A dynamically reconfigurable thermal management system based on dual battery system and control method

Abstract

The application relates to the technical field of power battery thermal management, and discloses a dynamic reconfigurable thermal management system based on a double-battery system and a control method, the system comprising two sets of thermal management units, two groups of battery packs, a controller and heat exchange pipelines connected between the two sets of thermal management units and the two groups of battery packs, the heat exchange pipelines being provided with first to seventh electric control valves; heat exchange medium inlets and outlets of the two sets of thermal management units are selectively communicated with heat exchange ports of the two groups of battery packs through the electric control valves; the controller controls the start and stop of the units and the on and off of the electric control valves according to temperature states of the two groups of battery packs and operation states of the two sets of thermal management units, so as to form heat exchange circulation loops between single units and single battery packs, single units and double battery packs or double units and double battery packs respectively; and the application reconstructs a heat exchange path according to heat exchange requirements and unit states, so that the flexible deployment of thermal management capacity is realized.

Description

Technical Field

[0001] This invention relates to the field of power battery thermal management technology, specifically to a dynamic reconfigurable thermal management system and control method based on a dual-battery system. Background Technology

[0002] As new energy construction machinery develops towards electrification and higher power, equipment such as electric road rollers, electric loaders, and electric excavators typically need to operate continuously for extended periods in open-pit mines, field construction sites, and other similar locations. To balance range and recharging efficiency, some equipment employs a power supply system consisting of two sets of batteries. These two sets of batteries alternately supply power to maintain continuous operation, and are simultaneously charged during charging. The power batteries generate heat during charging and discharging, and their operating temperature directly affects charging and discharging performance, lifespan, and operational safety. Therefore, it is necessary to cool or heat each set of batteries separately.

[0003] Existing dual-battery thermal management systems typically configure a separate thermal management unit for each battery group, ensuring that each unit forms a fixed heat exchange loop with only its corresponding battery group. These two heat exchange loops operate independently. When one battery group is at a higher charge / discharge rate while the other is in standby or at a lower rate, the thermal management unit on the side with lower heat exchange demand cannot provide heat to the other battery group, resulting in underutilization of thermal management capabilities. Furthermore, if either thermal management unit malfunctions, the other unit cannot take over the temperature regulation of the corresponding battery group through the existing heat exchange piping, potentially causing the equipment to operate at reduced power or cease operation. Summary of the Invention

[0004] The technical objective of this invention is to provide a dynamically reconfigurable thermal management system and control method based on a dual-battery system, in order to solve the problem that the heat exchange cycle path of the existing heat exchange system cannot be adjusted according to the battery temperature state and the operating state of the thermal management unit, resulting in the inflexible allocation of thermal management capabilities.

[0005] To achieve the above-mentioned technical objectives, the present invention provides the following technical solution:

[0006] In a first aspect, the present invention provides a dynamically reconfigurable thermal management system based on a dual-battery system, comprising a first thermal management unit, a second thermal management unit, a first battery pack, a second battery pack, a controller, and a reconfigurable heat exchange pipeline connected between the two thermal management units and the two battery packs. The reconfigurable heat exchange pipeline includes a first electrically controlled valve, a second electrically controlled valve, a third electrically controlled valve, a fourth electrically controlled valve, a fifth electrically controlled valve, a sixth electrically controlled valve, and a seventh electrically controlled valve.

[0007] The heat exchange medium inlet of the first thermal management unit is connected to the first heat exchange port of the first battery pack via the first electrically controlled valve, and is connected to the second heat exchange port of the first battery pack via the third electrically controlled valve; the heat exchange medium outlet of the first thermal management unit is connected to the first heat exchange port of the first battery pack via the second electrically controlled valve, and is connected to the first end of the seventh electrically controlled valve via the fourth electrically controlled valve.

[0008] The heat exchange medium inlet of the second thermal management unit is connected to the first heat exchange port of the second battery pack, and is connected to the second heat exchange port of the first battery pack via the fifth solenoid valve; the heat exchange medium outlet of the second thermal management unit is connected to the first end of the seventh solenoid valve via the sixth solenoid valve, and the second end of the seventh solenoid valve is connected to the second heat exchange port of the second battery pack.

[0009] The controller is connected to the first thermal management unit, the second thermal management unit, the first battery pack, the second battery pack, and the first to seventh solenoid valves, respectively. It is used to control the start and stop of the two thermal management units and the on / off state of the first to seventh solenoid valves according to the temperature status of the two battery packs and the operating status of the two thermal management units, so as to selectively form a heat exchange loop between a single thermal management unit and a single battery pack, a heat exchange loop between a single thermal management unit and a dual battery pack, or two heat exchange loops between the dual thermal management units and the dual battery packs respectively.

