Cooling control method, cooling system and controller

Abstract

The application relates to the technical field of heat dissipation, and discloses a cooling control method, a cooling system and a controller. The cooling system comprises a battery cooling loop and a PCS cooling loop, and a second heat exchange device is arranged on the battery cooling loop. The cooling control method comprises the following steps: acquiring a real-time temperature T1 of the PCS cooling loop; judging whether the real-time temperature T1 of the PCS cooling loop is not less than a first preset temperature T01; if yes, controlling the PCS cooling loop to pass through the second heat exchange device, and the PCS cooling loop and the battery cooling loop exchange heat through the second heat exchange device; and if no, controlling the second heat exchange device to be separated from the PCS cooling loop. The cooling control method, the cooling system and the controller disclosed by the application can solve or improve the problem of energy waste.

Description

Technical Field

[0001] This application relates to the field of heat dissipation technology, specifically to cooling control methods, cooling systems, and controllers. Background Technology

[0002] With the rapid development of renewable energy technologies, energy storage systems are playing an increasingly important role in the power system. Energy storage systems are gradually developing towards larger capacity and higher rate of operation. During operation, the heat generated by these systems also increases, thus placing increasingly higher demands on their thermal management systems.

[0003] In related technologies, single-channel energy storage liquid cooling units can no longer meet the cooling requirements of energy storage systems. Single-loop liquid cooling systems are mainly suitable for small and medium-sized energy storage projects with strict cost control, relatively simple system structure, and low temperature difference requirements, but they have poor cooling effect on energy storage systems.

[0004] With the increasing industry demand for more refined operation and efficiency improvements in energy storage systems, dual-channel liquid cooling systems are gaining popularity. While dual-channel liquid cooling systems improve the cooling effect of energy storage systems, the PCS (converter system) in the battery pack is heat-resistant and can operate normally in environments ranging from 40°C to 50°C. However, the optimal temperature for the battery pack is between 20°C and 30°C. Cooling both simultaneously with 20°C water is essentially "accommodating" the more demanding battery, resulting in overcooling of the PCS and energy waste. Summary of the Invention

[0005] This application provides a cooling control method, a cooling system, and a controller to solve or improve the problem of energy waste.

[0006] In a first aspect, this application provides a cooling control method applicable to a cooling system, the cooling system including a battery cooling circuit and a PCS cooling circuit, the battery cooling circuit being provided with a second heat exchange device, the cooling control method including: Obtain the real-time temperature T1 of the PCS cooling circuit; Determine whether the real-time temperature T1 of the PCS cooling circuit is not less than the first preset temperature T01; If so, the PCS cooling circuit is controlled to pass through the second heat exchange device, and the PCS cooling circuit and the battery cooling circuit exchange heat through the second heat exchange device; If not, the second heat exchange device is controlled to disconnect from the PCS cooling circuit.

[0007] In this implementation, in a traditional dual-loop liquid cooling system, the entire system typically provides a continuous supply of cryogenic coolant to meet the battery's stringent low-temperature requirements (e.g., 20 to 30°C). However, the high-temperature resistance of the PCS (Power Conversion System) allows it to operate normally in environments of 40 to 50°C. Continuously cooling the PCS with cryogenic coolant results in significant energy waste for the refrigeration system.

[0008] When the PCS itself generates little heat and the real-time temperature T1 does not exceed the first preset temperature T01 (the first preset temperature T01 ranges from 40℃ to 50℃), specifically, when the real-time temperature T1 is 35℃, the control system determines that the PCS does not require external forced cooling. At this time, it controls the second heat exchange device to disconnect from the PCS cooling circuit. This means that the PCS cooling circuit operates independently, relying solely on its own circuit for heat dissipation, thus disconnecting heat exchange with the battery cooling circuit and reducing the operating load and energy consumption of the cooling system.

[0009] Conversely, when the PCS operates under high load and its real-time temperature T1 exceeds the first preset temperature T01 (specifically, the first preset temperature T01 is set to 40℃, and the real-time temperature T1 is 45℃), it indicates that its own heat dissipation is insufficient to meet the demand. At this time, the PCS cooling circuit is controlled to flow through the second heat exchange device, utilizing the cooling capacity of the battery cooling circuit to exchange heat and lower the temperature, preventing the PCS from overheating and being damaged. This forms an "on-demand cooling" mode, improving the overall energy efficiency ratio of the system. It should be noted that the energy efficiency ratio is the ratio of energy conversion efficiency; the higher the energy efficiency ratio, the more electrical energy is saved. Furthermore, this control logic structure is simple, highly reliable, and easy to implement through controller programming.

