution, the cab system and battery system are integrated into a single integrated design through integrated thermal management control and circulation loops. This integrates two independent systems into a single system that shares a heat source and circulation loop. Furthermore, through detection modules and priority level judgment modules, the cab system and battery system are monitored to determine the proportion of heat generated by the heating device and cold generated by the cooling device flowing through the cab system and battery system, respectively. This enables precise control of the thermal management of the cab system and battery system, achieving bidirectional intelligent flow of heat between the battery and the cab and waste heat recovery. This significantly reduces additional energy consumption and improves the overall vehicle energy efficiency and range.

[0013] Preferably, a first heat exchanger and a second heat exchanger are respectively provided in the cab system and at the battery system, the heating device includes a PTC heater connected to the circulation loop, and the heat dissipation device includes a heat pump system connected to the circulation loop.

[0014] With this technical solution, the PTC heater can provide a stable heat source for rapid battery preheating and auxiliary cab heating in low-temperature environments, directly heating the coolant in the circulation loop. It has high heating efficiency, is safe, and is easy to control.

[0015] The heat pump system is used for battery cooling. In high-temperature summer environments, the heat pump system can operate in reverse, transferring the waste heat generated by the battery to the outside of the vehicle, thus cooling the battery. This eliminates the need for a separate, high-power battery cooling device, reducing energy consumption and allowing more energy to be used for vehicle operation, effectively increasing driving range. Simultaneously, the deep coupling between the heat pump system and the battery system enables dual-purpose operation. In cooling mode, the heat pump system's cooling capacity can be directly used to cool the battery; in heating mode, the waste heat generated by the battery can be recovered to heat the cabin system. This collaborative management avoids energy waste and improves the overall vehicle energy efficiency.

[0016] Preferably, the heat dissipation device further includes a large-fin radiator connected to the heat pump system. The large-fin radiator includes a fan system and is connected to the cab system through a cab ventilation duct. The cab ventilation duct is equipped with an airflow-driven fan and a second electric three-way proportional valve.

[0017] With this technical solution, when the battery system has a high heat dissipation, the excess heat can be transferred to the cab system through large finned heat sinks and fan systems, thereby raising the temperature of the cab system and realizing the effective utilization of the heat dissipation of the battery system, thus saving energy.

[0018] Preferably, the detection module includes temperature sensors respectively installed on the cab system and the battery system, a pressure sensor installed on the cab system, and a Hall current sensor installed on the battery system. The priority level determination module is set according to the forklift status, the suitable operating temperature of the battery, and the suitable operating temperature of the human body.

[0019] By adopting this technical solution, the installation of temperature sensors and other devices can improve the accuracy of the detection results of the cab system and battery system, thereby improving the accuracy of the integrated thermal management control system in regulating the cab system and battery system.

[0020] Preferably, the integrated thermal management master control also includes a historical operation module that can record the data of each adjustment by the integrated thermal management master control, and the historical operation module includes a BMS system.

[0021] After adopting this technical solution, the historical operation module can store relevant data on the integrated thermal management control of the battery system and the cab system. When the actual temperature of the battery system and the cab system is detected again, the relevant data stored in the historical operation module can be directly referenced to directly control the thermal management of the battery system and the cab system, which can further improve the speed and effect of the integrated thermal management control of the battery system and the cab system.

[0022] An integrated thermal management system and energy distribution management method for electric forklifts are adopted, including the following steps:

[0023] S1: The detection module obtains the forklift status, the actual temperature of the battery system and cab system, and whether there is a driver in the cab;

[0024] S2: The priority level judgment module determines the priority level of the heating device and the heat dissipation device for heating or dissipating heat from the battery system and the cab system, as well as the degree of thermal management control, based on the information obtained by the detection module.

[0025] S3: The integrated thermal management master control adjusts the heating device, heat dissipation device, and proportional control switch to perform thermal management of the battery system and cab system according to the priority level and thermal management control degree.

[0026] After adopting this technical solution, a priority level judgment module is first set up based on the forklift status, the battery's suitable operating temperature, and the human body's suitable operating temperature. This provides a basis for the integrated thermal management master control to adjust the battery system and cab system. The detection module detects the real-time temperature of the cab system and battery system and compares it with the priority level judgment module. Based on the comparison results, the integrated thermal management master control adjusts the heating device, heat dissipation device, and proportional control switch to precisely regulate the thermal management of the cab system and battery system. This ensures the comfort of using the electric forklift while reducing battery consumption and improving the electric forklift's range.

