A pure electric commercial vehicle fuel heater integrated thermal management system
Patent Information
- Application Number
- CN202611054026.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-07-15
- Publication Date
- 2026-09-29
AI Technical Summary
[0003]本发明的目的是克服现有纯电商用车高压PTC加热耗电、续航衰减的缺陷，实现低温采暖与电池加热不消耗动力电池电量；解决了分体式加热系统结构冗余、热量利用率低的问题，简化热管理管路与部件布局；同步兼顾驾驶室采暖与动力电池低温加热以及动力电池高温制冷，保障电池性能与驾乘舒适性
[0006]本发明既保证了驾驶室采暖舒适性，又能快速将动力电池预热至最佳工作温度，延长电池使用寿命。通过燃油加热代替高压PTC，大幅降低热管理能耗，保证车辆低温续驶里程，提升纯电商用车的运营实用性。
Smart Images
Figure CN122830332A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a thermal management system, specifically to an integrated thermal management system for a fuel heater in a pure e-commerce vehicle. Background Technology
[0002] Currently, in low-temperature environments, pure electric vehicles mainly use high-voltage PTC heaters to heat the cab and preheat the power battery. This method directly consumes the power battery's power, resulting in a significant reduction in vehicle range and seriously affecting operational efficiency. Some models use a split heating structure, with the cab separately equipped with a parking fuel heater and the battery separately equipped with a PTC heating device. The two systems are independent of each other, resulting in complex piping, redundant components, large space occupation, inability to share heat, and low energy utilization. Summary of the Invention
[0003] The purpose of this invention is to overcome the shortcomings of existing pure electric commercial vehicles, such as high-voltage PTC heating, which consumes a lot of power and reduces the driving range. It achieves low-temperature heating and battery heating without consuming the power battery's power. It solves the problems of redundant structure and low heat utilization of split heating systems, and simplifies the layout of thermal management pipelines and components. It simultaneously takes into account the heating of the cab and the low-temperature heating and high-temperature cooling of the power battery, ensuring battery performance and driving comfort.
[0004] This invention is achieved through the following technical solutions: An integrated thermal management system for fuel heaters in pure electric vehicles includes a fuel heater, a fuel supply component, an electric three-way regulating valve, a cab HVAC heating core, a battery cooling unit, a circulating water pump, a compensation water tank, and a controller. The fuel heater is connected to the vehicle fuel tank via the fuel supply assembly. The fuel heater outlet is connected to the driver heating tee. The driver heating tee is connected to the electric tee regulating valve and the driver's cab heating branch respectively. The electric tee regulating valve is a one-outlet, two-inlet type. The two inlets are connected to the water outlet of the driver heating tee and the return water of the battery heating branch respectively. The outlet is connected to the water inlet of the battery heating branch. The cab heating branch is connected to the cab HVAC heater core, the battery heating branch is connected to the power battery, and the battery cooling unit is on the same branch as the power battery. The HVAC heater core and the return water inlet of the power battery are both connected to the return water inlet of the fuel heater through pipelines, forming a closed-loop circulation circuit. The circulating water pump includes a heating water pump and a battery water pump. The heating water pump is integrated with the fuel oil heater, and the controller communicates with the fuel oil heater to control the heating water pump to turn on and off by controlling the working mode of the fuel oil heater. The battery water pump is integrated with the battery cooling unit, and the controller communicates with the battery cooling unit to control the battery water pump to turn on and off by controlling the working mode of the battery cooling unit.
[0005] The controller is electrically connected to the fuel heater, the electric three-way regulating valve, the battery cooling unit, the cab temperature sensor, and the battery temperature sensor. By collecting temperature signals, it controls the opening and flow direction of the electric three-way regulating valve to achieve individual or synchronous heat supply to the cab and the power battery.