[0010] Furthermore, the first thermal management unit includes a first heat exchanger and a first circulating pump, and the second thermal management unit includes a second heat exchanger and a second circulating pump; the first circulating pump and the second circulating pump are respectively used to drive the heat exchange medium to flow in the corresponding heat exchange circulation loop selected by the first solenoid valve to the seventh solenoid valve.

[0011] Furthermore, the controller is used to control the system to switch between the following seven operating modes:

[0012] In the first operating mode, the first thermal management unit and the first battery pack form a heat exchange circulation loop;

[0013] In the second working mode, the first thermal management unit and the second battery pack form a heat exchange circulation loop.

[0014] In the third operating mode, the second thermal management unit and the first battery pack form a heat exchange circulation loop.

[0015] In the fourth operating mode, the second thermal management unit and the second battery pack form a heat exchange circulation loop;

[0016] In the fifth operating mode, the first thermal management unit, the first battery pack, and the second battery pack form a heat exchange circulation loop containing two battery packs.

[0017] In the sixth operating mode, the second thermal management unit, together with the first and second battery packs, forms a heat exchange circulation loop containing two battery packs.

[0018] In the seventh operating mode, the first thermal management unit and the first battery pack form the first heat exchange cycle loop, and the second thermal management unit and the second battery pack form the second heat exchange cycle loop.

[0019] Furthermore, in the first operating mode, the second and third solenoid valves are turned on, while the remaining solenoid valves are turned off, starting the first thermal management unit and stopping the second thermal management unit; in the second operating mode, the third, fourth, fifth, and seventh solenoid valves are turned on, while the remaining solenoid valves are turned off, starting the first thermal management unit and stopping the second thermal management unit; in the third operating mode, the second, fourth, fifth, and sixth solenoid valves are turned on, while the remaining solenoid valves are turned off, starting the second thermal management unit and stopping the first thermal management unit; in the fourth operating mode, the sixth and seventh solenoid valves are turned on, while the remaining solenoid valves are turned off, starting the second thermal management unit and stopping the first thermal management unit.

[0020] Furthermore, in the fifth operating mode, the first, fourth, fifth, and seventh solenoid valves are turned on, while the second, third, and sixth solenoid valves are turned off, thus starting the first thermal management unit and stopping the second thermal management unit. In the sixth operating mode, the second, fourth, fifth, sixth, and seventh solenoid valves are turned on, while the first and third solenoid valves are turned off, thus starting the second thermal management unit and stopping the first thermal management unit.

[0021] Furthermore, in the seventh operating mode, the second, third, sixth, and seventh electrically controlled valves are turned on, while the first, fourth, and fifth electrically controlled valves are turned off, and both the first and second thermal management units are started.

[0022] Furthermore, the controller is used to acquire ambient temperature, average temperature and maximum temperature of individual cells of the first battery pack, average temperature and maximum temperature of individual cells of the second battery pack, charge / discharge rate and operating status of each of the two battery packs, operating parameters of the first thermal management unit and the second thermal management unit, and fault alarm signals. Based on the acquired parameters, preset temperature control thresholds and operating condition judgment rules, the controller determines one or two battery packs that need temperature adjustment, one or two thermal management units that are in an available state, and the target operating mode among the seven operating modes.

[0023] Furthermore, when only one battery pack requires temperature regulation, a target thermal management unit is selected from the available thermal management units, and a working mode is determined in which the target thermal management unit forms a heat exchange loop with the battery pack. When both battery packs require temperature regulation and only one thermal management unit is available, a working mode is determined in which the thermal management unit forms a heat exchange loop with both battery packs. When both battery packs require temperature regulation, both thermal management units are available, and the preset dual-machine start-up conditions are not met, a target working mode is selected from the fifth and sixth working modes. When both battery packs require temperature regulation, both thermal management units are available, and the preset dual-machine start-up conditions are met, a seventh working mode is determined.

[0024] The preset dual-machine start-up conditions include at least one of the following conditions: the ambient temperature is greater than or equal to the preset high temperature environmental threshold; the ambient temperature is less than or equal to the preset low temperature environmental threshold; the highest temperature of a single cell in at least one battery pack is greater than or equal to the preset high temperature enhancement threshold; the average temperature of at least one battery pack is less than or equal to the preset low temperature enhancement threshold; and the charging rate or discharging rate of at least one battery pack is greater than or equal to the preset high rate threshold.

[0025] In a second aspect, the present invention also provides a dynamically reconfigurable thermal management control method based on a dual-battery system, applied to the system described in the first aspect, comprising the following steps:

[0026] The system acquires ambient temperature, the temperature of the first and second battery packs, their charge / discharge rates and operating status, as well as the operating parameters and fault alarm signals of the first and second thermal management units.

[0027] Based on the obtained ambient temperature, the temperatures of the two battery packs, the charge / discharge rates and operating status, and the preset temperature control threshold, the target battery pack that needs temperature adjustment is determined from the first battery pack and the second battery pack, and the available thermal management unit is determined based on the operating parameters and fault alarm signals of the two thermal management units.

