Low temperature thermal management system and vehicle

Abstract

The application discloses a low-temperature thermal management system, comprising an integrated fuel heater, a heating device for converting electric energy into heat energy, a passenger cabin loop and a battery loop, the passenger cabin loop and the battery loop being connected with a water-water heat exchanger, the heating device and the integrated fuel heater being arranged in series, the heating device and the integrated fuel heater being connected with the passenger cabin loop, and the integrated fuel heater comprising a heater body for generating heat energy by burning fuel, and a fuel supply subsystem and an air intake subsystem connected with the heater body. The low-temperature thermal management system can improve the heating effect of a pure electric vehicle under low-temperature conditions by matching a WPTC and a high-efficiency complementary heat source at the fuel heater 2. The integrated and modular water heating fuel heater can provide sufficient heat source in winter and can balance energy consumption and heating. The application further discloses a vehicle.

Description

Technical Field

[0001] This invention belongs to the field of automotive thermal management technology. Specifically, this invention relates to a low-temperature thermal management system and a vehicle. Background Technology

[0002] In the harsh winter environment, the performance of new energy vehicles has become a major focus of attention for OEMs, industry organizations, and users. Low temperatures significantly reduce the mobility of lithium ions, directly leading to a decline in battery charging / discharging performance, resulting in slow charging, reduced driving range, insufficient discharge capacity, and large errors in remaining battery level display. Users in cold regions have widely reported that the driving range of pure electric vehicles is significantly reduced in winter, with some even experiencing complete battery depletion due to the cold. This causes significant range anxiety for users, who are hesitant to turn on the air conditioning to conserve electricity, severely impacting the user experience and the promotion and popularization of new energy vehicles.

[0003] Currently, most electric vehicle battery heating systems utilize self-heating films or WPTC (Water PTC) heating solutions. However, these solutions suffer from excessive energy consumption, and in low-temperature environments, the battery must be heated to a suitable temperature before it can discharge. When the battery itself is at a low temperature, it cannot discharge or heat itself, resulting in poor heating performance. Similarly, electric vehicle air conditioning heating typically uses APTC (Air PTC) or WPTC solutions, which also face high energy consumption issues. Furthermore, when the battery cannot discharge at low temperatures, APTC or WPTC cannot function properly, making effective heating difficult. Although heat pump solutions have emerged as an effective way to address battery and air conditioning heating in recent years, these solutions suffer from numerous system components, high costs, and low efficiency in low or ultra-low temperature environments, resulting in unsatisfactory heating performance.

[0004] An improved low-temperature thermal management system is provided, particularly regarding how to improve the heating performance of pure electric vehicles under low-temperature conditions. Summary of the Invention

[0005] This invention aims to at least solve one of the technical problems existing in the prior art. To this end, this invention provides a low-temperature thermal management system, with the purpose of improving the heating performance of pure electric vehicles under low-temperature conditions.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a low-temperature thermal management system, including an integrated fuel heater, a heating device for converting electrical energy into thermal energy, a passenger compartment circuit and a battery circuit, wherein the passenger compartment circuit and the battery circuit are connected to a water-to-water heat exchanger, the heating device and the integrated fuel heater are arranged in series, and the heating device and the integrated fuel heater are connected to the passenger compartment circuit. The integrated fuel heater includes a heater body for generating thermal energy by burning fuel oil and a fuel supply subsystem and an air intake subsystem connected to the heater body.

[0007] The integrated fuel heater also includes a lower heater housing and an upper heater housing connected in phase. The heater body, fuel supply subsystem and air intake subsystem are disposed on the lower heater housing, and the heater body, fuel supply subsystem and air intake subsystem are located in the inner cavity of the upper heater housing.

[0008] The fuel supply subsystem includes a fuel tank and a fuel pump. The fuel pump is connected to the fuel tank and the heater body, and the fuel pump and fuel tank are disposed on the lower housing of the heater.