[0010] In an optional embodiment, the cooling system further includes an air-cooling mechanism, and before determining whether the real-time temperature T1 of the PCS cooling circuit is not less than a first preset temperature T01, the system further includes: Determine whether the real-time temperature T1 of the PCS cooling circuit is not less than the second preset temperature T02 and less than the first preset temperature T01; If so, the air-cooling mechanism is controlled to cool the PCS cooling circuit; If not, determine whether the real-time temperature T1 of the PCS cooling circuit is less than the second preset temperature T02; If so, then control the air-cooling mechanism to stop; If not, then the determination is made as to whether the real-time temperature T1 of the PCS cooling circuit is not less than the first preset temperature T01.

[0011] In this embodiment, the temperature rise of the PCS is a gradual process. In the initial stage of temperature rise, the heat load has not yet reached the point where a second heat exchange device needs to be connected to connect the PCS cooling circuit to the battery cooling circuit. However, if left to develop naturally, it will quickly trigger the high-temperature threshold. This solution sets a second preset temperature T02 (the value of the second preset temperature T02 is between 30°C and 40°C) as the air-cooling start point; specifically, the second preset temperature T02 is 35°C. When the real-time temperature T1 is greater than the second preset temperature T02 but less than the first preset temperature T01, the system determines that the PCS has generated considerable heat, but it has not yet reached a dangerous level. At this time, the air-cooling mechanism (such as a fan dissipating heat from the radiator) is activated to cool the PCS cooling circuit. Air cooling consumes far less power than liquid cooling systems that drive compression refrigeration mechanisms and circulating pumps, making it a very economical heat dissipation method. Through this design, the system can keep the PCS temperature within a safe temperature range (below the first preset temperature T01) at a lower energy cost, thereby delaying or even avoiding the high-energy-consuming liquid cooling heat exchange mode (where the PCS cooling circuit passes through a second heat exchange device). It further saves energy and reduces the start-stop frequency and operating time of high-power compression refrigeration mechanisms, which helps to extend the service life of components such as compression refrigeration mechanisms and circulating pumps, and reduce system maintenance costs.

[0012] If the real-time temperature T1 is less than the second preset temperature T02, it means that the PCS cooling circuit does not need to dissipate heat through the air cooling mechanism and can dissipate heat naturally on its own.

[0013] In one optional embodiment, the cooling system further includes a gravity heat pipe and a compression refrigeration mechanism, and the cooling control method further includes: Obtain the real-time temperature T2 of the battery cooling circuit; Determine whether the real-time temperature T2 of the battery cooling circuit is not greater than the third preset temperature T03, wherein the third preset temperature T03 is not greater than the second preset temperature T02; If so, then control the gravity heat pipe to cool the battery cooling circuit; If not, then control the gravity heat pipe and the compression refrigeration mechanism to cool the battery cooling circuit.

[0014] In this embodiment, the optimal operating temperature range of the battery is relatively narrow. Traditional solutions require the compression refrigeration mechanism to operate continuously or frequently to maintain the low temperature, resulting in huge energy consumption. This solution introduces a gravity heat pipe. When the real-time temperature T2 is not greater than the third preset temperature T03, the gravity heat pipe is controlled to operate, thereby cooling the battery cooling circuit. Specifically, the third preset temperature T03 is 30°C.

[0015] Gravity heat pipes utilize the phase change cycle of the working fluid for heat transfer, resulting in high heat transfer efficiency without consuming electrical energy. In this scenario, the heat from the battery cooling circuit can be efficiently dissipated to a lower temperature environment through the gravity heat pipe, achieving zero-energy cooling.

[0016] In one optional implementation, after obtaining the real-time temperature T2 of the battery cooling circuit, the method further includes: Determine whether the first temperature difference ΔT between the real-time temperature T1 of the PCS cooling circuit and the real-time temperature T2 of the battery cooling circuit is not greater than the fourth preset temperature T04. If so, then increase the flow rate of the battery cooling circuit; If not, the flow rate of the battery cooling circuit is kept constant.

[0017] In this embodiment, the temperature difference between the PCS cooling circuit and the battery cooling circuit can be prevented from being too large, thus ensuring the stable operation of the battery system, including the battery and the PCS.

[0018] Secondly, this application also provides a controller suitable for implementing a cooling control method, the controller comprising: The acquisition module is used to acquire the real-time temperature T1 of the PCS cooling circuit; The judgment module determines whether the real-time temperature T1 of the PCS cooling circuit is greater than the first preset temperature T01; The control module is used to control the PCS cooling circuit to pass through the second heat exchange device, and the PCS cooling circuit and the battery cooling circuit exchange heat through the second heat exchange device, or to control the second heat exchange device to disconnect from the PCS cooling circuit.

