Plug-in si c compressor and thin film heater hybrid controller and thermal management system

Abstract

The application discloses a plug-in SiC compressor and thin film heater composite controller and a thermal management system. The controller comprises a controller main body, and a main control chip, a compressor driver, a film heater driver, a current detection module, a temperature detection module and a voltage detection module in the controller main body are arranged on a PCB board. The current detection module, the temperature detection module and the voltage detection module are connected with the film heater driver. Power devices in the compressor driver and the film heater driver are plug-in silicon carbide power devices. In the embodiment of the application, the electric compressor controller and the thin film heater controller in the 800V high-voltage platform new energy vehicle thermal management system are integrated into the same controller, so that the number of high-voltage wiring harnesses, electrical connectors of the whole vehicle can be effectively reduced, and the wiring difficulty and material cost of the whole vehicle can be reduced.

Description

Technical Field

[0001] This application relates to the field of controller technology for thermal management systems, and more particularly to a composite controller and thermal management system for plug-in SiC compressors and thin-film heaters. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the 800V high-voltage platform, with its core advantages such as high efficiency, fast charging, and low loss, has become the mainstream technology development direction in the industry. The vehicle thermal management system is a core system ensuring the driving comfort, component operational stability, and overall range of new energy vehicles. The on-board electric compressor and thin-film heater are the core actuators of the thermal management system, respectively undertaking the core functions of vehicle cooling and heating. The thin-film heater can adapt to diverse operating conditions such as cabin heating, pipeline antifreeze, and power component preheating. It needs to dynamically adjust its output power based on operating parameters such as coolant temperature and real-time cavity temperature to achieve precise thermal management control, placing high demands on control accuracy, operating condition adaptability, and operational reliability.

[0003] In the current field of thermal management technology for 800V high-voltage platforms in new energy vehicles, the main solutions still adopt an architecture of separate and independent control of the electric compressor and thin-film heater, and there is no integrated controller product that integrates the functions of compressor drive and thin-film heater drive. The existing technology uses separate controllers for the electric compressor and thin-film heater, which significantly increases the number of high-voltage wiring harnesses and electrical connectors used in the vehicle. This not only increases the difficulty of vehicle wiring and occupies a lot of chassis and engine compartment installation space, but also increases the vehicle assembly process and material costs. Summary of the Invention

[0004] This application provides a composite controller and thermal management system for a plug-in SiC compressor and a thin-film heater, which aims to solve the problem that the electric compressor controller and thin-film heater controller in the existing 800V high-voltage platform new energy vehicle thermal management system are set up separately, which greatly increases the number of high-voltage wiring harnesses and electrical connectors used in the whole vehicle. This not only increases the difficulty of vehicle wiring and occupies a lot of chassis and engine compartment installation space, but also increases the vehicle assembly process and material costs.

[0005] In a first aspect, embodiments of this application provide a composite controller for a plug-in SiC compressor and a thin-film heater, comprising a controller body, a PCB board, a main control chip, a compressor driver, a membrane heater driver, a current detection module, a temperature detection module, and a voltage detection module; the main control chip, the compressor driver, the membrane heater driver, the current detection module, the temperature detection module, and the voltage detection module are all disposed on the PCB board; the compressor driver, the membrane heater driver, the current detection module, the temperature detection module, and the voltage detection module are all connected to the main control chip, and the current detection module, the temperature detection module, and the voltage detection module are all connected to the membrane heater driver; wherein, the compressor driver... The power devices in the membrane heater driver are all plug-in silicon carbide power devices that are plugged into the PCB board. The main control chip is used to acquire the current parameter set collected by the current detection module, the current temperature parameter set collected by the temperature detection module, and the current voltage parameter set collected by the voltage detection module according to the operating parameter acquisition instructions generated according to the preset fault analysis cycle. If it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set. The current processing strategy is determined from the preset vehicle operating condition and processing strategy mapping table according to the current vehicle operating condition, and the current processing strategy is executed accordingly.

[0006] Secondly, embodiments of this application also provide a thermal management system, which includes a composite controller for a plug-in SiC compressor and a thin-film heater as described in the first aspect above, and further includes an on-board electric compressor and a thin-film heater. The compressor driver in the composite controller is connected to the on-board electric compressor, and the membrane heater driver in the composite controller is connected to the thin-film heater. The main control chip in the composite controller is used to acquire the current parameter set collected by the current detection module, the current temperature parameter set collected by the temperature detection module, and the current voltage parameter set collected by the voltage detection module according to the operating parameter acquisition instructions generated according to the preset fault analysis cycle. If it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set. The current processing strategy is determined from the preset vehicle operating condition and processing strategy mapping table according to the current vehicle operating condition, and the current processing strategy is executed accordingly.

[0007] Thirdly, embodiments of this application also provide an intelligent control method for a thermal management system, which is applied to the main control chip in the thermal management system described in the second aspect above; the intelligent control method for the thermal management system includes: In response to the operation parameter acquisition command generated according to the preset fault analysis cycle, the current current parameter set collected by the current detection module, the current temperature parameter set collected by the temperature detection module, and the current voltage parameter set collected by the voltage detection module are obtained. If it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, then the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set. Based on the current vehicle operating conditions, the current processing strategy is determined from the preset vehicle operating conditions and processing strategy mapping table, and the current processing strategy is executed accordingly.