[0027] Preferably, the forklift state in S1 includes charging, stationary, and discharging.

[0028] By adopting this technical solution, the status of the forklift is used as a basis, which simplifies the subsequent judgment logic, reduces the calculation process of the integrated thermal management control, and thus reduces the energy consumption of this system.

[0029] Preferably, in S2, when the detection module determines that the forklift is charging or stationary, the priority level judgment module compares the actual temperature of the battery system obtained by the detection module with the set operating temperature of the battery, and the control module controls the heating device, heat dissipation device and circulation loop to only dissipate heat or heat the battery system according to the comparison result.

[0030] In S2, when the detection module determines that the forklift is in a state of discharge, the detection module also checks whether there is anyone in the cab. The priority level judgment module compares the actual temperature of the battery system obtained by the detection module with the battery set operating temperature, the actual temperature of the cab system and the set operating temperature of the cab. Based on the comparison results, the control module controls the heating device, heat dissipation device and circulation loop to dissipate heat or heat only on the battery system or on both the battery system and the cab system as needed.

[0031] After adopting this technical solution, a preliminary judgment is made based on the forklift status, and then the priority level is adjusted based on whether there is anyone in the cab. On the one hand, this simplifies the control logic of the integrated thermal management master control and reduces the difficulty of algorithm control; on the other hand, it can improve the control speed of the integrated thermal management master control, thereby improving the control efficiency and control effect of the cab system and battery system.

[0032] Preferably, in S2, when the detection module determines that the forklift is in a discharged state, heat or cold energy is allocated according to the demand weights of the battery system and the cab system. This includes determining the actual demand index and dynamic allocation coefficient of the battery system and the cab system, as well as the opening degree of the proportional control switch.

[0033] After adopting this technical solution, thermal management of the battery system and cab system is set according to the actual demand index and dynamic allocation coefficient of the battery system and cab system, as well as the opening degree of the proportional control switch, thereby improving the accuracy of thermal management of the battery system and cab system.

[0034] Preferably, step S3 includes allocating resources based on the demand weights of the battery system and the cab system when both the cab system and the battery system have demand. This includes determining the actual demand index and dynamic allocation coefficient of the battery system and the cab system, as well as the opening degree of the proportional control switch. After adopting this technical solution,

[0035] Preferably, the actual demand index is calculated according to the following formula:

[0036]

[0037] in, It is the demand intensity of the battery system. It is the target temperature of the battery system. This is the current temperature of the battery system. It is the normalized reference temperature of the battery system (such as the maximum allowable temperature difference of the system, i.e., the difference between the high temperature warning and the upper limit of the suitable temperature). It is the demand intensity of the cab system. It is the target temperature of the cab system. This is the current temperature of the cab system. It is the normalized reference temperature of the cab system (such as the maximum allowable temperature difference of the system).

[0038] The dynamic allocation coefficient is calculated according to the following formula:

[0039] ;

[0040] ;

[0041] in, It is the dynamic distribution coefficient of the battery system. It maintains the weight of the previous state. It is the static demand weight of the battery system. It is the static demand weight of the cab system. It is to prevent extremely small numbers with a denominator of 0. It is the dynamic distribution coefficient of the cab system;

[0042] The opening degree of the proportional control switch is:

[0043]

[0044] in, It is the proportional control switch that sends the opening command to the battery system. It is the proportional control switch that sends the opening command to the cab system.

[0045] By adopting this technical solution, the actual temperature of the battery system and the cab system can be converted into the opening degree of the proportional control switch through the setting of the actual demand index, dynamic allocation coefficient and proportional control switch opening formula, thereby achieving precise control of the heat or cold of the battery system and the cab system.

[0046] Preferably, in S2, when the detection module determines that the forklift is in a discharged state, and when the battery system has a heat dissipation requirement and the cab system has a heat supply requirement, the intensity of the battery system's heat dissipation requirement and the intensity of the cab system's heat supply requirement are determined based on the temperature difference between the battery system's heat dissipation and the temperature difference between the cab system's heat demand, and the proportion of heat dissipated by the battery system transferred to the cab system and / or the outside world is determined.

[0047] With this technical solution, excess heat generated by the battery system can be transferred to the cab system through heat dissipation, thereby heating the cab system, reducing energy loss and improving energy utilization.