[0019] Thirdly, this application also provides a cooling system suitable for implementing a cooling control method, the cooling system further comprising: A first liquid cooling plate is adapted to cool the PCS. A first liquid cooling cavity is provided in the first liquid cooling plate and the first liquid cooling cavity is connected to the cooling circuit of the PCS. The second liquid cooling plate is suitable for cooling the battery. The second liquid cooling plate is provided with a second liquid cooling cavity, which is connected to the battery cooling circuit. A water circuit switching device is installed on the PCS cooling circuit. The water circuit switching device can control the PCS cooling circuit to pass through the second heat exchange device or control the second heat exchange device to disconnect from the PCS cooling circuit. The second drive pump is located on the battery cooling circuit.

[0020] In one optional embodiment, the waterway switching device includes: A three-way valve, wherein the first and second valve ports of the three-way valve are connected to the upstream section of the PCS cooling circuit; The cooling branch has one end connected to the downstream section of the PCS cooling circuit and the other end connected to the third valve port of the three-way valve. The portion of the PCS cooling circuit that connects to the first heat exchange inlet of the second heat exchange device is the upstream section, and the portion of the PCS cooling circuit that connects to the first heat exchange outlet of the second heat exchange device is the downstream section.

[0021] In one alternative implementation, it further includes: Refrigeration equipment; The first heat exchange device is connected to the refrigeration device and the battery cooling circuit.

[0022] In one alternative embodiment, the refrigeration device includes a gravity heat pipe and a compression refrigeration mechanism.

[0023] In one alternative implementation, it further includes: A first temperature sensor is installed on the PCS cooling circuit and located at the output port of the first liquid cooling chamber. The first temperature sensor is used to measure the real-time temperature T1 of the PCS cooling circuit. A second temperature sensor is installed on the battery cooling circuit and located at the output port of the second liquid cooling chamber. The second temperature sensor is used to measure the real-time temperature T2 of the battery cooling circuit.

[0024] In one optional embodiment, an air-cooling mechanism is further included, the air-cooling mechanism comprising: A heat dissipation tank is installed on the cooling circuit of the PCS; A fan is used to dissipate heat from the heat dissipation tank. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the specific embodiments of this application or 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 this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0026] Figure 1 This is a schematic flowchart of a cooling control method according to an embodiment of this application; Figure 2 This is a schematic flowchart of another cooling control method according to an embodiment of this application; Figure 3 This is a schematic diagram of a cooling system according to an embodiment of this application.

[0027] Explanation of reference numerals in the attached figures: 1. Battery cooling circuit; 2. PCS cooling circuit; 201. Upstream section; 202. Downstream section; 3. Second heat exchanger; 301. First heat exchange inlet; 302. First heat exchange outlet; 4. Water circuit switching device; 401. Three-way valve; 4011. First valve port; 4012. Second valve port; 4013. Third valve port; 402. Cooling branch; 403. Three-way connector; 4031. First interface; 4032. Second interface; 4033. Third interface; 5. Refrigeration device; 501. Coolant outlet; 502. Coolant return port; 503. Gravity heat pipe; 504. Compression refrigeration mechanism; 6. First heat exchanger; 7. Air-cooled mechanism; 701. Radiator; 702. Fan; 8. First drive pump; 9. Second drive pump. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, 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.

[0029] With the rapid development of renewable energy technologies, energy storage systems are playing an increasingly important role in the power system. Energy storage systems are gradually developing towards larger capacity and higher rate of operation. During operation, the heat generated by these systems also increases, thus placing increasingly higher demands on their thermal management systems.

[0030] In related technologies, single-channel energy storage liquid cooling units can no longer meet the cooling requirements of energy storage systems. Single-loop liquid cooling systems are mainly suitable for small and medium-sized energy storage projects with strict cost control, relatively simple system structure, and low temperature difference requirements, but they have poor cooling effect on energy storage systems.

[0031] With the increasing industry demand for refined operation and efficiency improvements in energy storage systems, dual-channel liquid cooling systems are gaining popularity. While dual-channel liquid cooling systems improve the cooling effect of energy storage systems, the PCS (converter system) in the battery pack is heat-resistant and can operate normally in environments ranging from 40°C to 50°C, whereas the optimal temperature for the battery is between 20°C and 30°C. Cooling both simultaneously with 20°C water is tantamount to "accommodating" the more demanding battery, resulting in overcooling of the PCS and energy waste. This application provides a cooling control method, cooling system, and controller to solve or improve the problem of energy waste.

[0032] The following is combined with Figures 1 to 3This describes an embodiment of the present application.

[0033] According to an embodiment of this application, a cooling control method is provided, applicable to a cooling system. The cooling system includes a battery cooling circuit 1 and a PCS cooling circuit 2. The battery cooling circuit 1 is equipped with a second heat exchange device 3, such as... Figures 1 to 2 As shown, the cooling control method includes:

[0034] Step S101: Obtain the real-time temperature T1 of the PCS cooling circuit 2.