[0008] This application provides a composite controller and thermal management system for a plug-in SiC compressor and a thin-film heater. The controller includes a controller body, a PCB board, a main control chip, a compressor driver, a membrane heater driver, a current detection module, a temperature detection module, and a voltage detection module. The main control chip, the compressor driver, the membrane heater driver, the current detection module, the temperature detection module, and the voltage detection module are all mounted on the PCB board. The compressor driver, the membrane heater driver, the current detection module, the temperature detection module, and the voltage detection module are all connected to the main control chip, and the current detection module, the temperature detection module, and the voltage detection module are all connected to the membrane heater driver. The power devices in the compressor driver and the membrane heater driver are all plug-in silicon carbide power devices that are plugged into the PCB board. This application integrates the electric compressor controller and the thin-film heater controller in the thermal management system of an 800V high-voltage platform new energy vehicle into a single controller, effectively reducing the number of high-voltage wiring harnesses and electrical connectors used in the vehicle, as well as reducing the difficulty of vehicle wiring and material costs. Attached Figure Description

[0009] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0010] Figure 1 An exploded view of the composite controller for a plug-in SiC compressor and a thin-film heater provided in this application embodiment; Figure 2 This is a schematic diagram of a first partial structure of the plug-in SiC compressor and thin-film heater composite controller provided in an embodiment of this application; Figure 3 This is a schematic diagram of a second partial structure of the plug-in SiC compressor and thin-film heater composite controller provided in an embodiment of this application; Figure 4 for Figure 3 A structural diagram showing the addition of the bottom cover plate; Figure 5 A schematic block diagram of the structure of the plug-in SiC compressor and thin-film heater composite controller provided in the embodiments of this application; Figure 6 A schematic block diagram of the structure of the thermal management system provided in the embodiments of this application; Figure 7 A flowchart illustrating the intelligent control method of the thermal management system provided in this application embodiment; Figure 8 A schematic diagram of the first sub-process of the intelligent control method for the thermal management system provided in this application embodiment; Figure 9 This is a schematic diagram of the second sub-process of the intelligent control method for the thermal management system provided in the embodiments of this application. Detailed Implementation

[0011] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0012] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0013] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0014] It should also be further understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0015] Please also refer to Figures 1-5 ,in Figure 1 An exploded view of the composite controller for a plug-in SiC compressor and a thin-film heater provided in this application embodiment; Figure 2 This is a schematic diagram of a first partial structure of the plug-in SiC compressor and thin-film heater composite controller provided in an embodiment of this application; Figure 3 This is a schematic diagram of a second partial structure of the plug-in SiC compressor and thin-film heater composite controller provided in an embodiment of this application; Figure 4 for Figure 3 A structural diagram showing the addition of the bottom cover plate; Figure 5 This is a schematic block diagram of the composite controller for a plug-in SiC compressor and a thin-film heater provided in an embodiment of this application. Figures 1-5 As shown, the plug-in SiC compressor and thin-film heater composite controller includes a controller body 100, a PCB board 110, a main control chip 120, a compressor driver 130, a membrane heater driver 140, a current detection module 150, a temperature detection module 160, and a voltage detection module 170; the main control chip 120, the compressor driver 130, the membrane heater driver 140, the current detection module 150, the temperature detection module 160, and the voltage detection module 170 are all mounted on the PCB board 110; The compressor driver 130, the membrane heater driver 140, the current detection module 150, the temperature detection module 160, and the voltage detection module 170 are all connected to the main control chip 120, and the current detection module 150, the temperature detection module 160, and the voltage detection module 170 are all connected to the membrane heater driver 140; wherein, the power devices in the compressor driver 130 and the membrane heater driver 140 are all plug-in silicon carbide power devices that are plugged into the PCB board 110.

[0016] The main control chip 120 is used to acquire the current parameter set collected by the current detection module 150, the current temperature parameter set collected by the temperature detection module 160, and the current voltage parameter set collected by the voltage detection module 170 according to the operating parameter acquisition instructions generated according to the preset fault analysis cycle. If it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set. The current processing strategy is determined from the preset vehicle operating condition and processing strategy mapping table according to the current vehicle operating condition, and the current processing strategy is executed accordingly.

[0017] In this embodiment, to integrate the electric compressor controller and thin-film heater controller in the 800V high-voltage platform new energy vehicle thermal management system into a single controller, the compressor driver 130 and the thin-film heater driver 140 can be integrated onto the same PCB board 110 of the same controller body 100. The PCB board 110 is located within the controller body 100, and the power devices in both the compressor driver 130 and the thin-film heater driver 140 are plug-in silicon carbide power devices that are plugged into the PCB board 110. This method allows the two drivers to share the same main control chip and, in practice, to share the high-voltage bus, reducing the number of high-voltage wiring harnesses and electrical connectors used in the vehicle, thus reducing the difficulty of vehicle wiring and material costs. When the silicon carbide power devices in the compressor driver 130 and the thin-film heater driver 140 are plug-in silicon carbide power devices, the core step in the installation process is to securely connect the plug-in silicon carbide power devices to the PCB board 110 with screws, and then weld the bent pins to the PCB board 110 for fixation. Of course, before completing the above installation, it is also necessary to apply thermal grease to the corresponding installation area on the PCB board 110 and attach the ceramic substrate to the surface of the thermal grease, as well as other heat dissipation structures or materials.