[0009] The heater body is located between the fuel tank and the intake subsystem.

[0010] One end of the heating device is connected to the passenger compartment circuit, the other end of the heating device is connected to one end of the integrated fuel heater, the other end of the integrated fuel heater is connected to one end of the first water pump, the other end of the first water pump is connected to the first expansion tank, and the first expansion tank is connected to the passenger compartment circuit.

[0011] The heater body is fixedly connected to the inlet pipe and the outlet pipe, which are located on the same side of the heater body. The inlet pipe is connected to the heating device, and the outlet pipe is connected to the first water pump. A water channel is provided inside the heater body, which is connected to the inlet pipe and the outlet pipe.

[0012] A three-way water valve is installed in the passenger compartment circuit. The inlet of the three-way water valve is connected to the heating device, the first outlet of the three-way water valve is connected to the water-to-water heat exchanger, and the second outlet of the three-way water valve is connected to the air conditioning system.

[0013] The battery circuit is equipped with a second water pump and a second expansion tank. One end of the second water pump is connected to the water-to-water heat exchanger, and the other end of the second water pump is connected to one end of the second expansion tank. The other end of the second expansion tank is connected to one end of the power battery pack, and the other end of the power battery pack is connected to the water-to-water heat exchanger.

[0014] A first temperature sensor is installed in the pipeline connecting the second water pump and the power battery pack, and a second temperature sensor is installed in the pipeline connecting the power battery pack and the water-water heat exchanger.

[0015] The present invention also provides a vehicle including the aforementioned cryogenic thermal management system.

[0016] The low-temperature thermal management system of this invention can improve the heating effect of pure electric vehicles under low-temperature conditions by matching two high-efficiency complementary heat sources, WPTC and fuel heater; the integrated and modular water-heated fuel heater provides sufficient heat source in winter, taking into account both energy consumption and heating. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the low-temperature thermal management system of the present invention;

[0018] Figure 2 This is an exterior view of a diesel heater;

[0019] Figure 3 This is a schematic diagram of the internal structure of the diesel heater after the upper casing has been removed;

[0020] Figure 4a and Figure 4b This is a simplified diagram of the WPTC structure;

[0021] Figures 5a to 5c This is a simplified structural diagram of a three-way water valve;

[0022] Figure 6a and Figure 6b This is a simplified diagram of the water pump structure;

[0023] Figure 7a and Figure 7b This is a simplified structural diagram of a water-to-water heat exchanger;

[0024] Figure 8 This is the control diagram of the vehicle's thermal management controller;

[0025] The markings in the above figures are as follows: 1. Heater upper housing; 2. Heater body; 3. Fuel tank; 4. Filler cap; 5. Fuel pump; 6. Heater lower housing; 7. Water outlet pipe; 8. Water inlet pipe; 9. Heater bracket; 10. Intake subsystem; 11. High-pressure connector; 12. Low-pressure connector; 13. Water inlet; 14. Water outlet; 15. Water inlet; 16. First water outlet; 17. Second water outlet; 18. Water inlet; 19. Water outlet; 20. Passenger compartment return. 21. Passenger compartment circuit water outlet; 22. Battery circuit water outlet; 23. Battery circuit water inlet; 24. First water pump; 25. First expansion tank; 26. Second water pump; 27. Second expansion tank; 28. Power battery pack; 29. ​​First temperature sensor; 30. Second temperature sensor; 31. Water-to-water heat exchanger; 32. Three-way water valve; 33. Air filter; 34. Silencer; 35. Heater core; 36. Blower; 37. Heating device. Detailed Implementation

[0026] To facilitate understanding of the present invention, a more comprehensive description of the present invention will be given below with reference to the accompanying drawings, which illustrate several embodiments of the present invention. However, the present invention can be implemented in different forms and is not limited to the embodiments described in the text. Rather, these embodiments are provided to make the disclosure of the present invention more thorough and complete.