[0028] Based on the target battery pack, available thermal management unit, and preset dual-machine start-up conditions, the target operating mode is determined from the seven operating modes;

[0029] Based on the pre-stored correspondence between the working mode and the on / off combination of the solenoid valve, the on / off of the first solenoid valve to the seventh solenoid valve and the start / stop of the thermal management unit corresponding to the target working mode are controlled to form a heat exchange circulation loop corresponding to the target working mode.

[0030] The system continuously acquires the status of the two battery packs and the two thermal management units and redetermines the target operating mode. When the redetermined target operating mode is different from the current operating mode, the system switches the start / stop status of the two thermal management units and the on / off combination of the first to the seventh electronic control valves.

[0031] Furthermore, when there is only one target battery pack, a target thermal management unit is selected from the available thermal management units, and a working mode is determined in which the target thermal management unit and the target battery pack form a heat exchange loop. When there are two target battery packs and one available thermal management unit, a working mode is determined in which the available thermal management unit and the two battery packs form a heat exchange loop. When there are two target battery packs, two available thermal management units, and the preset dual-unit start-up conditions are not met, a target thermal management unit is selected from the two available thermal management units, and a working mode is determined in which the target thermal management unit and the two battery packs form a heat exchange loop. When there are two target battery packs, two available thermal management units, and the preset dual-unit start-up conditions are met, a working mode is determined in which the first thermal management unit and the first battery pack form a first heat exchange loop, and the second thermal management unit and the second battery pack form a second heat exchange loop.

[0032] The beneficial effects of this invention are as follows:

[0033] 1. The present invention constructs a reconfigurable heat exchange pipeline through the first to the seventh electrically controlled valves, enabling any thermal management unit to selectively form a heat exchange circulation loop with any or two battery packs, thereby changing the fixed pipeline structure between the thermal management unit and the battery pack and realizing flexible allocation of thermal management capabilities between the two battery packs.

[0034] 2. The present invention determines the target operating mode based on the temperature, charge / discharge rate, and operating status of the two battery packs and the operating status of the two thermal management units. It can switch between single-unit operation and dual-unit operation, reduce the energy consumption caused by the simultaneous operation of the two thermal management units when the heat exchange demand is low, and improve the utilization rate of thermal management capabilities.

[0035] 3. When any thermal management unit fails, the present invention can utilize another available thermal management unit to form a heat exchange loop with one or two battery packs that require temperature regulation, allowing the thermal management unit that has not failed to take over the corresponding temperature regulation task, thereby improving the operational reliability of the dual-battery thermal management system. Attached Figure Description

[0036] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0037] The above and other aspects of the invention will now be described by way of example only, with reference to the accompanying drawings, in which:

[0038] Figure 1 This is a diagram showing the overall architecture of the thermal management system of the present invention.

[0039] Figure 2 This is a diagram illustrating the unit control mode of the thermal management system of the present invention;

[0040] Figure 3 This is a diagram showing the matching relationship between the working conditions and working modes of the present invention.

[0041] Figure 4 The schematic diagram of the heat exchange cycle loop in the first working mode;

[0042] Figure 5 This is a schematic diagram of the heat exchange cycle loop for the second working mode.

[0043] Figure 6 The schematic diagram of the heat exchange cycle loop for the third working mode;

[0044] Figure 7 This is a schematic diagram of the heat exchange cycle loop for the fourth operating mode.

[0045] Figure 8 This is a schematic diagram of the heat exchange cycle loop for the fifth operating mode.

[0046] Figure 9 This is a schematic diagram of the heat exchange cycle loop for the sixth operating mode.

[0047] Figure 10 This is a schematic diagram of the heat exchange cycle loop for the seventh operating mode.

[0048] In the diagram: 010, First electrically controlled valve; 011, Second electrically controlled valve; 012, Third electrically controlled valve; 013, Fourth electrically controlled valve; 014, Fifth electrically controlled valve; 015, Sixth electrically controlled valve; 016, Seventh electrically controlled valve; 101, First circulating pump; 102, First heat exchanger; 103, First heater; 110, First compressor; 111, First air-side heat exchanger; 112, First fan; 113, First liquid receiver; 114, First expansion valve; 201, Second circulating pump; 202, Second heat exchanger; 203, Second heater; 210, Second compressor; 211, Second air-side heat exchanger; 212, Second fan; 213, Second liquid receiver; 214, Second expansion valve. Detailed Implementation

[0049] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0050] Example 1

[0051] like Figure 1 and Figure 4 As shown, this embodiment provides a dynamically reconfigurable thermal management system based on a dual-battery system, including a first thermal management unit, a second thermal management unit, a first battery pack, a second battery pack, a controller, and heat exchange pipelines connecting the two thermal management units and the two battery packs. The heat exchange pipelines are equipped with a first electrically controlled valve 010, a second electrically controlled valve 011, a third electrically controlled valve 012, a fourth electrically controlled valve 013, a fifth electrically controlled valve 014, a sixth electrically controlled valve 015, and a seventh electrically controlled valve 016.