[0018] The main control chip 120 is used to acquire the current parameter set collected by the current detection module 150, the current temperature parameter set collected by the temperature detection module 160, and the current voltage parameter set collected by the voltage detection module 170 according to the operating parameter acquisition instructions generated according to the preset fault analysis cycle. If it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set. The current processing strategy is determined from the preset vehicle operating condition and processing strategy mapping table according to the current vehicle operating condition, and the current processing strategy is executed accordingly.

[0019] The temperature detection module 160 set on the PCB board 110, as well as a small area near the temperature detection module 160 on the PCB board 110 that is not marked, and the low-voltage auxiliary power supply, flyback circuit, etc., all belong to the low-voltage area. Other areas besides the low-voltage area belong to the high-voltage area. The components in the low-voltage area are connected to the components in the high-voltage area through isolation circuits. The isolation circuits include at least isolation transformers, digital isolation circuits, and analog isolation circuits.

[0020] Furthermore, the PCB board 110 is equipped with a current detection module 150, a temperature detection module 160, and a voltage detection module 170, all of which are connected to the membrane heater driver 140. The current detection module 150 accurately detects the operating current of the membrane heater driver 140; the temperature detection module 160 accurately detects the water temperature and ambient temperature of the mounting cavity at the location of the membrane heater connected to the membrane heater driver 140; and the voltage detection module 170 accurately detects the operating voltage of the membrane heater driver 140. The operating parameters related to the membrane heater driver 140 detected by these three detection circuits can be used to accurately determine the operating conditions of the new energy vehicle thermal management system specifically applied to the plug-in SiC compressor and thin-film heater composite controller. For example, if the current coolant temperature detected by the temperature detection module 160 is within the second preset coolant temperature range (e.g., set to 30~45℃, which can be flexibly adjusted according to the user's actual needs, not limited to the example range) and the current heater cavity temperature is within the first preset heater cavity temperature range (e.g., set to 45~55℃, which can be flexibly adjusted according to the user's actual needs, not limited to the example range), and at the same time it is determined that the current parameter detected by the current detection module 150 is within the preset current range (e.g., set to 3.5~4.5A, which can be flexibly adjusted according to the user's actual needs, not limited to the example range), then it is determined that the poor heat dissipation condition is the current vehicle operating condition. At this time, it is necessary to adjust the current heating power of the membrane heater connected to the membrane heater driver according to the preset power reduction ratio (e.g., any ratio between 1 / 3 and 1 / 2 can be used, which can be flexibly adjusted according to the user's actual needs, not limited to the example value) to perform power limiting protection and achieve effective safety protection for the new energy vehicle thermal management system and the thermal management system.

[0021] In one embodiment, such as Figures 1-5 As shown, the compressor driver 130 includes a W-phase SiC plug-in driver device 131, a V-phase SiC plug-in driver device 132, and a U-phase SiC plug-in driver device 133 arranged in a row on the PCB board 110; the W-phase SiC plug-in driver device 131, the V-phase SiC plug-in driver device 132, and the U-phase SiC plug-in driver device 133 are all connected to the main control chip 120.

[0022] In this embodiment, the three-phase SiC plug-in drive device included in the compressor driver 130 is connected to the W phase, V phase and U phase of the vehicle electric compressor respectively, and the three-phase full-bridge drive circuit is formed by the W phase SiC plug-in drive device 131, the V phase SiC plug-in drive device 132 and the U phase SiC plug-in drive device 133.

[0023] If each of the W-phase SiC plug-in drive device 131, V-phase SiC plug-in drive device 132, and U-phase SiC plug-in drive device 133 includes two SiC plug-in power devices, specifically, the W-phase SiC plug-in drive device 131 includes a first SiC plug-in power device 1311 and a second SiC plug-in power device 1312 (which respectively serve as the upper and lower half-bridge power devices of the W phase in the vehicle electric compressor, and are centrally located in the first column of the compressor driver 130 area on the PCB board 110), and the V-phase SiC plug-in drive device 132 includes a third SiC plug-in power device 1321 and a fourth SiC plug-in power device 1322 (… The upper and lower half-bridge power devices of the V phase in the vehicle-mounted electric compressor are respectively located in the second column of the compressor driver 130 area on the PCB board 110. The U-phase SiC plug-in driver device 133 includes a fifth SiC plug-in power device 1331 and a sixth SiC plug-in power device 1332 (which serve as the upper and lower half-bridge power devices of the U phase in the vehicle-mounted electric compressor, respectively, and are located in the third column of the compressor driver 130 area on the PCB board 110). The pins of the above six SiC plug-in power devices, which have undergone bending treatment, are soldered and fixed to the PCB board 110, and can share the same heat sink for heat dissipation in specific implementations. The compressor driver with the above structure realizes that each phase has a corresponding SiC plug-in driver device for individual driving.