[0048] In summary, due to the adoption of the above technical solution, the beneficial effects of the invention are:

[0049] (1) The cab system and battery system are integrated into a single integrated design through integrated thermal management control and circulation loop, integrating two independent systems into a system that shares a cold and heat source and circulation loop. Through detection modules and priority level judgment modules, the cab system and battery system are detected to determine the proportion of heat generated by the heating device and cold generated by the heat dissipation device flowing through the cab system and battery system respectively, so as to achieve precise control of thermal management of the cab system and battery system, achieving bidirectional intelligent flow of heat between the battery and the cab and waste heat recovery, significantly reducing additional energy consumption and improving the overall vehicle energy efficiency and range.

[0050] (2) The PTC heater can provide a stable heat source for rapid preheating of the battery and auxiliary heating of the cab in low temperature environment, and directly heats the coolant in the circulation loop. It has high heating efficiency, is safe and easy to control.

[0051] The heat pump system is used for battery cooling. In high-temperature summer environments, the heat pump system can operate in reverse, transferring the waste heat generated by the battery to the outside of the vehicle, thus cooling the battery. This eliminates the need for a separate, high-power battery cooling device, reducing energy consumption and allowing more energy to be used for vehicle operation, effectively increasing driving range. Simultaneously, the deep coupling between the heat pump system and the battery system enables dual-purpose operation. In cooling mode, the heat pump system's cooling capacity can be directly used to cool the battery; in heating mode, the waste heat generated by the battery can be recovered to heat the cabin system. This collaborative management avoids energy waste and improves the overall vehicle energy efficiency.

[0052] (3) Setting up temperature sensors and other equipment can improve the accuracy of the detection results of the cab system and battery system, thereby improving the accuracy of the integrated thermal management control of the cab system and battery system.

[0053] (4) The historical operation module can store relevant data on the control of the battery system and the cab system by the integrated thermal management master control. When the actual temperature of the battery system and the cab system is detected again, the relevant data stored in the historical operation module can be directly referenced to directly control the thermal management of the battery system and the cab system, which may further improve the speed and effect of the integrated thermal management master control on the battery system and the cab system.

[0054] (5) Based on the forklift status, the battery's suitable working temperature, and the human body's suitable working temperature, a priority level judgment module is set up to provide a basis for the integrated thermal management master control to adjust the battery system and the cab system. The detection module detects the real-time temperature of the cab system and the battery system and compares it with the priority level judgment module. Based on the comparison results, the integrated thermal management master control adjusts the heating device, heat dissipation device, and proportional control switch to accurately control the thermal management of the cab system and the battery system, so as to ensure the comfort of the electric forklift while reducing battery consumption and improving the electric forklift's range.

[0055] (6) First, make a preliminary judgment based on the status of the forklift, and then consider whether there is anyone in the cab and adjust the priority level. On the one hand, it simplifies the control logic of the integrated thermal management control and reduces the difficulty of algorithm control; on the other hand, it can improve the control speed of the integrated thermal management control, thereby improving the control efficiency and control effect of the cab system and battery system.

[0056] (7) By setting the actual demand index, dynamic allocation coefficient and proportional control switch opening formula, the actual temperature of the battery system and cab system is converted into the opening of the proportional control switch, so as to achieve precise control of the heat or cold of the battery system and cab system.

[0057] (8) Excess heat generated by the battery system can be transferred to the cab system through heat dissipation, which can reduce the loss of electrical energy and improve the energy utilization rate. Attached Figure Description

[0058] The invention will be described by way of example and with reference to the accompanying drawings, wherein:

[0059] Figure 1 This is a schematic diagram of the system structure of the integrated thermal management system and energy distribution management method for electric forklifts according to the present invention;

[0060] Figure 2 This is a control logic diagram of the priority level determination module of the integrated thermal management system for electric forklifts according to the present invention.

[0061] Figure Labels

[0062] 1-Integrated thermal management control, 2-Heat pump system, 201-Electric scroll compressor, 3-Large fin radiator, 301-Fan system, 4-Second electric three-way proportional valve, 5-Airflow driven fan, 6-Cab ventilation duct, 7-First electric three-way proportional valve, 8-Cab, 801-First heat exchanger, 9-Battery system, 901-Second heat exchanger, 902-BMS system, 10-Circulation loop, 11-PTC heater, 12-Electrically driven water pump. Detailed Implementation

[0063] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below in conjunction with the embodiments and accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. The components of the embodiments of this application described and marked in the accompanying drawings can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0064] In the description of the embodiments of this application, it should be noted that the terms "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0065] The following is combined Figures 1-2 The invention will be described in detail.