[0052] The first thermal management unit includes a first compressor 110, a first heat exchanger 102, a first heater 103, a first circulating pump 101, a first air-side heat exchanger 111, a first fan 112, a first liquid receiver 113, and a first expansion valve 114. The first compressor 110, the first air-side heat exchanger 111, the first liquid receiver 113, the first expansion valve 114, and the refrigerant side of the first heat exchanger 102 form a refrigerant circulation section. The first circulating pump 101 drives the heat exchange medium to flow through the heat exchange medium side of the first heat exchanger 102, the first heater 103, and external heat exchange pipelines. The first heat exchanger 102 facilitates heat exchange between the refrigerant and the heat exchange medium, and the first heater 103 heats the heat exchange medium when the battery pack requires heating.

[0053] The structure of the second thermal management unit corresponds to that of the first thermal management unit, including a second circulating pump 201, a second heat exchanger 202, a second heater 203, a second compressor 210, a second air-side heat exchanger 211, a second fan 212, a second liquid receiver 213, and a second expansion valve 214. The second circulating pump 201 is used to drive the heat exchange medium to flow through the heat exchange medium side of the second heat exchanger 202, the second heater 203, and the external heat exchange pipeline selected by the electrically controlled valve.

[0054] The first and second battery packs are each equipped with heat exchange channels for heat exchange with individual battery cells. Each heat exchange channel has a first heat exchange port and a second heat exchange port. When the thermal management unit is in cooling mode, the heat exchange medium absorbs the heat generated by the corresponding battery pack and releases it within the thermal management unit. When the thermal management unit is in heating mode, the heated heat exchange medium transfers heat to the corresponding battery pack.

[0055] The heat exchange medium inlet of the first thermal management unit has two optional connection paths. One path connects to the first heat exchange port of the first battery pack via the first solenoid valve 010, and the other path connects to the second heat exchange port of the first battery pack via the third solenoid valve 012. The heat exchange medium outlet of the first thermal management unit also has two optional connection paths. One path connects to the first heat exchange port of the first battery pack and the inlet end of the first solenoid valve 010 via the second solenoid valve 011, and the other path connects to the first end of the seventh solenoid valve 016 via the fourth solenoid valve 013.

[0056] The heat exchange medium inlet of the second thermal management unit is connected to the first heat exchange port of the second battery pack, and is connected to the second heat exchange port of the first battery pack via the fifth solenoid valve 014. The heat exchange medium outlet of the second thermal management unit is connected to the first end of the seventh solenoid valve 016 via the sixth solenoid valve 015, and the second end of the seventh solenoid valve 016 is connected to the second heat exchange port of the second battery pack. The pipe section containing the first ends of the fourth solenoid valve 013, the sixth solenoid valve 015, and the seventh solenoid valve 016 constitutes the common connection point between the two thermal management units and the two battery packs.

[0057] The controller is connected to two thermal management units, two battery packs, and seven electronically controlled valves. Ambient temperature is obtained from an ambient temperature sensor. The average temperature, maximum temperature of individual cells, charge / discharge rate, and charging / discharging or standby status of each battery pack are provided by its respective battery management system. The two thermal management units provide operating parameters and fault alarm signals for the circulating pump, compressor, and heat exchanger status. Based on this information, the controller generates start / stop commands for the thermal management units and on / off commands for the electronically controlled valves, ensuring that the heat exchange pipeline forms a heat exchange circulation loop corresponding to the current temperature regulation requirements.

[0058] Example 2

[0059] like Figure 2As shown, the controller in this embodiment pre-stores seven operating modes and the corresponding on / off combinations of the electrically controlled valves for each operating mode; as... Figure 3 As shown, the controller determines the target operating mode from seven operating modes based on the number of battery packs requiring temperature adjustment, the number of thermal management units in an available state, and whether the preset dual-machine start-up conditions are met.

[0060] like Figure 4 As shown, in the first operating mode, the second solenoid valve 011 and the third solenoid valve 012 are open, while the other solenoid valves are closed. The first thermal management unit starts, and the second thermal management unit stops. The heat exchange medium enters the first heat exchange port of the first battery pack from the heat exchange medium outlet of the first thermal management unit through the second solenoid valve 011, flows through the heat exchange channel of the first battery pack, flows out from the second heat exchange port, and then returns to the heat exchange medium inlet of the first thermal management unit through the third solenoid valve 012, thus forming a heat exchange circulation loop between the first thermal management unit and the first battery pack.