[0024] In one embodiment, such as Figures 1-5 As shown, the membrane heater driver 140 includes an upper tube SiC plug-in driver 141, a first lower tube SiC plug-in driver 142, and a second lower tube SiC plug-in driver 143, all located in the same row on the PCB board 110. The upper tube SiC plug-in driver 141, the first lower tube SiC plug-in driver 142, and the second lower tube SiC plug-in driver 143 are all connected to the main control chip 120.

[0025] In this embodiment, when the membrane heater driver 140 employs the above-described three-channel SiC plug-in driver device, the input terminal of the upper-tube SiC plug-in driver device 141 is connected to the positive terminal of the 800V high-voltage bus, and the first lower-tube SiC plug-in driver device 142 and the second lower-tube SiC plug-in driver device 143 share the input terminal of the upper-tube SiC plug-in driver device 141 connected to the positive terminal of the 800V high-voltage bus. The output terminals of the three SiC plug-in driver devices are each connected to a corresponding thin-film heater, and the other end of the thin-film heater can... The upper SiC plug-in driver 141 includes a seventh SiC plug-in power device 1411, the first lower SiC plug-in driver 142 includes an eighth SiC plug-in power device 1421, and the second lower SiC plug-in driver 143 includes a ninth SiC plug-in power device 1431. The pins of each of the three SiC plug-in power devices have been bent and soldered to the PCB board 110, and they can share the same heat sink for heat dissipation in practical implementation. Each of the three SiC plug-in driver devices is powered by an independent PWM (Pulse Width Modulation) signal output by the main control chip 120, enabling independent adjustment of power and temperature for each channel.

[0026] In one embodiment, such as Figures 1-5 As shown, the current detection module 150, the temperature detection module 160, and the voltage detection module 170 are all connected to the upper tube SiC plug-in driver device 141, the first lower tube SiC plug-in driver device 142, and the second lower tube SiC plug-in driver device 143.

[0027] In this embodiment, when the above three types of detection modules are connected to the upper tube SiC plug-in driver device 141, the first lower tube SiC plug-in driver device 142, and the second lower tube SiC plug-in driver device 143, the detected current parameters, coolant water temperature, and the ambient temperature of the thin film heater mounting cavity are acquired by the main control chip, providing parameter basis for closed-loop power regulation and fault judgment.

[0028] In one embodiment, such as Figures 1-5 As shown, the current detection module 150 includes three current detection branches, which are respectively connected to the upper tube SiC plug-in driver device 141, the first lower tube SiC plug-in driver device 142, and the second lower tube SiC plug-in driver device 143.

[0029] In this embodiment, each heating branch corresponding to the membrane heater driver 140 can be equipped with an independent current detection branch to collect the operating current of each heating branch in real time, and to determine whether there is a fault in the thermal management system of the new energy vehicle by combining the operating current of each heating branch. Moreover, if a single fault occurs in the above three SiC plug-in drive devices, it will not affect the normal operation of other branches. For example, even if the first lower tube SiC plug-in drive device 142 and the second lower tube SiC plug-in drive device 143 both fail, the thin film heater can be shut down through the upper tube SiC plug-in drive device 141 to prevent further damage to the plug-in SiC compressor and thin film heater composite controller.

[0030] As can be seen, the embodiment of implementing this device integrates the electric compressor controller and the thin-film heater controller in the 800V high-voltage platform new energy vehicle thermal management system into the same controller, which can effectively reduce the number of high-voltage wiring harnesses and electrical connectors used in the whole vehicle, as well as reduce the difficulty of vehicle wiring and material costs.

[0031] This application also provides a thermal management system, such as... Figure 6 As shown, the thermal management system includes a plug-in SiC compressor and thin-film heater composite controller 10 as described in any of the preceding embodiments, and also includes an on-board electric compressor 20 and a thin-film heater 30. The compressor driver 130 in the plug-in SiC compressor and thin-film heater composite controller 10 is connected to the on-board electric compressor 20, and the membrane heater driver 140 in the plug-in SiC compressor and thin-film heater composite controller 10 is connected to the thin-film heater 30.

[0032] In this embodiment, please continue to refer to Figures 1-5The main control chip 120 in the plug-in SiC compressor and thin-film heater composite controller 10 is used to acquire the current current parameter set collected by the current detection module 150, the current temperature parameter set collected by the temperature detection module 160, and the current voltage parameter set collected by the voltage detection module 170 according to the operating parameter acquisition instructions generated according to the preset fault analysis cycle. If it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set. The current processing strategy is determined from the preset vehicle operating condition and processing strategy mapping table according to the current vehicle operating condition, and the current processing strategy is executed accordingly. To integrate the electric compressor controller and thin-film heater controller in the thermal management system of an 800V high-voltage platform new energy vehicle into a single controller, a compressor driver 130 and a thin-film heater driver 140 can be integrated onto the same PCB board 110 of the same controller body 100. The power devices in both the compressor driver 130 and the thin-film heater driver 140 are plug-in silicon carbide power devices that are inserted into the PCB board 110. When the silicon carbide power devices in the compressor driver 130 and the thin-film heater driver 140 are plug-in silicon carbide power devices, the core step in the installation process is to secure the plug-in silicon carbide power devices to the PCB board 110 with screws, and then solder the bent leads to the PCB board 110 for fixation. Before completing the above installation, it is necessary to apply thermal grease to the corresponding installation area on the PCB board 110 and attach a ceramic substrate to the surface of the thermal grease, as well as other heat dissipation structures or materials.