[0066] Example 1

[0067] Integrated thermal management system for electric forklifts, such as Figures 1-2 As shown, it includes:

[0068] Integrated Thermal Management Control Unit 1: The integrated thermal management control unit 1 includes a detection module, a priority level judgment module, and a control module; the detection module is used to acquire the forklift status, the actual temperature of the battery system 9 and the cab system 8, and whether there is a driver in the cab; the priority level judgment module determines the priority level of heating or cooling and the degree of thermal management control based on the detection results of the detection module; the control module controls the heating and cooling devices to perform thermal management control on the cab system 8 and the battery system 9;

[0069] Thermal management device: includes a heating device and a heat dissipation device, wherein the integrated thermal management control unit 1 is electrically connected to the heating device and the heat dissipation device;

[0070] Circulation loop 10: The heating device and the heat dissipation device are connected to the cab system 8 and the battery system 9 through the circulation loop 10. The circulation loop 10 is equipped with a drive device and a proportional control switch. The drive device and the proportional control switch are electrically connected to the integrated thermal management control 1.

[0071] In this embodiment, the electrical connection refers to a connection via a wire.

[0072] In this embodiment, the integrated thermal management master controller 1 is a 32-bit multi-core MCU that supports CAN FD communication and has multi-channel PWM and high-precision ADC sampling.

[0073] In this embodiment, the circulation loop 10 includes a delivery pipe, which is a galvanized steel pipe with good corrosion resistance. The refrigerant circulates in the delivery pipe and receives heat or coolness from the heating device and the heat dissipation device. It circulates in the circulation loop 10 to raise or lower the temperature of the cab system and the battery system, thereby achieving the purpose of thermal management.

[0074] In this embodiment, the driving device is an electronically driven water pump 12, which mainly provides power for the circulation of coolant. At the same time, it also has a speed regulation function to match the flow requirements under different working conditions, saving energy and reducing noise. It adjusts the motor speed in real time according to actual needs through the electronic control unit (ECU), thereby accurately controlling the flow rate and velocity of coolant or liquid.

[0075] In this embodiment, the electronically driven water pump 12 and the delivery pipe are connected by a flange, ensuring a stable and reliable connection. Flanges and connecting bolts are required to connect the electronically driven water pump 12 and the delivery pipe.

[0076] In this embodiment, the proportional control switch is a first electric three-way proportional valve 7. The first electric three-way proportional valve 7 is also connected to the delivery pipe via a flange connection, providing good sealing performance and resistance to high temperature and high pressure.

[0077] In this embodiment, the side of the battery system 9 and the cab system 8 connected to the first electric three-way proportional valve 7 is the inlet, and the side away from the first electric three-way proportional valve 7 is the outlet.

[0078] In this embodiment, a first heat exchanger 801 and a second heat exchanger 901 are respectively provided in the cab system 8 and the battery system 9. The heating device includes a PTC heater 11 connected to the circulation loop 10, and the heat dissipation device includes a heat pump system 2 connected to the circulation loop 10.

[0079] In this embodiment, the first heat exchanger 801 is a cab air heater heat exchanger, which transfers the heat or cold of the coolant to the air in the cab to achieve temperature regulation. It is a copper tube and aluminum fin type with a high-efficiency centrifugal fan. It is compact, has low air resistance, and high heat exchange efficiency.

[0080] In this embodiment, the cab air heater heat exchanger is existing technology and can be selected as needed, such as a forklift heater produced by Anhui Lingtuo Electromechanical Co., Ltd. The first heat exchanger 801 is directly inserted into the delivery pipe via a connecting hose and then connected to the delivery pipe via a clip.

[0081] In this embodiment, the PTC heater 11 includes an interface, to which a flexible hose is connected by adhesive. The flexible hose is then connected to a delivery pipe, and the connection between the flexible hose and the delivery pipe is the same as the connection between the first heat exchanger 801 and the delivery pipe, which will not be described in detail here.

[0082] In this embodiment, the heat pump system 2 includes an electric scroll compressor 201. The electric scroll compressor 201 is the heart of the system in both cooling and heat pump heating modes of the present invention, providing core cooling / heating power. It is the core heat source / cold source of the entire system, and the scroll compressor operates smoothly with low noise and long life.