[0061] like Figure 5 As shown, in the second operating mode, the third solenoid valve 012, the fourth solenoid valve 013, the fifth solenoid valve 014, and the seventh solenoid valve 016 are open, while the remaining solenoid valves are closed. The first thermal management unit starts, and the second thermal management unit stops. The first thermal management unit is connected to the second heat exchange port of the second battery pack via the fourth solenoid valve 013 and the seventh solenoid valve 016. The pipe section containing the first heat exchange port of the second battery pack is connected to the heat exchange medium inlet of the first thermal management unit via the fifth solenoid valve 014 and the third solenoid valve 012, thus forming a heat exchange circulation loop between the first thermal management unit and the second battery pack. Because the first heat exchange port of the first battery pack is not selected, the first battery pack does not constitute a complete heat exchange circulation loop.

[0062] like Figure 6 As shown, in the third operating mode, the second solenoid valve 011, the fourth solenoid valve 013, the fifth solenoid valve 014, and the sixth solenoid valve 015 are open, while the remaining solenoid valves are closed. The second thermal management unit starts, and the first thermal management unit stops. The heat exchange medium outlet of the second thermal management unit is connected to the first heat exchange port of the first battery pack via the sixth solenoid valve 015, the fourth solenoid valve 013, and the second solenoid valve 011 in sequence. The second heat exchange port of the first battery pack is connected to the heat exchange medium inlet of the second thermal management unit via the fifth solenoid valve 014, thereby forming a heat exchange circulation loop between the second thermal management unit and the first battery pack.

[0063] like Figure 7As shown, in the fourth operating mode, the sixth and seventh solenoid valves 015 and 016 are turned on, while the remaining solenoid valves are turned off, starting the second thermal management unit and stopping the first thermal management unit. The heat exchange medium enters the second heat exchange port of the second battery pack from the heat exchange medium outlet of the second thermal management unit through the sixth and seventh solenoid valves 015 and 016, flows through the heat exchange channel of the second battery pack, and then returns to the heat exchange medium inlet of the second thermal management unit from the first heat exchange port, thus forming a heat exchange circulation loop between the second thermal management unit and the second battery pack.

[0064] like Figure 8 As shown, in the fifth operating mode, the first solenoid valve 010, the fourth solenoid valve 013, the fifth solenoid valve 014, and the seventh solenoid valve 016 are open, while the second solenoid valve 011, the third solenoid valve 012, and the sixth solenoid valve 015 are closed. The first thermal management unit starts, and the second thermal management unit stops. The aforementioned connecting pipe section connects the first battery pack and the second battery pack to the heat exchange medium circulation path of the first thermal management unit, causing the first circulation pump 101 to drive the heat exchange medium to flow through the two battery packs and return to the first thermal management unit, forming a heat exchange circulation loop containing the two battery packs.

[0065] like Figure 9 As shown, in the sixth operating mode, the second solenoid valve 011, the fourth solenoid valve 013, the fifth solenoid valve 014, the sixth solenoid valve 015, and the seventh solenoid valve 016 are open, while the first solenoid valve 010 and the third solenoid valve 012 are closed. The second thermal management unit starts, and the first thermal management unit stops. The heat exchange medium outlet of the second thermal management unit is connected to the heat exchange branches of the first and second battery groups via the sixth solenoid valve 015. The two heat exchange branches converge into the heat exchange medium inlet of the second thermal management unit via the fifth solenoid valve 014 and the pipe section where the first heat exchange port of the second battery group is located, thus forming a heat exchange circulation loop in which the second thermal management unit simultaneously regulates the temperature of the two battery groups.

[0066] like Figure 10 As shown, in the seventh operating mode, the second solenoid valve 011, the third solenoid valve 012, the sixth solenoid valve 015, and the seventh solenoid valve 016 are open, while the first solenoid valve 010, the fourth solenoid valve 013, and the fifth solenoid valve 014 are closed, and both the first and second thermal management units are started. The second solenoid valve 011 and the third solenoid valve 012 enable the first thermal management unit to form a first heat exchange loop with the first battery pack; the sixth solenoid valve 015 and the seventh solenoid valve 016 enable the second thermal management unit to form a second heat exchange loop with the second battery pack. The two heat exchange loops are independent of each other, and the two thermal management units regulate the temperature of their respective battery packs.

[0067] Example 3

[0068] This embodiment provides a dynamically reconfigurable thermal management control method applied to the thermal management systems described in Embodiments 1 and 2; the control method is executed cyclically by the controller, and the specific steps are as follows:

[0069] The controller acquires the ambient temperature, the average temperature, maximum temperature of individual cells, charge / discharge rate, and operating status of both the first and second battery packs, and the operating parameters and fault alarm signals of both the first and second thermal management units. Operating status includes charging, discharging, and standby states, and operating parameters characterize the normal operation of the circulating pump, compressor, and heat exchange functions.