[0033] Furthermore, the PCB board 110 is equipped with a current detection module 150, a temperature detection module 160, and a voltage detection module 170, all of which are connected to the membrane heater driver 140. The current detection module 150 accurately detects the operating current of the membrane heater driver 140; the temperature detection module 160 accurately detects the water temperature and ambient temperature of the mounting cavity at the location of the membrane heater connected to the membrane heater driver 140; and the voltage detection module 170 accurately detects the operating voltage of the membrane heater driver 140. The operating parameters related to the membrane heater driver 140 detected by these three detection circuits can be used to accurately determine the operating conditions of the new energy vehicle thermal management system specifically applied to the plug-in SiC compressor and thin-film heater composite controller. For example, if the current coolant temperature detected by the temperature detection module 160 is within the second preset coolant temperature range (e.g., set to 30~45℃, which can be flexibly adjusted according to the user's actual needs, not limited to the example range) and the current heater cavity temperature is within the first preset heater cavity temperature range (e.g., set to 45~55℃, which can be flexibly adjusted according to the user's actual needs, not limited to the example range), and at the same time it is determined that the current parameter detected by the current detection module 150 is within the preset current range (e.g., set to 3.5~4.5A, which can be flexibly adjusted according to the user's actual needs, not limited to the example range), then it is determined that the poor heat dissipation condition is the current vehicle operating condition. At this time, it is necessary to adjust the current heating power of the membrane heater connected to the membrane heater driver according to the preset power reduction ratio (e.g., any ratio between 1 / 3 and 1 / 2 can be used, which can be flexibly adjusted according to the user's actual needs, not limited to the example value) to perform power limiting protection and achieve effective safety protection for the new energy vehicle thermal management system and the thermal management system.

[0034] This application also provides an intelligent control method for a thermal management system, such as... Figure 7 The diagram shown is a flowchart illustrating the intelligent control method of a thermal management system provided in this application embodiment. The intelligent control method of the thermal management system is applied to the main control chip in the thermal management system as described in any of the foregoing embodiments, such as... Figure 7 As shown, the intelligent control method for the thermal management system provided in this application includes steps S110 to S130.

[0035] S110. In response to the operation parameter acquisition command generated according to the preset fault analysis cycle, acquire the current current parameter set acquired by the current detection module, the current temperature parameter set acquired by the temperature detection module, and the current voltage parameter set acquired by the voltage detection module.

[0036] In this embodiment, please refer to again Figures 1-5 The PCB board 110 also includes a current detection module 150, a temperature detection module 160, and a voltage detection module 170, all of which are connected to the membrane heater driver 140. The current detection module 150 accurately detects the operating current of the membrane heater driver 140; the temperature detection module 160 accurately detects the water temperature and ambient temperature of the mounting cavity at the location of the membrane heater connected to the membrane heater driver 140; and the voltage detection module 170 accurately detects the operating voltage of the membrane heater driver 140. The operating parameters related to the membrane heater driver 140 detected by these three detection circuits can be used to accurately determine the operating conditions of the new energy vehicle thermal management system specifically applied to the plug-in SiC compressor and thin-film heater composite controller.

[0037] S120. If it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, then the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set.

[0038] In this embodiment, if the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage range (e.g., set to 350V~800V, which can be flexibly adjusted according to the user's actual needs and is not limited to the example value range), it means that the new energy vehicle thermal management system specifically applied by the plug-in SiC compressor and thin film heater composite controller has no abnormalities in the current operating voltage parameter dimension. The current vehicle operating condition can be further determined based on the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set.

[0039] Of course, if the current voltage value corresponding to the current voltage parameter set does not belong to the preset normal operating voltage value range, for example, if the current voltage value is lower than 350V, then for the undervoltage fault range, it is further determined whether the current voltage value is lower than 300V. If the current voltage value is greater than 300V and less than 350V, it is determined that the warning undervoltage condition is the current vehicle operating condition. If the current voltage value is less than or equal to 300V, it is determined that the shutdown undervoltage condition is the current vehicle operating condition.

[0040] For example, if the current voltage value is higher than 800V, then for the overvoltage fault range, it is further determined whether the current voltage value is higher than 900V. If the current voltage value is greater than 800V and less than 900V, then the overvoltage warning condition is determined as the current vehicle operating condition. If the current voltage value is greater than or equal to 900V, then the shutdown overvoltage condition is determined as the current vehicle operating condition.