[0083] In this embodiment, the heat pump system 2 is existing technology, an environmentally friendly and energy-saving technology that transfers heat through reverse circulation, mainly used for heating, cooling, and providing domestic hot water. Its core principle is to use a small amount of high-grade energy (such as electricity or heat) to drive the working fluid circulation, "transporting" low-temperature heat from environmental media (such as air, soil, or water) to a target area with a higher temperature, thereby achieving efficient energy utilization. For winter heating: it absorbs heat from the low-temperature outdoor environment, increases its temperature through compression, and releases the heat into the indoor space or hot water system, replacing traditional coal-fired or gas-fired boilers and significantly reducing energy consumption. For summer cooling: it transfers indoor heat to the outdoors through reverse operation, achieving an air conditioning cooling effect, serving two purposes in one unit.

[0084] In this embodiment, the heat dissipation device further includes a large finned radiator 3 connected to the heat pump system 2. A fan system 301 is installed inside the large finned radiator 3. The large finned radiator 3 is connected to the cab system 8 through a cab ventilation pipe 6. An airflow driven fan 5 and a second electric three-way proportional valve 4 are installed on the cab ventilation pipe 6.

[0085] In this embodiment, the second electric three-way proportional valve 4 can also be switched to connect with the outside world to transfer the heat generated by the battery system 9 to the outside world.

[0086] In this embodiment, the large-fin radiator 3 is a prior art heat exchange device used for heat exchange between gas and liquid. It improves heat transfer efficiency by adding fins to the surface of the base tube. In this embodiment, a copper tube with aluminum fins is used to ensure efficient heat exchange, with a power of ≥10 kW to meet peak heat dissipation demands such as battery fast charging.

[0087] The fan system 301 uses a DC brushless axial fan to achieve efficient and adjustable speed control, supports PWM (pulse width modulation) speed regulation, and the integrated thermal management master controller 1 intelligently adjusts the air volume according to the temperature, which also has the effect of energy saving and noise reduction.

[0088] In this embodiment, the airflow driven fan 5 is a DC brushless centrifugal fan with a rated air volume of not less than 700 m³ / h, an operating voltage that matches the vehicle's low-voltage power supply platform, and accepts PWM signals from the controller to achieve stepless speed regulation.

[0089] In this embodiment, the detection module includes temperature sensors respectively installed on the cab system 8 and the battery system 9, a pressure sensor installed on the cab system 8, and a Hall current sensor installed on the battery system 9. The priority level judgment module is set according to the forklift status, the suitable working temperature of the battery, and the suitable working temperature of the human body.

[0090] In this embodiment, the temperature sensor is located at the center and corners of the battery pack in the battery system 9, and the temperature sensor is located in the middle of the cockpit system 8 during driving, while the pressure sensor is located in the middle of the seat.

[0091] In this embodiment, the temperature sensor is a high-precision T-type thermocouple, which enables accurate measurement of high and low temperatures.

[0092] In this embodiment, the temperature sensor and pressure sensor are connected to the integrated thermal management controller 1 via electrical connection.

[0093] In this embodiment, the detection module has a built-in multi-channel high-precision ADC (analog-to-digital converter) and memory. All sensors (temperature and pressure sensors) are scanned at a fixed frequency (e.g., 10Hz), and the data is packaged and stored over time. For critical abnormal data (such as sudden temperature changes, voltage changes, or resistance changes), higher-frequency data parameter recording is triggered.

[0094] In this embodiment, a Hall current sensor is used to monitor the charging and discharging status of the battery system 9, thereby determining the forklift's condition. The Hall current sensor is also electrically connected to both the integrated thermal management control unit 1 and the battery system 9.

[0095] An integrated thermal management system and energy distribution management method for electric forklifts includes the following steps:

[0096] S1: The detection module obtains the forklift status, the actual temperature of the battery system 9 and the cab system 8, and whether there is a driver in the cab;

[0097] S2: The priority level judgment module determines the priority level and thermal management control degree of the heating device and the heat dissipation device for heating or dissipating heat on the battery system 9 and the cab system 8 based on the information obtained by the detection module.

[0098] S3: Integrated thermal management master control 1 regulates the heating device, heat dissipation device, and proportional control switch to perform thermal management on the battery system 9 and the cab system 8 according to the priority level and thermal management control degree.

[0099] In this embodiment, the forklift state described in S1 includes charging, stationary, and discharging.

[0100] In this embodiment, when the detection module determines that the forklift is charging or stationary in S2, the priority level judgment module compares the actual temperature of the battery system 9 obtained by the detection module with the set working temperature of the battery. The control module controls the heating device, heat dissipation device and circulation loop 10 to only dissipate heat or heat the battery system 9 according to the comparison result.