[0070] Furthermore, the controller determines whether the two battery packs require temperature adjustment based on preset temperature control thresholds. In this embodiment, when the average temperature of any battery pack is less than or equal to the preset low-temperature temperature control threshold, that battery pack is identified as the target battery pack with heating requirements; when the highest temperature of any single cell in any battery pack is greater than or equal to the preset high-temperature temperature control threshold, that battery pack is identified as the target battery pack with cooling requirements. Ambient temperature, charge / discharge rate, and operating status are used to determine the target battery pack according to pre-calibrated operating condition judgment rules, so as to select the appropriate temperature adjustment mode when the charge / discharge load changes.

[0071] The controller also determines the available thermal management units based on the operating parameters and fault alarm signals of the two thermal management units. When a thermal management unit has no fault alarms and its circulating pump, compressor, and communication status meet the preset operating conditions, the thermal management unit is determined to be in an available state; when a thermal management unit has alarm signals corresponding to circulating pump failure, compressor failure, heat exchange abnormality, or communication failure, the thermal management unit is excluded and is no longer considered as an available thermal management unit for this mode selection.

[0072] When only the first battery pack is the target battery pack, if the first thermal management unit is available, the first operating mode is determined; if the first thermal management unit is unavailable but the second thermal management unit is available, the third operating mode is determined. When only the second battery pack is the target battery pack, if the second thermal management unit is available, the fourth operating mode is determined; if the second thermal management unit is unavailable but the first thermal management unit is available, the second operating mode is determined. Thus, when one thermal management unit fails, the other thermal management unit can take over the temperature regulation task of the target battery pack.

[0073] When both the first and second battery packs are target battery packs and only the first thermal management unit is available, the fifth operating mode is determined. When both battery packs are target battery packs and only the second thermal management unit is available, the sixth operating mode is determined. When both battery packs are target battery packs, both thermal management units are available, and the preset dual-unit start-up conditions are not met, this embodiment prioritizes determining the fifth operating mode, allowing the first thermal management unit to handle the temperature regulation of both battery packs. Under another preset unit priority, the sixth operating mode can also be determined.

[0074] When both battery packs are target battery packs, both thermal management units are in a usable state, and the preset dual-machine start-up conditions are met, the seventh operating mode is determined. The preset dual-machine start-up conditions are that at least one of the following conditions is met: ambient temperature is greater than or equal to a preset high-temperature environmental threshold; ambient temperature is less than or equal to a preset low-temperature environmental threshold; the highest temperature of any single cell in any target battery pack is greater than or equal to a preset high-temperature threshold; the average temperature of any target battery pack is less than or equal to a preset low-temperature threshold; or the charging or discharging rate of any target battery pack is greater than or equal to a preset rate threshold. The preset low-temperature environmental threshold and the preset high-temperature environmental threshold together define a preset ambient temperature range.

[0075] The aforementioned preset temperature control threshold, preset ambient temperature range, and preset rate threshold are calibrated and stored in the controller before the system is put into operation, based on the battery pack's allowable operating temperature range, charge and discharge performance, and the heat exchange capacity of the thermal management unit. Therefore, the controller determines whether to start the dual-machine system based on the comparison between the collected parameters and the preset thresholds, rather than directly using unquantified operating condition names as the basis for mode switching.

[0076] After determining the target operating mode, the controller recalls the pre-stored correspondence between the operating mode and the on / off combinations of the electrically controlled valves, and controls the first electrically controlled valve 010 to the seventh electrically controlled valve 016 according to the valve combination described in Embodiment 2. It then sends a start command to the thermal management unit corresponding to the target operating mode and a stop command to the non-target thermal management units. The corresponding circulating pump drives the heat exchange medium to flow along the selected pipe section, and the thermal management unit performs heat exchange according to the cooling or heating requirements of the target battery pack.

[0077] During the operation of the thermal management system, the controller continuously acquires the status of the two battery packs and two thermal management units, and redetermines the target operating mode according to the same judgment process. When the redetermined target operating mode is the same as the current operating mode, the current start / stop status of the thermal management units and the on / off combination of the electronically controlled valves are maintained; when they are different, the start / stop status of the two thermal management units and the on / off combination of the seven electronically controlled valves are switched according to the redetermined target operating mode. If any thermal management unit experiences a fault alarm during operation, the controller will exclude it in the next judgment, and another available thermal management unit will be used to match one or both battery packs that require temperature regulation.

[0078] The above embodiments are used to illustrate the structure and control process of the present invention. Without changing the connection relationship formed by the two thermal management units, the two battery packs and the seven electronically controlled valves, as well as the seven working modes, each preset threshold and control cycle can be calibrated according to the battery parameters and thermal management capabilities of the specific vehicle.

[0079] The description herein is provided to enable those skilled in the art to implement or use the present disclosure. Various modifications to the present disclosure will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other variations without departing from the scope of the disclosure. Therefore, this disclosure is not limited to the examples and designs described herein, but should be given the broadest scope consistent with the principles and novel features disclosed herein.