[0041] In one embodiment, such as Figure 8 As shown, step S120 includes: S121. If it is determined that the first branch current, the second branch circuit and the third branch current included in the current current parameter set are the same or the current value error between any two does not exceed the preset current threshold, and the current coolant temperature in the current temperature parameter set is in the first preset coolant temperature range and the current heater cavity temperature is in the first preset heater cavity temperature range, then it is determined that the standard operating condition is taken as the current vehicle operating condition. S122. If it is determined that the first branch current, the second branch circuit, and the third branch current included in the current current parameter set are the same or the current value error between any two does not exceed a preset current threshold, and the current coolant temperature in the current temperature parameter set is within the second preset coolant temperature range and the current heater cavity temperature is within the first preset heater cavity temperature range, then it is determined that the poor heat dissipation condition is the current vehicle operating condition; wherein, the upper limit temperature value of the second preset coolant temperature range is less than the lower limit temperature value of the first preset coolant temperature range; S123. If it is determined that there is a pairwise current value error between the first branch current, the second branch circuit, and the third branch current included in the current current parameter set that exceeds the preset current threshold, the water temperature rise rate corresponding to the current temperature parameter set is lower than the first preset water temperature rise rate, and the current heater cavity temperature is not in the first preset heater cavity temperature range, then it is determined that the current vehicle operating condition is that the heating wire in the membrane heater driver is aging.

[0042] In this embodiment, if it is determined that the current of the first branch circuit, the second branch circuit, and the third branch circuit included in the current current parameter set are the same, or the current value error between any two does not exceed the preset current threshold (e.g., the preset current threshold is 0.15A, which can be flexibly adjusted according to the user's actual needs and is not limited to the example value), and the current coolant temperature in the current temperature parameter set is within the first preset coolant temperature range (e.g., set to 65~85℃, which can be flexibly adjusted according to the user's actual needs and is not limited to the example value range), and the current heater cavity temperature is within the first preset heater cavity temperature range (e.g., set to 45~55℃), then it is determined that the standard operating condition is taken as the current vehicle operating condition. The overall temperature stability of the new energy vehicle thermal management system is stable, fault-free, and without power limitations, which can be regarded as the optimal operating condition.

[0043] If it is determined that the current of the first branch circuit, the second branch circuit, and the third branch circuit included in the current current parameter set are the same or the current value error between any two does not exceed the preset current threshold, and the current coolant temperature in the current temperature parameter set is within the second preset coolant temperature range (e.g., set to 30~45℃) and the current heater cavity temperature is within the first preset heater cavity temperature range, then the poor heat dissipation condition is determined as the current vehicle operating condition. The new energy vehicle thermal management system can determine that the coolant temperature rises slowly or the water circuit heat dissipation is abnormal, and can correspondingly execute power limiting protection and report an early warning, while also retaining the heating function of the thin film heater.

[0044] If it is determined that the current value error between any two of the current branches in the current current parameter set exceeds the preset current threshold, the water temperature rise rate corresponding to the current temperature parameter set is lower than the first preset water temperature rise rate (e.g., set to 0.18℃ / s, which can be flexibly adjusted according to the user's actual needs and is not limited to the example value), and the current heater cavity temperature is not within the first preset heater cavity temperature range, then the current vehicle operating condition is determined to be the aging condition of the heating wire in the membrane heater driver. The new energy vehicle thermal management system can determine the aging of a single device in the membrane heater driver and can operate with fault tolerance without reporting voltage or overall machine failure, only triggering a warning of aging of a single device in the membrane heater driver.

[0045] In one embodiment, such as Figure 8 As shown, step S120 further includes: S124. If it is determined that the current of the first branch circuit, the second branch circuit, and the third branch circuit included in the current current parameter set are the same or the current value error between any two does not exceed the preset current threshold, the water temperature rise rate corresponding to the current temperature parameter set is equal to 0℃ / s and the current heater cavity temperature exceeds the upper limit temperature value of the first preset heater cavity temperature range, then it is determined that the dry burning fault condition is the current vehicle operating condition.

[0046] In this embodiment, if it is determined that the first branch current, the second branch circuit, and the third branch current included in the current current parameter set are the same or the current value error between any two does not exceed the preset current threshold, and the water temperature rise rate corresponding to the current temperature parameter set is equal to 0℃ / s and the current heater cavity temperature exceeds the upper limit temperature value of the first preset heater cavity temperature range, then it indicates that there is a mechanical dry burning fault, and it is necessary to immediately cut off the high voltage circuit and automatically lock the machine to avoid the risk of fire of the whole vehicle.

[0047] S130. Determine the current processing strategy from the preset vehicle operating condition and processing strategy mapping table based on the current vehicle operating condition, and execute the current processing strategy accordingly.

[0048] In this embodiment, after the main control chip determines the current vehicle operating condition of the thermal management system, it is necessary to promptly determine the current processing strategy by combining it with the processing strategy mapping table, and execute the current processing strategy accordingly to eliminate the corresponding operational hazards and make the whole vehicle operate more safely.

[0049] In one embodiment, such as Figure 9 As shown, step S130 includes: S131. If it is determined that the current vehicle operating condition is either the standard operating condition or the aging condition of the heating wire in the membrane heater driver, then the corresponding strategy to continue normal operation is obtained from the vehicle operating condition and processing strategy mapping table as the current processing strategy. S132. If it is determined that the current vehicle operating condition is a poor heat dissipation condition, then the corresponding power limiting protection strategy is obtained from the vehicle operating condition and processing strategy mapping table as the current processing strategy; wherein, the power limiting protection strategy is used to adjust the current heating power of the membrane heater connected to the membrane heater driver according to a preset power reduction ratio. S133. If it is determined that the current vehicle operating condition is a dry-burning fault condition, then the shutdown protection strategy is obtained from the vehicle operating condition and processing strategy mapping table as the current processing strategy.