[0027] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," and similar expressions used in this document are for illustrative purposes only.

[0028] It should be noted that in the following embodiments, the terms "first" and "second" do not represent an absolute distinction in structure and / or function, nor do they represent the order of execution, but are merely for the convenience of description.

[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly associated with those skilled in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0030] Firstly, such as Figures 1 to 8 As shown, this embodiment of the invention provides a low-temperature thermal management system, including an integrated fuel heater, a heating device 37 for converting electrical energy into heat energy, a passenger compartment circuit, and a battery circuit. The passenger compartment circuit and the battery circuit are connected to a water-to-water heat exchanger 31. The coolant in the passenger compartment circuit and the coolant in the battery circuit exchange heat when flowing through the water-to-water heat exchanger 31, thereby heating the coolant in the battery circuit. The heating device 37 and the integrated fuel heater are connected in series and are connected to the passenger compartment circuit. The integrated fuel heater includes a heater body 2 for generating heat energy by burning fuel, and a fuel supply subsystem and an air intake subsystem 10 connected to the heater body 2.

[0031] Specifically, in this embodiment of the invention, a low-temperature thermal management system for new energy pure electric vehicles is provided. An integrated fuel heater is used to heat the vehicle's air conditioning and power battery, solving problems related to heating, range, and charging time in low-temperature environments for pure electric vehicles. Simultaneously, the series-connected heating device 37 and the fuel heater can complement each other's thermal energy in winter, such as when fuel runs out or a heat source fails. Therefore, in pure electric vehicles, the battery can be kept at the most suitable temperature to ensure range and eliminate range anxiety; and sufficient heat source is provided to the air conditioning to solve the problem of heating the passenger compartment.

[0032] In this embodiment of the invention, the heating device 37 is a WPTC, such as... Figure 1 As shown, one end of the heating device 37 is connected to the passenger compartment circuit, the other end of the heating device 37 is connected to one end of the integrated fuel heater, the other end of the integrated fuel heater is connected to one end of the first water pump 24, the other end of the first water pump 24 is connected to the first expansion tank 25, and the first expansion tank 25 is connected to the passenger compartment circuit.

[0033] In this embodiment of the invention, the two heat sources of the integrated fuel heater are connected in series to provide heat energy to the entire vehicle. The fuel heater provides heat energy to the entire vehicle by burning diesel fuel, serving as the primary heat source in low-temperature environments. The heating device 37 converts electrical energy into heat energy, primarily acting as an auxiliary heat source during intelligent control. For example, in low-temperature environments, after the power battery pack 28 is fully charged, the heating device 37 is controlled to operate, generating heat to continuously keep the power battery pack 28 warm at a low power. The charging pile operates at a low power to keep the power battery pack 28 warm. Furthermore, the two heat sources can complement each other, ensuring continuous heat energy supply to the entire vehicle even if one heat source fails. This significantly reduces or eliminates the entire cooling circuit piping and connection structure, and reduces the coolant transfer path, improving transfer efficiency. This not only reduces the overall vehicle cost but also improves system performance. The overall "boxy" design, especially in the commercial vehicle sector, simplifies vehicle assembly, maximizes space utilization, and improves the smoothness of piping layout and assembly efficiency.

[0034] In embodiments of the present invention, such as Figure 2 and Figure 3 As shown, the integrated fuel heater also includes a lower heater housing and an upper heater housing 1 connected in phase. The heater body 2, fuel supply subsystem, and air intake subsystem 10 are disposed on the lower heater housing 6, and the heater body 2, fuel supply subsystem, and air intake subsystem 10 are located in the inner cavity of the upper heater housing 1. The fuel supply subsystem includes a fuel tank 3 and a fuel pump 5. The fuel pump 5 is connected to the fuel tank 3 and the heater body 2. The fuel pump 5 and the fuel tank 3 are disposed on the lower heater housing 6, and the fuel pump 5 pumps diesel fuel from the fuel tank 3 to the heater body 2.