[0035] Specifically, the real-time temperature T1 is measured by a first temperature sensor installed on the PCS cooling circuit 2.

[0036] Step S102: Determine whether the real-time temperature T1 of the PCS cooling circuit 2 is not less than the second preset temperature T02 and less than the first preset temperature T01.

[0037] In some embodiments, the range of the first preset temperature T01 is 40°C to 50°C, and the first preset temperature T01 can be set to 40°C. The range of the second preset temperature T02 is 30°C to 40°C, and the second preset temperature T02 can be set to 35°C.

[0038] Step S103: If so, control the air-cooling mechanism 7 to cool the PCS cooling circuit 2.

[0039] Step S104: If not, determine whether the real-time temperature T1 of the PCS cooling circuit 2 is less than the second preset temperature T02.

[0040] Step S105: If yes, then control the air-cooling mechanism 7 to stop;

[0041] Step S106: If not, then determine whether the real-time temperature T1 of the PCS cooling circuit 2 is not less than the first preset temperature T01.

[0042] Step S107: If yes, then control the PCS cooling circuit 2 to pass through the second heat exchange device 3, and the PCS cooling circuit 2 and the battery cooling circuit 1 exchange heat through the second heat exchange device 3.

[0043] Step S108: If not, control the second heat exchange device 3 to disconnect from the PCS cooling circuit 2.

[0044] Step S109: Obtain the real-time temperature T2 of battery cooling circuit 1.

[0045] Specifically, the real-time temperature T2 is measured by a second temperature sensor installed on the battery cooling circuit 1.

[0046] Step S1010: Determine whether the real-time temperature T2 of the battery cooling circuit 1 is not greater than the third preset temperature T03, wherein the third preset temperature T03 is not greater than the second preset temperature T02.

[0047] Specifically, the range of the third preset temperature T03 is 20℃ to 30℃, and the third preset temperature T03 can be set to 30℃.

[0048] Step S1011: If so, control the gravity heat pipe 503 to cool the battery cooling circuit 1.

[0049] Step S1012: If not, control the gravity heat pipe 503 and the compression refrigeration mechanism 504 to cool the battery cooling circuit 1.

[0050] Step S1013: Determine whether the first temperature difference ΔT between the real-time temperature T1 of the PCS cooling circuit 2 and the real-time temperature T2 of the battery cooling circuit 1 is not greater than the fourth preset temperature T04.

[0051] Specifically, the fourth preset temperature T04 is 10℃ to 20℃, preferably 15℃.

[0052] Step S1014: If so, increase the flow rate of battery cooling circuit 1.

[0053] Specifically, the PCS cooling circuit 2 heats up relatively quickly. The fourth preset temperature T04 is 15℃, and when the temperature difference ΔT between the real-time temperatures T1 and T2 is greater than 15℃, it is necessary to rapidly reduce this temperature difference to ensure that both the battery and the PCS operate at suitable temperatures, thus guaranteeing the stable operation of the battery system, including the battery and PCS. Therefore, by controlling the power of the second drive pump 9, the flow rate of the cooling medium in the battery cooling circuit 1 is increased, thereby cooling the battery.

[0054] Step S1015: If not, then control the flow rate of battery cooling circuit 1 to remain unchanged.

[0055] Specifically, when the temperature difference ΔT between the real-time temperature T1 and T2 is no greater than 15℃, it indicates that the temperature difference between the battery and the PCS is small. In order to save energy, the battery and PCS do not need to be further cooled, the power of the second drive pump 9 does not need to be changed, and the flow rate of the cooling medium in the battery cooling circuit 1 does not need to be increased to cool the battery.

[0056] Specifically, the real-time temperature T1 of PCS cooling circuit 2 is 42℃, the real-time temperature T2 of battery cooling circuit 1 is 28℃, and the battery operating temperature does not exceed 30℃. Therefore, in order to save energy, it is not necessary to add cooling medium in battery cooling circuit 1 to cool the battery.

[0057] According to an embodiment of this application, another aspect provides a controller suitable for implementing a cooling control method. The controller includes an acquisition module, a judgment module, and a control module. The acquisition module is used to acquire the real-time temperature T1 of the PCS cooling circuit 2. The judgment module is used to determine whether the real-time temperature T1 of the PCS cooling circuit 2 is greater than a first preset temperature T01. The control module is used to control the PCS cooling circuit 2 to pass through the second heat exchange device 3, and the PCS cooling circuit 2 and the battery cooling circuit 1 exchange heat through the second heat exchange device 3, or to control the second heat exchange device 3 to disconnect from the PCS cooling circuit 2.