[0050] In this embodiment, if the current vehicle operating condition is determined to be either the standard operating condition or the aging condition of the heating wire in the membrane heater driver, and continuing operation will not pose a risk of vehicle fire or other serious threats to user safety, then the corresponding strategy for maintaining normal operation can be obtained from the vehicle operating condition and processing strategy mapping table as the current processing strategy to maintain the vehicle's continued operation. Of course, for the aging condition of the heating wire in the membrane heater driver, a warning message indicating aging of the heating wire in the membrane heater driver can also be generated and displayed on the vehicle's display screen.

[0051] If the current vehicle operating condition is determined to be a poor heat dissipation condition, and continued operation could lead to a risk of vehicle fire or other serious threats to user safety, a power limiting protection strategy can be implemented. This will adjust the current heating power of the membrane heater connected to the membrane heater driver by a preset power reduction ratio (e.g., any ratio between 1 / 3 and 1 / 2 can be used, and can be flexibly adjusted according to actual user needs, not limited to the example value). This reduces the heating power, preventing further increase in cooling water pressure. Similarly, if the current vehicle operating condition is determined to be a warning undervoltage or warning overvoltage condition, a power limiting protection strategy can also be implemented to adjust the current heating power of the membrane heater connected to the membrane heater driver by a preset power reduction ratio, effectively protecting the entire vehicle.

[0052] If the current vehicle operating condition is determined to be a dry-burning fault, continuing operation would likely lead to a risk of vehicle fire or other serious threats to user safety. Therefore, immediate shutdown is necessary to effectively protect the vehicle's safety. Similarly, if the current vehicle operating condition is determined to be a shutdown undervoltage or shutdown overvoltage condition, immediate shutdown is also required to effectively protect the vehicle's safety.

[0053] In summary, this application provides a composite controller and thermal management system for a plug-in SiC compressor and a thin-film heater. The controller includes a controller body, a PCB board, a main control chip, a compressor driver, a membrane heater driver, a current detection module, a temperature detection module, and a voltage detection module. The main control chip, the compressor driver, the membrane heater driver, the current detection module, the temperature detection module, and the voltage detection module are all mounted on the PCB board. The compressor driver, the membrane heater driver, the current detection module, the temperature detection module, and the voltage detection module are all connected to the main control chip, and the current detection module, the temperature detection module, and the voltage detection module are all connected to the membrane heater driver. The power devices in the compressor driver and the membrane heater driver are all plug-in silicon carbide power devices that are plugged into the PCB board. This application integrates the electric compressor controller and the thin-film heater controller in the thermal management system of an 800V high-voltage platform new energy vehicle into a single controller, effectively reducing the number of high-voltage wiring harnesses and electrical connectors used in the vehicle, as well as reducing the difficulty of vehicle wiring and material costs.

[0054] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this application.

[0055] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative. For example, the division of each unit is merely a logical functional division, and there may be other division methods in actual implementation. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed.

[0056] The steps in the methods of this application embodiment can be adjusted, merged, or deleted according to actual needs. The units in the apparatus of this application embodiment can be merged, divided, or deleted according to actual needs. Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0057] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, a terminal, or a network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application.

[0058] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A composite controller for a plug-in SiC compressor and a thin-film heater, characterized in that, The system includes a controller body, a PCB board, a main control chip, a compressor driver, a membrane heater driver, a current detection module, a temperature detection module, and a voltage detection module. The main control chip, the compressor driver, the membrane heater driver, the current detection module, the temperature detection module, and the voltage detection module are all mounted on the PCB board. The compressor driver, the membrane heater driver, the current detection module, the temperature detection module, and the voltage detection module are all connected to the main control chip, and the current detection module, the temperature detection module, and the voltage detection module are all connected to the membrane heater driver. The power devices in the compressor driver and the membrane heater driver are all... A plug-in silicon carbide power device is used to connect to the PCB board; the main control chip is used to acquire the current current parameter set collected by the current detection module, the current temperature parameter set collected by the temperature detection module, and the current voltage parameter set collected by the voltage detection module according to the operating parameter acquisition instructions generated according to the preset fault analysis cycle; if it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set; the current processing strategy is determined from the preset vehicle operating condition and processing strategy mapping table according to the current vehicle operating condition, and the current processing strategy is executed accordingly.

2. The composite controller for the plug-in SiC compressor and thin-film heater according to claim 1, characterized in that, The compressor driver includes W-phase SiC plug-in driver devices, V-phase SiC plug-in driver devices, and U-phase SiC plug-in driver devices arranged in columns on the PCB board; the W-phase SiC plug-in driver devices, the V-phase SiC plug-in driver devices, and the U-phase SiC plug-in driver devices are all connected to the main control chip.

3. The composite controller for the plug-in SiC compressor and thin-film heater according to claim 1, characterized in that, The membrane heater driver includes an upper tube SiC plug-in driver, a first lower tube SiC plug-in driver, and a second lower tube SiC plug-in driver, all located in the same row on the PCB board. The upper tube SiC plug-in driver, the first lower tube SiC plug-in driver, and the second lower tube SiC plug-in driver are all connected to the main control chip.