[0035] In embodiments of the present invention, such as Figure 2 and Figure 3 As shown, the heater body 2 is located between the fuel tank 3 and the intake subsystem 10, which includes components such as an air filter and an air pipe. The lower housing 6 of the heater also houses components such as a muffler and a catalytic converter.

[0036] In embodiments of the present invention, such as Figure 2 and Figure 3 As shown, the heater body 2 is fixedly connected to the inlet pipe 8 and the outlet pipe 7, which are located on the same side of the heater body 2. The inlet pipe 8 is connected to the heating device 37, and the outlet pipe 7 is connected to the first water pump 24. A water channel is provided inside the heater body 2, which communicates with the inlet pipe 8 and the outlet pipe 7. An opening is provided on the lower housing 6 of the heater to expose the inlet pipe 8 and the outlet pipe 7.

[0037] In embodiments of the present invention, such as Figure 2 and Figure 3 As shown, the heat energy of the heater body 2 comes from the combustion of diesel fuel. The diesel fuel in the fuel tank 3 is supplied to the combustion chamber of the heater body 2 by the fuel pump 5, and the intake subsystem 10 provides sufficient and clean air to the combustion chamber of the heater body 2. The system ignites at the most suitable time and obtains heat energy by burning the atomized diesel fuel. The heat is used to heat the coolant that enters the heater body 2 through the water inlet pipe 8. The heated coolant is then discharged to the passenger compartment coolant circuit through the water outlet pipe 7.

[0038] In embodiments of the present invention, such as Figure 4a and Figure 4b As shown, the heating device 37 is equipped with a high-pressure plug 11 and a low-pressure plug 12. The low-pressure plug 12 controls whether the heating device 37 is working, and provides high-voltage electricity to the whole vehicle through the high-pressure plug 11. The coolant enters the heating device 37 through the inlet 13. The heating device 37 converts electrical energy into heat energy. The heated coolant enters the three-way water valve 32 of the passenger compartment coolant circuit through the outlet 14. The coolant is heated according to the vehicle thermal management control command.

[0039] In embodiments of the present invention, such as Figure 1 , Figure 5a , Figure 5b and Figure 5cAs shown, a three-way water valve 32 is installed in the passenger compartment circuit. The inlet 15 of the three-way water valve 32 is connected to the outlet of the heating device 37. The first outlet 16 of the three-way water valve 32 is connected to the inlet of the water-to-water heat exchanger 31. The second outlet 17 of the three-way water valve 32 is connected to the inlet of the heater core of the air conditioning system. The outlets of the water-to-water heat exchanger 31 and the heater core are connected to the inlet of the first expansion tank 25. During operation, the distribution ratio of coolant entering the three-way water valve 32 through the vehicle thermal management controller (TMS) is controlled, such as allocating 60% coolant to the first outlet 16 and 40% coolant to the second outlet 17.

[0040] In embodiments of the present invention, such as Figure 1 As shown, a second water pump 26 and a second expansion tank 27 are provided in the battery circuit. One end of the second water pump 26 is connected to the water-to-water heat exchanger 31, and the other end of the second water pump 26 is connected to one end of the second expansion tank 27. The other end of the second expansion tank 27 is connected to one end of the power battery pack 28, and the other end of the power battery pack 28 is connected to the water-to-water heat exchanger 31.

[0041] In embodiments of the present invention, such as Figure 1 As shown, a first temperature sensor 29 is installed in the pipeline connecting the second water pump 26 and the power battery pack 28, and a second temperature sensor 30 is installed in the pipeline connecting the power battery pack 28 and the water-to-water heat exchanger 31. The first temperature sensor 29 and the second temperature sensor 30 are used to detect the coolant temperature at the inlet and outlet of the power battery pack 28, respectively.