[0058] According to embodiments of this application, another aspect provides a cooling system suitable for implementing a cooling control method, such as... Figure 3 As shown, the cooling system also includes a first liquid cooling plate, a second liquid cooling plate, a water circuit switching device 4, and a second drive pump 9. Specifically, the first liquid cooling plate is suitable for cooling the PCS, and a first liquid cooling cavity is provided inside the first liquid cooling plate, which is connected to the PCS cooling circuit 2; the second liquid cooling plate is suitable for cooling the battery, and a second liquid cooling cavity is provided inside the second liquid cooling plate, which is connected to the battery cooling circuit 1; the water circuit switching device 4 is provided on the PCS cooling circuit 2, and the water circuit switching device 4 can control the PCS cooling circuit 2 to pass through the second heat exchange device 3 or control the second heat exchange device 3 to disconnect from the PCS cooling circuit 2; the second drive pump 9 is provided on the battery cooling circuit 1.

[0059] In this embodiment, such as Figure 3 As shown, the water circuit switching device 4 can dynamically control whether the PCS cooling circuit 2 is coupled with the second heat exchange device 3. This allows the PCS cooling circuit 2 to exchange heat with the battery cooling circuit 1 through the second heat exchange device 3 at the appropriate time.

[0060] It should be noted that the PCS cooling circuit 2 includes a pipeline for conveying a first coolant that flows through the PCS and whose temperature rises, and the first liquid cooling plate is connected to the PCS cooling circuit 2; the battery cooling circuit 1 includes a pipeline for conveying a second coolant that flows through the battery and whose temperature rises, and the second liquid cooling plate is connected to the battery cooling circuit 1; the second heat exchange device 3 is a device for exchanging heat between the first coolant and the second coolant.

[0061] In one embodiment, such as Figure 3As shown, the water circuit switching device 4 includes a three-way valve 401 and a cooling branch 402. The first valve port 4011 and the second valve port 4012 of the three-way valve 401 are connected to the upstream section 201 of the PCS cooling circuit 2. One end of the cooling branch 402 is connected to the downstream section 202 of the PCS cooling circuit 2, and the other end is connected to the third valve port 4013 of the three-way valve 401. The part of the PCS cooling circuit 2 connected to the first heat exchange inlet 301 of the second heat exchange device 3 is the upstream section 201, and the part of the PCS cooling circuit 2 connected to the first heat exchange outlet 302 of the second heat exchange device 3 is the downstream section 202.

[0062] In this embodiment, the first valve port 4011 and the second valve port 4012 of the three-way valve 401 are connected to the upstream section 201 of the PCS cooling circuit 2 (the section of pipeline before the first heat exchange inlet 301), while the third valve port 4013 is directly connected to the downstream section 202 of the PCS cooling circuit 2 (the section of pipeline after the first heat exchange outlet 302) through the cooling branch 402. Thus, by controlling the position of the valve core of the three-way valve 401, two flow path modes can be achieved. In the first flow path, when the valve core is connected to the first valve port 4011 and the third valve port 4013, the first coolant flows through the cooling branch 402, bypassing the second heat exchange device 3, thus exiting the state of the second heat exchange device 3. When the valve core is connected to the first valve port 4011 and the second valve port 4012, the first coolant flows to the inlet of the second heat exchange device 3, and after heat exchange, flows back to the downstream section 202 from the outlet, thus passing through the second heat exchange device 3.

[0063] The water circuit switching device 4 has a simple structure and is easy to maintain. It is compatible with various heat exchangers such as plate heat exchangers and shell-and-tube heat exchangers, which improves the versatility and configurability of the system and provides a flexible thermal management solution for energy storage systems of different power levels.

[0064] In some embodiments, such as Figure 3 As shown, it also includes a three-way connector 403. The first port 4031 and the second port 4032 of the three-way connector 403 are connected to the downstream section 202 of the PCS cooling circuit 2. The third port 4033 of the three-way connector 403 is connected to the third valve port 4013 of the three-way valve 401 through the cooling branch 402.

[0065] In some embodiments, such as Figure 3 As shown, a first drive pump 8 is installed on the PCS cooling circuit 2, and a second drive pump 9 is installed on the battery cooling circuit 1.

[0066] In one embodiment, such as Figure 3 As shown, it also includes a refrigeration device 5 and a first heat exchange device 6, which are connected to the refrigeration device 5 and the battery cooling circuit 1.

[0067] In some embodiments, the refrigeration device 5 is used to cool the second coolant in the battery cooling circuit 1 and deliver it to the second liquid cooling chamber to cool the battery.

[0068] Specifically, the cooling device 5 provides coolant at temperatures far below ambient levels. This coolant exchanges heat with the second coolant in the battery cooling circuit 1 via the first heat exchange device 6 (such as an evaporator), thereby maintaining the battery temperature within its optimal operating range (20°C to 30°C). The cooling device 5 primarily addresses the conditions of high temperatures in summer and high-rate operation of the battery. Integrating the cooling device 5 and the first heat exchange device 6 as standard modules into the system allows for adaptation to various climatic environments, from cold to hot, thus expanding the market applicability of energy storage products (battery packs).