[0006] This invention ensures both comfortable cab heating and rapid preheating of the power battery to its optimal operating temperature, extending battery life. By replacing high-voltage PTC with fuel heating, thermal management energy consumption is significantly reduced, ensuring vehicle range in low temperatures and improving the operational practicality of pure electric vehicles. Attached Figure Description
[0007] Figure 1 This is a schematic diagram of the components of the present invention. Detailed Implementation
[0008] like Figure 1 As shown, the present invention is an integrated thermal management system for a fuel heater in a pure electric vehicle, including a fuel heater, a fuel supply component, an electric three-way regulating valve, a cab HVAC heating core, a battery cooling unit, a circulating water pump, a compensation water tank, and a controller. The fuel heater is connected to the vehicle fuel tank through the fuel supply assembly. The fuel heater outlet is connected to the driver's heating tee. The driver's heating tee is connected to the electric tee regulating valve and the driver's cab heating branch respectively. The electric tee regulating valve is a one-outlet and two-inlet type. The two inlets (inlet I1 and inlet II3) are connected to the outlet of the heater tee and the return water of the battery heating branch respectively. The outlet 2 is connected to the inlet of the battery heating branch.
[0009] The cab HVAC heating core is connected to the cab heating branch, and the power battery is connected to the battery heating branch. The oil supply assembly includes an oil pump, an oil extractor, and oil pipe connection parts; The battery cooling unit has a battery cooling function to ensure the cooling needs when the battery temperature is high, and it is on the same branch as the power battery. The return water inlets of the HVAC heater core and the power battery are both connected to the return water inlet of the fuel heater through pipelines, forming a closed-loop circulation circuit. Two circulating water pumps are installed. The heating water pump is integrated with the fuel oil heater, and the controller communicates with the fuel oil heater to control the heating water pump's on / off state by controlling the fuel oil heater's operating mode. The battery water pump is integrated with the battery cooling unit, and the controller communicates with the battery cooling unit to control the battery water pump's on / off state by controlling the battery cooling unit's operating mode.
[0010] The controller is electrically connected to the fuel heater, electric three-way regulating valve, battery cooling unit, cab temperature sensor, and battery temperature sensor. By collecting temperature signals, it controls the opening and flow direction of the electric three-way regulating valve to achieve individual or synchronous heat supply to the cab and power battery.
[0011] 1. Cab heating alone: When the cab heating is turned on, the controller receives the cab temperature sensor signal and the heating start signal, and controls the opening of the electric three-way regulating valve to switch the port 3 and port 2 to be connected and port 1 to be cut off. This controls the heating water pump to start, the oil pump to start supplying oil, and the fuel heater to start heating. The water flow between the heater core, the heating water pump, and the fuel heater in the cab heating branch starts to circulate, thus realizing the cab heating function.
[0012] 2. Single-on power battery heating and dual-on power battery heating and cab heating: When the power battery temperature reaches the required heating level, the controller receives signals from the cab temperature sensor, the heating activation signal, and the power battery temperature value signal. It then controls the opening of the electric three-way regulating valve to connect ports 1 and 2 while shutting off port 3. This controls the oil pump to start supplying oil, the fuel heater to start heating, and the battery water pump in the battery cooling unit to start. Water circulation begins between the power battery, battery cooling unit, and fuel heater in the battery heating branch, achieving the battery heating function. Simultaneously, the cab heating requirement can also be met. 3. Independent cooling of the power battery: When the power battery temperature reaches the required cooling level, the controller receives the power battery temperature signal and controls the opening of the electric three-way regulating valve to switch the 3-port and 2-ports connected and the 1-port cut off, thereby controlling the battery cooling unit to start the cooling mode and realizing the independent cooling function of the power battery.
[0013] When the battery is charging and heating up in low-temperature environments and requires cooling, the cab heating can be turned on at the same time. The battery cooling and cab heating functions do not affect each other.