[0042] In this embodiment of the invention, the first water pump 24 and the second water pump 26 are electrically connected to the vehicle thermal management controller. The first water pump 24 and the second water pump 26 are controlled by the vehicle thermal management controller. The vehicle thermal management controller can simultaneously control the rotation speed of the first water pump 24 and the second water pump 26, thereby controlling the flow rate and head of the water pump output.

[0043] In embodiments of the present invention, such as Figure 7a and Figure 7b As shown, the water-to-water heat exchanger 31 is provided with a passenger compartment circuit inlet 20, a passenger compartment circuit outlet 21, a battery circuit outlet 22, and a battery circuit inlet 23. The heated passenger compartment circuit coolant and the battery circuit coolant are heated by thermal convection in the water-to-water heat exchanger 31.

[0044] In embodiments of the present invention, such as Figure 2 and Figure 3As shown, the lower housing 6 of the heater is fixedly connected to the heater bracket 9. The heater bracket 9 is located outside the upper housing 1 of the heater. The fuel heater and the vehicle only need to be fixed through the heater bracket 9 and connected with the corresponding water pipes and wiring harnesses. The assembly is simple and the operation is easy. The overall modular design is neat and can save more space for the vehicle.

[0045] In this embodiment of the invention, the integrated fuel heater integrates a heating device 37, a first water pump 24, a first expansion tank 25, a three-way water valve 32, a temperature sensor, a fuel pump 5, an air filter 33, a muffler 34, a catalytic converter, a heater body 2, a fuel tank 3, water pipes, oil pipes, air pipes, a bracket, etc. The air filter 33 and the muffler 34 are connected to the heater body 2, and the muffler 34 is connected to the catalytic converter. Through integration, about 10 pipelines and connection structures are reduced, the heat transfer path is greatly shortened, the transfer efficiency is greatly improved, and the connection structure is greatly reduced through integrated design, reducing the system failure points. This not only reduces costs but also improves reliability and saves more space in the vehicle.

[0046] In embodiments of the present invention, such as Figure 8 As shown, the vehicle thermal management controller collects heating request signals from the control panel, water temperature signals from the power battery water temperature sensor, and charging status and battery cell temperature from the BMS (Battery Thermal Management Module). It then controls the flow rate and dust control of the first water pump 24 and the second water pump 26, and controls the opening ratio of the three-way water valve 32, thereby intelligently distributing the heat energy required by the battery and air conditioning.

[0047] In this embodiment of the invention, by arranging a water-to-water heat exchanger 31, different water temperature and thermal power requirements of the air conditioner and the power battery pack 28 can be met by using the same heat source.

[0048] In this embodiment of the invention, the vehicle thermal energy control collects demand through the vehicle thermal management controller and controls the switching, power, and opening degree of components in the thermal management architecture to achieve centralized control of vehicle thermal management. The overall architecture is simple, the implementation is easy, the overall cost is relatively low, and the effect is significant.

[0049] The low-temperature thermal management system described above has the following advantages:

[0050] The integrated fuel heater features an integrated and modular design (invention point), eliminating approximately 10 pipes and interfaces. Through the integrated design of multiple components, it reduces connection structures, improves system reliability, and its "box-like" structure, protected by upper and lower shells, effectively enhances the waterproof and dustproof performance of integrated components. The overall layout is neat and suitable for various new energy vehicle models, especially in the field of non-load-bearing commercial vehicles. Integration reduces pipes and connection structures, significantly shortening the heat transfer path and greatly improving transfer efficiency. Furthermore, the integrated design significantly reduces connection structures, minimizing system failure points, resulting in lower costs and improved reliability. Its function is to simultaneously provide sufficient heat for air conditioning and batteries, facilitating fuel combustion. With a thermal efficiency greater than 93%, it provides a large amount of heat, addressing the heating needs of the battery and the air conditioning for passengers in winter. The opening of the three-way water valve 32 is controlled to distribute heat to the air conditioning and battery, or to disconnect them. Simultaneously, a series heating device 37 draws power from the charging station to heat the battery during low-temperature charging, improving charging time. Once the battery is fully charged, the heating device 37 draws power from the charging station at a low power level to keep the battery warm. Furthermore, because the series heating device 37 and the fuel heater complement each other in winter, common complaints about long charging times, short range, and poor air conditioning heating in pure electric vehicles during winter are effectively resolved. The fuel heater has a simple structure (atomization and ignition), requires no work, and is highly efficient and inexpensive.