[0080] Although one or more exemplary embodiments of this disclosure have been described with reference to the accompanying drawings, those skilled in the art will understand that various changes in form and detail may be made therein without departing from the spirit and scope of this disclosure as defined by the appended claims.

[0081] The foregoing description is merely illustrative of this disclosure, and modifications may be made to the invention in light of the above detailed description. The terminology used in the appended claims should not be construed as limiting the invention to the specific embodiments disclosed in the specification. Rather, the scope of the invention will be fully defined by the appended claims, which will be interpreted according to established principles of claim interpretation.

Claims

1. A dynamically reconfigurable thermal management system based on a dual-battery system, characterized in that, It includes a first thermal management unit, a second thermal management unit, a first battery pack, a second battery pack, a controller, and heat exchange pipelines connecting the two thermal management units and the two battery packs. The heat exchange pipelines include a first electrically controlled valve, a second electrically controlled valve, a third electrically controlled valve, a fourth electrically controlled valve, a fifth electrically controlled valve, a sixth electrically controlled valve, and a seventh electrically controlled valve. The heat exchange medium inlet of the first thermal management unit is connected to the first heat exchange port of the first battery pack via a first electrically controlled valve, and is also connected to the second heat exchange port of the first battery pack via a third electrically controlled valve. The heat exchange medium outlet of the first thermal management unit is connected to the first heat exchange port of the first battery pack via the second electrically controlled valve, and is also connected to the first end of the seventh electrically controlled valve via the fourth electrically controlled valve. The heat exchange medium inlet of the second thermal management unit is connected to the first heat exchange port of the second battery pack, and is connected to the second heat exchange port of the first battery pack via the fifth electronically controlled valve; The heat exchange medium outlet of the second thermal management unit is connected to the first end of the sixth and seventh solenoid valves via the sixth solenoid valve, and the second end of the seventh solenoid valve is connected to the second heat exchange port of the second battery pack. The controller is connected to the first thermal management unit, the second thermal management unit, the first battery pack, the second battery pack, and the first to seventh solenoid valves, respectively. It is used to control the start and stop of the two thermal management units and the on / off state of the first to seventh solenoid valves according to the temperature status of the two battery packs and the operating status of the two thermal management units.

2. The dynamically reconfigurable thermal management system based on a dual-battery system according to claim 1, characterized in that, The first thermal management unit includes a first heat exchanger and a first circulating pump, and the second thermal management unit includes a second heat exchanger and a second circulating pump; the first circulating pump and the second circulating pump are used to drive the heat exchange medium to flow in the heat exchange pipeline.

3. The dynamically reconfigurable thermal management system based on a dual-battery system according to claim 1, characterized in that, The controller is configured to control the system to switch between the following seven operating modes: In the first operating mode, the first thermal management unit and the first battery pack form a heat exchange circulation loop; In the second working mode, the first thermal management unit and the second battery pack form a heat exchange circulation loop. In the third operating mode, the second thermal management unit and the first battery pack form a heat exchange circulation loop. In the fourth operating mode, the second thermal management unit and the second battery pack form a heat exchange circulation loop; In the fifth operating mode, the first thermal management unit, the first battery pack, and the second battery pack form a heat exchange circulation loop containing two battery packs. In the sixth operating mode, the second thermal management unit, together with the first and second battery packs, forms a heat exchange circulation loop containing two battery packs. In the seventh operating mode, the first thermal management unit and the first battery pack form the first heat exchange cycle loop, and the second thermal management unit and the second battery pack form the second heat exchange cycle loop.

4. The dynamically reconfigurable thermal management system based on a dual-battery system according to claim 3, characterized in that: In the first operating mode, the second and third electrically controlled valves are turned on, the remaining electrically controlled valves are turned off, the first thermal management unit starts, and the second thermal management unit stops. In the second operating mode, the third, fourth, fifth, and seventh solenoid valves are turned on, while the remaining solenoid valves are turned off, the first thermal management unit starts, and the second thermal management unit stops. In the third operating mode, the second, fourth, fifth, and sixth solenoid valves are turned on, the remaining solenoid valves are turned off, the second thermal management unit starts, and the first thermal management unit stops. In the fourth operating mode, the sixth and seventh solenoid valves are turned on, the remaining solenoid valves are turned off, the second thermal management unit starts, and the first thermal management unit stops.

5. The dynamically reconfigurable thermal management system based on a dual-battery system according to claim 3, characterized in that: In the fifth operating mode, the first, fourth, fifth, and seventh solenoid valves are turned on, while the second, third, and sixth solenoid valves are turned off. The first thermal management unit starts up, and the second thermal management unit stops. In the sixth operating mode, the second, fourth, fifth, sixth, and seventh solenoid valves are turned on, the first and third solenoid valves are turned off, the second thermal management unit starts, and the first thermal management unit stops.