[0069] In one embodiment, such as Figure 3 As shown, the refrigeration device 5 includes a gravity heat pipe 503 and a compression refrigeration mechanism 504.

[0070] The compression refrigeration mechanism 504 is provided with a coolant outlet 501 and a coolant return outlet 502, which are respectively connected to the first heat exchange device 6.

[0071] The gravity heat pipe 503 is connected to the first heat exchange device 6 and is used to supply coolant at a temperature lower than the ambient temperature to the first heat exchange device 6.

[0072] In this embodiment, the gravity heat pipe 503 is a superconducting heat transfer device that operates without power, relying on phase change and gravity. It excels at transferring large amounts of heat under small temperature differences, but its cooling temperature limit is limited by the ambient temperature. The compression refrigeration mechanism 504 is an active heat pump that can provide strong cooling below ambient temperature, but it consumes electrical energy. This solution combines the two and uses control logic for intelligent scheduling. The gravity heat pipe 503 serves as the first line of defense and a backup radiator, handling most of the conventional heat dissipation load; the compression refrigeration mechanism 504 is activated when the heat load exceeds the capacity of the gravity heat pipe 503.

[0073] During low-to-medium load operation, the system relies entirely on the zero-power gravity heat pipe 503 to maintain stable temperature, resulting in low operating costs. When strong cooling is required, the compression refrigeration mechanism 504 activates, while the gravity heat pipe 503 continues to operate, assisting in rapid cooling and reducing the load and operating time of the compression refrigeration mechanism 504. This improves the system's annual energy efficiency ratio and reduces costs, achieving a synergistic effect greater than the sum of its parts.

[0074] In one embodiment, such as Figure 3 As shown, it also includes an air-cooling mechanism 7, which includes a heat sink 701 and a fan 702. The heat sink 701 is installed on the PCS cooling circuit 2; the fan 702 is used to dissipate heat from the heat sink 701.

[0075] In this implementation, such as Figure 3 As shown, the heat sink 701 (air-cooled condenser with heat dissipation fins) is installed on the PCS cooling circuit 2. The fan 702 drives ambient air to flow over the heat dissipation fins, thereby removing heat from the coolant. When the temperature of the PCS return water pipe is at a moderate level (T02 ≤ T1 < T01), the controller activates the air-cooling mechanism 7. Compared to activating the entire liquid cooling heat exchanger, air cooling only consumes a small amount of electrical energy from the fan 702 (typically tens to hundreds of watts), with an energy consumption difference of more than an order of magnitude.

[0076] The air-cooling mechanism 7 enables the PCS cooling circuit 2 to form a subsystem with its own heat dissipation capabilities, reducing reliance on the refrigeration unit 5. Furthermore, air cooling offers a fast response time. In winter or low-temperature environments, intermittent operation of the fan 702 may be sufficient to meet the PCS's heat dissipation needs, resulting in more significant energy savings. The system is simple in structure, low in cost, and easy to maintain.

[0077] The following three examples illustrate... Figures 1 to 3 A comprehensive explanation of all the above-mentioned plans is provided.

[0078] Example 1 This embodiment provides a cooling control method, which is applied to a cooling system including a battery cooling circuit 1 and a PCS cooling circuit 2. The battery cooling circuit 1 and the PCS cooling circuit 2 are connected by a second heat exchange device 3, and the connection is controlled by a water circuit switching device 4.

[0079] Step S101: Obtain the real-time temperature T1 of the PCS cooling circuit 2.

[0080] Step S102: Determine whether the real-time temperature T1 of the PCS cooling circuit 2 is not less than the second preset temperature T02 and less than the first preset temperature T01.

[0081] Step S103: If so, control the air-cooling mechanism 7 to cool the PCS cooling circuit 2.

[0082] Step S104: If not, determine whether the real-time temperature T1 of the PCS cooling circuit 2 is less than the second preset temperature T02.

[0083] Step S105: If yes, then control the air-cooling mechanism 7 to stop; Step S106: If not, then determine whether the real-time temperature T1 of the PCS cooling circuit 2 is not less than the first preset temperature T01.

[0084] Step S107: If yes, then control the PCS cooling circuit 2 to pass through the second heat exchange device 3, and the PCS cooling circuit 2 and the battery cooling circuit 1 exchange heat through the second heat exchange device 3. Step S108: If not, control the second heat exchange device 3 to disconnect from the PCS cooling circuit 2.

[0085] Step S109: Obtain the real-time temperature T2 of battery cooling circuit 1.

[0086] Step S1010: Determine whether the real-time temperature T2 of the battery cooling circuit 1 is not greater than the third preset temperature T03, wherein the third preset temperature T03 is not greater than the second preset temperature T02.