[0051] Secondly, embodiments of the present invention also provide a vehicle including a low-temperature thermal management system with the above-described structure. The vehicle is a new energy light truck, and this electric vehicle range extender device can be referenced... Figures 1 to 8 Further details will not be elaborated here. Since the vehicle of the present invention includes the cryogenic thermal management system described in the above embodiments, it possesses all the advantages of the aforementioned cryogenic thermal management system.

[0052] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A low-temperature thermal management system, characterized in that: It includes an integrated fuel heater, a heating device for converting electrical energy into heat energy, a passenger compartment circuit and a battery circuit. The passenger compartment circuit and the battery circuit are connected to a water-to-water heat exchanger. The heating device and the integrated fuel heater are connected in series and are connected to the passenger compartment circuit. The integrated fuel heater includes a heater body for generating heat energy by burning fuel oil and a fuel supply subsystem and an air intake subsystem connected to the heater body.

2. The low-temperature thermal management system according to claim 1, characterized in that: The integrated fuel heater also includes a lower heater housing and an upper heater housing connected in phase. The heater body, fuel supply subsystem and air intake subsystem are disposed on the lower heater housing, and the heater body, fuel supply subsystem and air intake subsystem are located in the inner cavity of the upper heater housing.

3. The low-temperature thermal management system according to claim 2, characterized in that: The fuel supply subsystem includes a fuel tank and a fuel pump. The fuel pump is connected to the fuel tank and the heater body, and the fuel pump and fuel tank are disposed on the lower housing of the heater.

4. The low-temperature thermal management system according to claim 4, characterized in that: The heater body is located between the fuel tank and the intake subsystem.

5. The low-temperature thermal management system according to any one of claims 1 to 4, characterized in that: One end of the heating device is connected to the passenger compartment circuit, the other end of the heating device is connected to one end of the integrated fuel heater, the other end of the integrated fuel heater is connected to one end of the first water pump, the other end of the first water pump is connected to the first expansion tank, and the first expansion tank is connected to the passenger compartment circuit.

6. The low-temperature thermal management system according to claim 5, characterized in that: The heater body is fixedly connected to the inlet pipe and the outlet pipe, which are located on the same side of the heater body. The inlet pipe is connected to the heating device, and the outlet pipe is connected to the first water pump. A water channel is provided inside the heater body, which is connected to the inlet pipe and the outlet pipe.

7. The low-temperature thermal management system according to any one of claims 1 to 6, characterized in that: A three-way water valve is installed in the passenger compartment circuit. The inlet of the three-way water valve is connected to the heating device, the first outlet of the three-way water valve is connected to the water-to-water heat exchanger, and the second outlet of the three-way water valve is connected to the air conditioning system.

8. The low-temperature thermal management system according to any one of claims 1 to 6, characterized in that: The battery circuit is equipped with a second water pump and a second expansion tank. One end of the second water pump is connected to the water-to-water heat exchanger, and the other end of the second water pump is connected to one end of the second expansion tank. The other end of the second expansion tank is connected to one end of the power battery pack, and the other end of the power battery pack is connected to the water-to-water heat exchanger.

9. The low-temperature thermal management system according to claim 8, characterized in that: A first temperature sensor is installed in the pipeline connecting the second water pump and the power battery pack, and a second temperature sensor is installed in the pipeline connecting the power battery pack and the water-water heat exchanger.

10. A vehicle, characterized in that: Includes the low-temperature thermal management system as described in any one of claims 1 to 9.

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