[0101] In S2, when the detection module determines that the forklift is in a state of discharge, the detection module also detects whether there is anyone in the cab. The priority level judgment module compares the actual temperature of the battery system 9 obtained by the detection module with the battery set operating temperature, the actual temperature of the cab system 8 and the cab set operating temperature. Based on the comparison results, the control module controls the heating device, the heat dissipation device and the circulation loop 10 to dissipate heat or heat only on the battery system 9 or on the battery system 9 and the cab system 8 as needed.

[0102] In this embodiment, the battery's set operating temperature is based on the battery's suitable operating temperature, which is 10-55 degrees Celsius. The battery's set operating temperature includes a low temperature warning, a suitable temperature, and a high temperature warning. The low temperature warning is -10 degrees Celsius, the suitable temperature is 10-55 degrees Celsius, and the high temperature warning is 70 degrees Celsius.

[0103] In this embodiment, the operating temperature of the cab is set according to the human body's suitable operating temperature, which is 15-25 degrees Celsius. The operating temperature of the cab also includes low temperature warning, suitable temperature and high temperature warning. The low temperature warning temperature is 5 degrees Celsius, the suitable temperature is 15-25 degrees Celsius, and the high temperature warning temperature is 35 degrees Celsius.

[0104] In this embodiment, when the detection module determines that the forklift is in a discharged state in S2, the heat or cold energy is allocated according to the demand weight of the battery system 9 and the cab system 8. This includes determining the actual demand index and dynamic allocation coefficient of the battery system 9 and the cab system 8, as well as the opening degree of the proportional control switch.

[0105] In this embodiment, the actual demand index is calculated according to the following formula:

[0106]

[0107] in, It is the demand intensity of battery system 9. It is the target temperature of the battery system. This is the current temperature of battery system 9. It is the normalized reference temperature of the battery system (such as the maximum allowable temperature difference of the system, i.e., the difference between the high temperature warning and the upper limit of the suitable temperature). The required strength of the cab system 8 It is the target temperature of the cab system 8. This is the current temperature of the cab system 8. It is the normalized reference temperature of the cab system (such as the maximum allowable temperature difference of the system).

[0108] The dynamic allocation coefficient is calculated according to the following formula:

[0109] ;

[0110] ;

[0111] in, It is the dynamic allocation coefficient of battery system 9. It maintains the weight of the previous state. This is the static demand weight of battery system 9 (determined based on AHP). ∈ (0,1) It is the static demand weight of the cab system 8 ( + =1), It is to prevent extremely small numbers with a denominator of 0 (constant values ​​have no meaning). It is the dynamic allocation coefficient of the cab system 8;

[0112] The opening degree of the proportional control switch is:

[0113]

[0114] in, This is the opening command from the proportional control switch to the battery system 9. It is the opening command of the proportional control switch to the cab system 8.

[0115] In this embodiment, when the detection module determines that the forklift is in a discharging state in S2, and when the battery system 9 has a heat dissipation requirement and the cab system 8 has a heat supply requirement, the heat dissipation requirement intensity of the battery system 9 and the heat supply requirement intensity of the cab system 8 are determined based on the heat dissipation temperature difference of the battery system 9 and the heat supply temperature difference of the cab system 8, and the proportion of heat dissipation heat from the battery system 9 transferred to the cab system 8 and / or the outside is determined.

[0116] In this embodiment, the heat dissipation intensity of the battery system 9 and the heating intensity of the cab are calculated according to the following formula:

[0117]

[0118] when When the value is 0, the battery system 9 does not require heat dissipation and remains unchanged.

[0119] when When the value is 0, the cab system 8 does not require heating, and the battery system has independent heat dissipation;

[0120] in, To meet the heat dissipation requirements of battery system 9, To meet the heating demand intensity of the driver's cab;

[0121] Heat transfer is determined using the following formula:

[0122]

[0123] When the value is 0, the battery system 9 has independent heat dissipation;

[0124] Equal to 1 and Less than or equal to At that time, all the heat generated by the battery system 9 is transferred to the cockpit system 8;

[0125] Equal to 1 and Greater than At that time, all the heat generated by the battery system 9 is distributed proportionally to the cockpit system 8 and the outside environment;

[0126] in, It is the minimum effective heat transfer temperature difference.

[0127] The heat dissipation of the battery system 9 is transferred to the cab system 8 and the outside environment according to the following formula;

[0128]

[0129] in, The proportion of heat flowing to the driver's cab (0~1), The proportion of heat flowing to the driver's cab (0~1);

[0130] The specific method of using the invention is as follows:

[0131] Reference Figures 1-2 When using this device, first set the low temperature warning, indicated operating temperature range, and high temperature warning temperature of the battery according to the battery's suitable operating temperature, and take into account the battery's condition.