[0087] Step S1011: If so, control the gravity heat pipe 503 to cool the battery cooling circuit 1.

[0088] Step S1012: If not, control the gravity heat pipe 503 and the compression refrigeration mechanism 504 to cool the battery cooling circuit 1.

[0089] Step S1013: Determine whether the first temperature difference ΔT between the real-time temperature T1 of the PCS cooling circuit 2 and the real-time temperature T2 of the battery cooling circuit 1 is not greater than the fourth preset temperature T04.

[0090] Step S1014: If so, increase the flow rate of battery cooling circuit 1.

[0091] Step S1015: If not, then control the flow rate of battery cooling circuit 1 to remain unchanged.

[0092] Example 2 This embodiment provides a controller. The controller can be a standalone control unit or integrated into a BMS. The controller includes: The acquisition module has multiple analog / digital input channels, which are connected to the first temperature sensor and the second temperature sensor respectively, to acquire real-time temperatures T1 and T2.

[0093] The judgment module is usually implemented by a microprocessor (MCU) or digital signal processor (DSP). It internally stores preset parameters: a first preset temperature T01, a second preset temperature T02, a third preset temperature T03, and a fourth preset temperature T04. The judgment module has a pre-set control algorithm program that executes the logical judgment as shown in Example 1.

[0094] The control module has multiple digital output channels, which send control signals to each actuator according to the instructions of the judgment module. For example, one output controls the coil of the three-way valve 401 to switch the water circuit; one output controls the fan 702; and one output controls the start and stop of the compressor refrigeration mechanism 504.

[0095] Example 3 This embodiment provides a cooling system. The PCS cooling circuit 2 includes a first liquid cooling plate, a first drive pump 8, and a heat dissipation tank 701 connected in series. The PCS cooling circuit 2 is filled with a first coolant. The battery cooling circuit 1 includes a second liquid cooling plate (attached to the battery module), a second drive pump 9, and a second heat exchange device 3 connected in series. The battery cooling circuit 1 is filled with a second coolant. The second heat exchanger 3 is a plate heat exchanger. The primary side channel of the plate heat exchanger is connected in series in the battery cooling circuit 1, and the secondary side channel of the plate heat exchanger is connected to the PCS cooling circuit 2. The water circuit switching device 4 includes a three-way valve 401, a cooling branch 402, and a three-way connector 403. The first valve port 4011 and the second valve port 4012 of the three-way valve 401 are connected to the upstream section 201 of the PCS cooling circuit 2, and the third valve port 4013 is connected to the downstream section 202 of the PCS cooling circuit 2 through the cooling branch 402. When the first valve port 4011 and the third valve port 4013 of the three-way valve 401 are connected, the PCS cooling circuit 2 flows through the cooling branch 402 and does not pass through the second heat exchanger 3; when the first valve port 4011 and the second valve port 4012 of the three-way valve 401 are connected, the PCS cooling circuit 2 flows through the secondary side of the second heat exchanger 3.

[0096] The refrigeration device 5 includes a gravity heat pipe 503 and a compression refrigeration mechanism 504.

[0097] The compression refrigeration mechanism 504 includes an evaporator, a compressor, a condenser, and an expansion valve. The cooling capacity generated by the compression refrigeration mechanism 504 is transferred to the battery cooling circuit 1 through the first heat exchange device 6.

[0098] The evaporation section of the gravity heat pipe 503 is embedded in the first heat exchange device 6, while the condensation section is exposed to the air.

[0099] The air-cooling mechanism 7 includes a heat sink 701 and a fan 702 that blows air onto it. The heat sink 701 and the fan 702 are integrated on the PCS cooling circuit 2.

[0100] The controller receives temperature signals and controls the operation of the three-way valve 401, the fan 702, and the compression refrigeration mechanism 504.

[0101] Although embodiments of this application have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of this application, and such modifications and variations all fall within the scope defined by the appended application.

[0102] Furthermore, in the description of this application, the term "comprising" means "including but not limited to". The terms first, second, third, etc., are used merely as illustrative purposes and do not impose numerical requirements or establish an order.

[0103] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0104] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0105] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0106] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

Claims

1. A cooling control method, applicable to a cooling system, characterized in that, The cooling system includes a battery cooling circuit and a PCS cooling circuit. The battery cooling circuit is equipped with a second heat exchange device. The cooling control method includes: Obtain the real-time temperature T1 of the PCS cooling circuit; Determine whether the real-time temperature T1 of the PCS cooling circuit is not less than the first preset temperature T01; If so, the PCS cooling circuit is controlled to pass through the second heat exchange device, and the PCS cooling circuit and the battery cooling circuit exchange heat through the second heat exchange device; If not, then control the second heat exchange device to disconnect from the PCS cooling circuit.