[0014] The beneficial effects of this invention are: 1. Using a fuel heater as the sole heat source completely replaces the high-voltage PTC, and the heating process does not consume power from the battery, thus completely solving the problem of range reduction at low temperatures; 2. A heat source is equipped with two heating branches, which are integrated and diverted through an electric three-way valve to achieve independent / synchronous operation of cab heating and power battery heating, simplifying the system structure and reducing redundant components; 3. It can simultaneously achieve cab heating and power battery heating and cooling functions, balancing battery performance and driving comfort; 4. The overall structure is a closed-loop liquid cooling system, which is suitable for mass production assembly of various pure e-commerce vehicles.
Claims
1. An integrated thermal management system for a fuel heater in a pure e-commerce vehicle, characterized by: Includes fuel heater, fuel supply assembly, electric three-way regulating valve, cab HVAC heating core, battery cooling unit, circulating water pump, compensation water tank, and controller; The fuel heater is connected to the vehicle fuel tank via the fuel supply assembly. The fuel heater outlet is connected to the driver heating tee. The driver heating tee is connected to the electric tee regulating valve and the driver's cab heating branch respectively. The electric tee regulating valve is a one-outlet, two-inlet type. Inlet I and inlet II are connected to the water outlet of the driver heating tee and the return water of the battery heating branch respectively. The outlet is connected to the water inlet of the battery heating branch. The cab heating branch is connected to the cab HVAC heater core, the battery heating branch is connected to the power battery, and the battery cooling unit is on the same branch as the power battery. The HVAC heater core and the return water inlet of the power battery are both connected to the return water inlet of the fuel heater through pipelines, forming a closed-loop circulation circuit. The circulating water pump includes a heating water pump and a battery water pump. The controller communicates with the fuel oil heater and controls the heating water pump to turn on and off by controlling the working mode of the fuel oil heater. The controller also communicates with the battery cooling unit and controls the battery water pump to turn on and off by controlling the working mode of the battery cooling unit.
2. The integrated thermal management system for a pure electric vehicle fuel heater according to claim 1, characterized in that: The heating water pump and fuel oil heater are structurally integrated.
3. The integrated thermal management system for a pure electric vehicle fuel heater according to claim 1, characterized in that: The battery water pump is integrated with the battery cooling unit.
4. The integrated thermal management system for a pure e-commerce vehicle fuel heater according to claim 1, characterized in that: The controller is electrically connected to the fuel heater, the electric three-way regulating valve, the battery cooling unit, the cab temperature sensor, and the battery temperature sensor. By collecting temperature signals, it controls the opening and flow direction of the electric three-way regulating valve to achieve individual or synchronous heat supply to the cab and the power battery.
5. The integrated thermal management system for a pure e-commerce vehicle fuel heater according to claim 4, characterized in that: The controller controls the opening and flow direction of the electric three-way regulating valve to achieve the individual or synchronous supply of heat to the cab and power battery. 1) Cab heating alone: When the cab heating is turned on, the controller receives the cab temperature sensor signal and the heating start signal and controls the opening of the electric three-way regulating valve to switch the inlet II to connect with the outlet and the inlet I to close. This controls the heating water pump to start, the oil pump to start supplying oil, and the fuel heater to start heating. The water flow between the heating core, the heating water pump, and the fuel heater in the cab heating branch starts to circulate to realize the cab heating function. 2) Single-on power battery heating and dual-on power battery heating and cab heating: When the power battery temperature reaches the required heating level, the controller receives signals from the cab temperature sensor, the heating activation signal, and the power battery temperature value signal. It then controls the opening of the electric three-way regulating valve to connect inlet I to the outlet and cut off inlet II. This controls the oil pump to start supplying oil, the fuel heater to start heating, and the battery water pump in the battery cooling unit to start. Water circulation begins between the power battery, battery cooling unit, and fuel heater in the battery heating branch, achieving the battery heating function. Simultaneously, the cab heating requirement is also met. 3) Independent cooling of power battery: When the power battery temperature reaches the required cooling level, the controller receives the power battery temperature signal and controls the opening of the electric three-way regulating valve to switch the inlet II to connect with the outlet and the inlet I to close, thereby controlling the battery cooling unit to start the cooling mode and realize the independent cooling function of the power battery.