4. The composite controller for the plug-in SiC compressor and thin-film heater according to claim 3, characterized in that, The current detection module, the temperature detection module, and the voltage detection module are all connected to the upper-side SiC plug-in driver, the first lower-side SiC plug-in driver, and the second lower-side SiC plug-in driver.

5. The composite controller for the plug-in SiC compressor and thin-film heater according to claim 4, characterized in that, The current detection module includes three current detection branches, which are respectively connected to the upper tube SiC plug-in driver device, the first lower tube SiC plug-in driver device, and the second lower tube SiC plug-in driver device.

6. A thermal management system, characterized in that, The device includes a composite controller for a plug-in SiC compressor and a thin-film heater as described in any one of claims 1-5, and further includes an on-board electric compressor and a thin-film heater, wherein the compressor driver in the composite controller for the plug-in SiC compressor and the thin-film heater is connected to the on-board electric compressor, and the membrane heater driver in the composite controller for the plug-in SiC compressor and the thin-film heater is connected to the thin-film heater. The main control chip in the composite controller of the plug-in SiC compressor and thin film heater is used to acquire the current current parameter set collected by the current detection module, the current temperature parameter set collected by the temperature detection module, and the current voltage parameter set collected by the voltage detection module according to the operating parameter acquisition instructions generated according to the preset fault analysis cycle; if it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set. Based on the current vehicle operating conditions, the current processing strategy is determined from the preset vehicle operating conditions and processing strategy mapping table, and the current processing strategy is executed accordingly.

7. An intelligent control method for a thermal management system, applied to the main control chip in the thermal management system as described in claim 6, characterized in that, The methods include: In response to the operation parameter acquisition command generated according to the preset fault analysis cycle, the current current parameter set collected by the current detection module, the current temperature parameter set collected by the temperature detection module, and the current voltage parameter set collected by the voltage detection module are obtained. If it is determined that the current voltage value corresponding to the current voltage parameter set belongs to the preset normal operating voltage value range, then the current vehicle operating condition is determined according to the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set. Based on the current vehicle operating conditions, the current processing strategy is determined from the preset vehicle operating conditions and processing strategy mapping table, and the current processing strategy is executed accordingly.

8. The method according to claim 7, characterized in that, The determination of the current vehicle operating condition based on the preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set includes: If it is determined that the current of the first branch circuit, the second branch circuit, and the third branch circuit included in the current current parameter set are the same or the current value error between any two does not exceed the preset current threshold, and the current coolant temperature in the current temperature parameter set is within the first preset coolant temperature range and the current heater cavity temperature is within the first preset heater cavity temperature range, then the standard operating condition is determined as the current vehicle operating condition. If it is determined that the current of the first branch circuit, the second branch circuit, and the third branch circuit included in the current current parameter set are the same or the current value error between any two does not exceed a preset current threshold, and the current coolant temperature in the current temperature parameter set is within the second preset coolant temperature range and the current heater cavity temperature is within the first preset heater cavity temperature range, then the poor heat dissipation condition is determined as the current vehicle operating condition; wherein, the upper limit temperature value of the second preset coolant temperature range is less than the lower limit temperature value of the first preset coolant temperature range; If it is determined that there is a pairwise current value error between the first branch current, the second branch circuit, and the third branch current included in the current current parameter set that exceeds the preset current threshold, and the water temperature rise rate corresponding to the current temperature parameter set is lower than the first preset water temperature rise rate and the current heater cavity temperature is not within the first preset heater cavity temperature range, then the current vehicle operating condition is determined to be the condition of heating wire aging in the membrane heater driver.

9. The method according to claim 8, characterized in that, The method of determining the current vehicle operating condition based on a preset vehicle operating condition determination strategy, the current current parameter set, and the current temperature parameter set further includes: If it is determined that the current of the first branch circuit, the second branch circuit, and the third branch circuit included in the current current parameter set are the same or the current value error between any two does not exceed the preset current threshold, and the water temperature rise rate corresponding to the current temperature parameter set is equal to 0℃ / s and the current heater cavity temperature exceeds the upper limit temperature value of the first preset heater cavity temperature range, then the dry burning fault condition is determined as the current vehicle operating condition.

10. The method according to claim 9, characterized in that, The step of determining the current processing strategy from a preset vehicle condition and processing strategy mapping table based on the current vehicle operating condition includes: If it is determined that the current vehicle operating condition is either the standard operating condition or the aging condition of the heating wire in the membrane heater driver, then the corresponding strategy to continue normal operation is obtained from the vehicle operating condition and processing strategy mapping table as the current processing strategy. If the current vehicle operating condition is determined to be a poor heat dissipation condition, then the corresponding power limiting protection strategy is obtained from the vehicle operating condition and processing strategy mapping table as the current processing strategy; wherein, the power limiting protection strategy is used to adjust the current heating power of the membrane heater connected to the membrane heater driver according to a preset power reduction ratio. If the current vehicle operating condition is determined to be a dry-burning fault condition, then the corresponding shutdown protection strategy is obtained from the vehicle operating condition and processing strategy mapping table as the current processing strategy.

Images