2. The cooling control method according to claim 1, characterized in that, The cooling system further includes an air-cooling mechanism, and before determining whether the real-time temperature T1 of the PCS cooling circuit is not less than the first preset temperature T01, the system further includes: Determine whether the real-time temperature T1 of the PCS cooling circuit is not less than the second preset temperature T02 and less than the first preset temperature T01; If so, the air-cooling mechanism is controlled to cool the PCS cooling circuit; If not, determine whether the real-time temperature T1 of the PCS cooling circuit is less than the second preset temperature T02; If so, then control the air-cooling mechanism to stop; If not, then the determination is made as to whether the real-time temperature T1 of the PCS cooling circuit is not less than the first preset temperature T01.

3. The cooling control method according to claim 2, characterized in that, The cooling system further includes a gravity heat pipe and a compression refrigeration mechanism, and the cooling control method further includes: Obtain the real-time temperature T2 of the battery cooling circuit; Determine whether the real-time temperature T2 of the battery cooling circuit is not greater than the third preset temperature T03, wherein the third preset temperature T03 is not greater than the second preset temperature T02; If so, then control the gravity heat pipe to cool the battery cooling circuit; If not, then control the gravity heat pipe and the compression refrigeration mechanism to cool the battery cooling circuit.

4. The cooling control method according to claim 3, characterized in that, After obtaining the real-time temperature T2 of the battery cooling circuit, the method further includes: Determine whether the first temperature difference ΔT between the real-time temperature T1 of the PCS cooling circuit and the real-time temperature T2 of the battery cooling circuit is not greater than the fourth preset temperature T04. If so, then increase the flow rate of the battery cooling circuit; If not, the flow rate of the battery cooling circuit is kept constant.

5. A controller, characterized in that, Suitable for implementing the cooling control method according to any one of claims 1 to 4, the controller comprises: The acquisition module is used to acquire the real-time temperature T1 of the PCS cooling circuit (2); The judgment module determines whether the real-time temperature T1 of the PCS cooling circuit (2) is greater than the first preset temperature T01; The control module is used to control the PCS cooling circuit (2) to pass through the second heat exchange device (3), the PCS cooling circuit (2) and the battery cooling circuit (1) exchange heat through the second heat exchange device (3), or control the second heat exchange device (3) to disconnect from the PCS cooling circuit (2).

6. A cooling system, characterized in that, Suitable for implementing the cooling control method according to any one of claims 1 to 4, the cooling system further includes: The first liquid cooling plate is suitable for cooling the PCS. The first liquid cooling plate is provided with a first liquid cooling cavity, which is connected to the PCS cooling circuit (2). The second liquid cooling plate is suitable for cooling the battery. The second liquid cooling plate is provided with a second liquid cooling cavity, which is connected to the battery cooling circuit (1). A water circuit switching device (4) is installed on the PCS cooling circuit (2). The water circuit switching device (4) can control the PCS cooling circuit (2) to pass through the second heat exchange device (3) or control the second heat exchange device (3) to disconnect from the PCS cooling circuit (2). The second drive pump (9) is installed on the battery cooling circuit (1).

7. The cooling system according to claim 6, characterized in that, The waterway switching device (4) includes: Three-way valve (401), the first valve port (4011) and the second valve port (4012) of the three-way valve (401) are connected to the upstream section (201) of the PCS cooling circuit (2). The cooling branch (402) has one end connected to the downstream section (202) of the PCS cooling circuit (2) and the other end connected to the third valve port (4013) of the three-way valve (401). The portion of the PCS cooling circuit (2) connected to the first heat exchange inlet (301) of the second heat exchange device (3) is the upstream section (201), and the portion of the PCS cooling circuit (2) connected to the first heat exchange outlet (302) of the second heat exchange device (3) is the downstream section (202).

8. The cooling system according to claim 6, characterized in that, Also includes: Refrigeration unit (5); The first heat exchange device (6) is connected to the refrigeration device (5) and the battery cooling circuit (1).

9. The cooling system according to claim 8, characterized in that, The refrigeration device (5) includes a gravity heat pipe (503) and a compression refrigeration mechanism (504).

10. The cooling system according to claim 6, characterized in that, Also includes: The first temperature sensor is set on the PCS cooling circuit (2) and located at the output port of the first liquid cooling chamber. The first temperature sensor is used to measure the real-time temperature T1 of the PCS cooling circuit (2). The second temperature sensor is installed on the battery cooling circuit (1) and located at the output port of the second liquid cooling chamber. The second temperature sensor is used to measure the real-time temperature T2 of the battery cooling circuit (1).

11. The cooling system according to claim 10, characterized in that, It also includes an air-cooling mechanism (7), which includes: A heat dissipation tank (701) is installed on the PCS cooling circuit (2); A fan (702) is used to dissipate heat from the heat dissipation tank (701).

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