[0132] When the battery is charging or stationary, the cab does not consider whether there are people present. Therefore, when the temperature sensor detects the actual temperature of the battery system 9, it compares it with the battery's low-temperature warning, suitable operating temperature, and high-temperature warning. When the actual temperature of the battery system 9 is lower than the low-temperature warning, the integrated thermal management control 1 generates heat through the PTC heater 11 and provides all the generated heat to the battery system 9 through the delivery pipe. When the actual temperature of the battery system 9 is higher than the high-temperature warning, the integrated thermal management control 1 generates cooling through the heat pump system 2 and provides all the generated cooling to the battery system 9 through the delivery pipe.

[0133] When the battery is discharging and there is no one in the cab, the battery system 9 is thermally managed according to the battery charging and static states. When there is someone in the cab, the heat or cold generated by the PTC heater 11 or the heat pump system 2 is adjusted to regulate the battery system 9 and the cab system 8 respectively, according to the above requirements.

[0134] In addition, when the battery is discharging, if there are people in the cab, and the battery system 9 has a heat dissipation requirement and the cab system 8 has a heating requirement, then the excess heat of the battery system 9 will be transferred to the cab system 8 or the cab system 8 and the outside according to the above requirements.

[0135] This invention integrates the cab system 8 and battery system 9 into a single integrated design through a thermal management control unit 1 and a circulation loop 10. This integrates two independent systems into a single system that shares a heat source and a cold / heat source and a circulation loop 10. Furthermore, through detection modules and priority level judgment modules, the invention detects the cab system 8 and battery system 9, determining the proportions of heat generated by the heating device and cold generated by the cooling device flowing through the cab system 8 and battery system 9, respectively. This enables precise control of the thermal management of the cab system 8 and battery system 9, achieving bidirectional intelligent flow of heat between the battery and the cab and waste heat recovery, significantly reducing additional energy consumption and improving the overall vehicle energy efficiency and range.

[0136] Example 2

[0137] In this embodiment, the integrated thermal management control 1 also includes a historical operation module that can record the data of each adjustment of the integrated thermal management control 1, and the historical operation module includes the BMS system 902.

[0138] In this embodiment, the historical operation module records timestamps, battery system 9 temperature, cab system 8 temperature, and battery system discharge / charge current at a high frequency (10Hz). The historical operation module divides the continuous operation of the forklift into representative process stages. It calculates the statistical characteristics of each micro-stroke (such as average temperature, temperature rise rate, and average current). Using algorithms such as K-means, the historical micro-strokes are clustered into several typical "characteristic operating condition patterns" and stored in the historical pattern library.

[0139] The integrated thermal management master controller 1 calculates the similarity between the data (temperature, current, etc.) obtained from the current forklift operation and the historical pattern library. After matching a similar historical pattern, it calls up the validated optimal thermal management parameters (such as PTC heater 11 power and electric three-way proportional valve opening) for that pattern. The called parameters are used for control, and the control effect is recorded. The control parameters in the historical pattern library are evaluated and dynamically updated through algorithms (such as reinforcement learning) to achieve continuous improvement.

[0140] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An integrated thermal management system for electric forklifts, characterized in that: include: Integrated thermal management control (1): The integrated thermal management control (1) includes a detection module, a priority level judgment module and a control module; the detection module is used to obtain the forklift status, the actual temperature of the battery system (9) and the cab system (8) and whether there is a driver in the cab; the priority level judgment module judges the priority level of heating or cooling and the degree of thermal management control based on the detection results of the detection module; the control module controls the heating device and the cooling device to perform thermal management control on the cab system (8) and the battery system (9); Thermal management device: includes heating device and heat dissipation device, wherein the integrated thermal management control (1) is electrically connected to the heating device and heat dissipation device; Circulation loop (10): The heating device and the heat dissipation device are connected to the cab system (8) and the battery system (9) through the circulation loop (10). The circulation loop (10) is equipped with a drive device and a proportional control switch. The drive device and the proportional control switch are electrically connected to the integrated thermal management control (1).

2. The integrated thermal management system for electric forklifts according to claim 1, characterized in that: The cab system (8) and the battery system (9) are respectively provided with a first heat exchanger (801) and a second heat exchanger (901). The heating device includes a PTC heater (11) connected to the circulation loop (10), and the heat dissipation device includes a heat pump system (2) connected to the circulation loop (10).