6. The dynamically reconfigurable thermal management system based on a dual-battery system according to claim 3, characterized in that, In the seventh operating mode, the second, third, sixth, and seventh electrically controlled valves are turned on, while the first, fourth, and fifth electrically controlled valves are turned off, and both the first and second thermal management units are started.

7. The dynamically reconfigurable thermal management system based on a dual-battery system according to claim 3, characterized in that, The controller is used to acquire ambient temperature, average temperature and maximum temperature of individual cells of the first battery pack, average temperature and maximum temperature of individual cells of the second battery pack, charge / discharge rate and operating status of each of the two battery packs, operating parameters of the first and second thermal management units, and fault alarm signals. Based on the acquired parameters, preset temperature control thresholds and operating condition judgment rules, it determines one or two battery packs that need temperature adjustment, one or two thermal management units that are in an available state, and the target operating mode among the seven operating modes.

8. The dynamically reconfigurable thermal management system based on a dual-battery system according to claim 7, characterized in that, The controller is configured to: When only one battery pack needs temperature regulation, a target thermal management unit is selected from the available thermal management units, and the working mode in which the target thermal management unit and the battery pack form a heat exchange loop is determined. When both the first and second battery packs require temperature regulation, and only one thermal management unit is available, the working mode is determined to be that the thermal management unit forms a heat exchange loop with the first and second battery packs. When both the first and second battery packs require temperature regulation, both thermal management units are in a usable state and the preset dual-machine start-up conditions are not met, the target working mode is determined from the fifth and sixth working modes. When both the first and second battery packs require temperature regulation, both thermal management units are in a usable state, and the preset dual-machine start-up conditions are met, the seventh working mode is determined. The preset dual-machine start-up conditions include at least one of the following conditions: the ambient temperature is greater than or equal to a preset high-temperature environment threshold; the ambient temperature is less than or equal to a preset low-temperature environment threshold; the highest temperature of a single cell in at least one battery pack is greater than or equal to a preset high-temperature enhancement threshold; the average temperature of at least one battery pack is less than or equal to a preset low-temperature enhancement threshold; and the charging rate or discharging rate of at least one battery pack is greater than or equal to a preset high-rate threshold.

9. A dynamically reconfigurable thermal management control method based on a dual-battery system, applied to the system described in any one of claims 1-8, characterized in that, Includes the following steps: The system acquires ambient temperature, the temperature of the first and second battery packs, their charge / discharge rates and operating status, as well as the operating parameters and fault alarm signals of the first and second thermal management units. Based on the obtained ambient temperature, the temperatures of the two battery packs, the charge / discharge rates and operating status, and the preset temperature control threshold, the target battery pack that needs temperature adjustment is determined from the first battery pack and the second battery pack. The available thermal management unit is determined based on the operating parameters and fault alarm signals of the first thermal management unit and the second thermal management unit. Based on the target battery pack, the available thermal management unit, and the preset dual-machine start-up conditions, the target operating mode is determined from seven preset operating modes; Based on the pre-stored correspondence between the working mode and the on / off combination of the electrically controlled valves, the on / off of the first to the seventh electrically controlled valves and the start / stop of the thermal management unit corresponding to the target working mode are controlled to form a heat exchange circulation loop corresponding to the target working mode. The system continuously acquires the status of the two battery packs and the two thermal management units and redetermines the target operating mode. When the redetermined target operating mode is different from the current operating mode, the system switches the start / stop status of the two thermal management units and the on / off combination of the first to the seventh electronic control valves.

10. The dynamically reconfigurable thermal management control method based on a dual-battery system according to claim 9, characterized in that, Based on the target battery pack, the available thermal management unit, and the preset dual-machine start-up conditions, the target operating mode is determined from seven preset operating modes, including: When the target battery pack is a group, a target thermal management unit is determined from the available thermal management units, and the working mode in which the target thermal management unit and the target battery pack form a heat exchange loop is determined. When there are two target battery packs and one available thermal management unit, the working mode is determined to be that the available thermal management unit forms a heat exchange loop with the first battery pack and the second battery pack. When there are two target battery packs and two available thermal management units, and the preset dual-machine start-up conditions are not met, one target thermal management unit is determined from the two available thermal management units, and the working mode in which the target thermal management unit forms a heat exchange loop with the first battery pack and the second battery pack is determined. When there are two target battery packs, two available thermal management units, and the preset dual-machine start-up conditions are met, the working mode is determined to be that the first thermal management unit and the first battery pack form a first heat exchange cycle loop, and the second thermal management unit and the second battery pack form a second heat exchange cycle loop. The preset dual-machine start-up conditions are met if at least one of the following conditions is met: the ambient temperature exceeds the preset ambient temperature range; the average temperature of any target battery pack is less than or equal to the preset low temperature threshold; the highest temperature of any single cell in any target battery pack is greater than or equal to the preset high temperature threshold; or the charging rate or discharging rate of any target battery pack is greater than or equal to the preset rate threshold.

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