3. The integrated thermal management system for electric forklifts according to claim 1, characterized in that: The heat dissipation device also includes a large finned radiator (3) connected to the heat pump system (2). The large finned radiator (3) includes a fan system (301). The large finned radiator (3) is connected to the cab system (8) through a cab ventilation pipe (6). The cab ventilation pipe (6) is equipped with an airflow driven fan (5) and a second electric three-way proportional valve (4).

4. The integrated thermal management system for electric forklifts according to claim 1, characterized in that: The detection module includes temperature sensors respectively installed on the cab system (8) and the battery system (9), a pressure sensor installed on the cab system (8), and a Hall current sensor installed on the battery system (9). The priority level judgment module is set according to the forklift status, the battery's suitable working temperature, and the human body's suitable working temperature.

5. An energy distribution management method for an integrated thermal management system used in electric forklifts, characterized in that: The integrated thermal management system for electric forklifts according to any one of claims 1-4 is used, comprising the following steps: S1: The detection module obtains the forklift status, the actual temperature of the battery system (9) and the cab system (8), and whether there is a driver in the cab; S2: The priority level judgment module determines the priority level and thermal management control degree of the heating device and the heat dissipation device for heating or dissipating heat on the battery system (9) and the cab system (8) based on the information obtained by the detection module. S3: Integrated thermal management master control (1) regulates the heating device, heat dissipation device and proportional control switch to perform thermal management on the battery system (9) and the cab system (8) according to the priority level and thermal management control degree.

6. The energy distribution management method for an integrated thermal management system for electric forklifts according to claim 5, characterized in that: The forklift states described in S1 include charging, stationary, and discharging.

7. The energy distribution management method for an integrated thermal management system for electric forklifts according to claim 6, characterized in that: In S2, when the detection module determines that the forklift is charging or stationary, the priority level judgment module compares the actual temperature of the battery system (9) obtained by the detection module with the set working temperature of the battery. The control module controls the heating device, heat dissipation device and circulation loop (10) to only dissipate heat or heat the battery system (9) according to the comparison result. In S2, when the detection module determines that the forklift is in a state of discharge, the detection module also detects whether there is anyone in the cab. The priority level judgment module compares the actual temperature of the battery system (9) obtained by the detection module with the battery set operating temperature, the actual temperature of the cab system (8) with the cab set operating temperature. The control module controls the heating device, the heat dissipation device and the circulation loop (10) to dissipate heat or heat only on the battery system (9) or on the battery system (9) and the cab system (8) as needed, based on the comparison results.

8. The energy distribution management method for an integrated thermal management system for electric forklifts according to claim 7, characterized in that: In S2, when the detection module determines that the forklift is in a state of discharge, it allocates heat or cold according to the demand weight of the battery system (9) and the cab system (8), including determining the actual demand index and dynamic allocation coefficient of the battery system (9) and the cab system (8) as well as the opening degree of the proportional control switch.

9. The energy distribution management method for an integrated thermal management system for electric forklifts according to claim 8, characterized in that: The actual demand index is calculated according to the following formula: in, It is the demand intensity of the battery system (9), The target temperature of the battery system (9) is... The current temperature of the battery system (9) It is the normalized reference temperature of the battery system (9). The demand intensity of the cab system (8) The target temperature of the cab system (8) is... The current temperature of the cab system (8) It is the normalized reference temperature of the cab system (8); The dynamic allocation coefficient is calculated according to the following formula: ； ； in, It is the dynamic distribution coefficient of the battery system (9). It maintains the weight of the previous state. It is the static demand weight of the battery system (9). It is the static demand weight of the cab system (8). It is to prevent extremely small numbers with a denominator of 0. It is the dynamic allocation coefficient of the cab system (8); The opening degree of the proportional control switch is: in, It is the proportional control switch that sends the opening command to the battery system. It is the opening command of the proportional control switch to the cab system (8).

10. The energy distribution management method for an integrated thermal management system for an electric forklift according to claim 7, characterized in that: In S2, when the detection module determines that the forklift is in a state of discharge, when the battery system (9) has a heat dissipation requirement and the cab system (8) has a heat supply requirement, the heat dissipation requirement intensity of the battery system (9) and the heat supply requirement intensity of the cab system (8) are determined based on the heat dissipation temperature difference of the battery system (9) and the heat supply temperature difference of the cab system (8), and the proportion of heat dissipation heat from the battery system (9) transferred to the cab system (8) and / or the outside is determined.

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