Integrated thermal management system of pure electric truck

Abstract

The utility model relates to an integrated thermal management system of a pure electric truck, and belongs to the technical field of vehicle thermal management. Comprising a refrigeration branch and a heat dissipation branch, the refrigeration branch is connected with a first expansion valve in series and then connected with an HVAC assembly in series to form a cab air conditioner circulation loop, and the refrigeration branch is connected with a second expansion valve in series and then connected with the refrigerant side of a battery cooler in series to form a battery refrigeration circulation loop; the heat dissipation branch is connected in series with a first water pump and a motor heat exchanger and then connected with two ends of a four-way valve to form a motor liquid cooling branch, the other two ends of the four-way valve are further connected in series with a liquid cooling side of a battery cooler, and a second water pump and a battery heat exchanger to form a battery liquid cooling branch; and the four-way valve is used for realizing communication of two ends of the motor liquid cooling branch to form motor liquid cooling self-circulation or communication of two ends of the battery liquid cooling branch to form battery liquid cooling self-circulation or communication of the motor liquid cooling branch and the battery liquid cooling branch to form liquid cooling common circulation. Adjustment of four heat management functions can be achieved by adjusting the four-way valve, and adjustment of the heat management functions is simple.

Description

Technical Field

[0001] The utility model relates to an integrated thermal management system for a pure electric truck, belonging to the technical field of vehicle thermal management. Background Art

[0002] Pure electric trucks have higher horsepower, longer driving range and faster charging speed. Compared with traditional trucks, pure electric trucks can avoid the occupation of gas tanks, gas tank maintenance and the safety hazard of gas leakage; and pure electric trucks cause less pollution to the environment and are more environmentally friendly. With the advancement of battery technology and the reduction of costs, the market share of pure electric trucks will continue to expand and will be an important competitive advantage in the future truck market.

[0003] As the mileage of trucks increases, the battery capacity of pure electric trucks gradually increases. In order to improve battery life and charging and discharging efficiency, the temperature requirements for batteries are getting higher and higher. Not only do batteries need to be cooled in the summer, but they also need to be heated in the winter. Even in low ambient temperatures, the battery temperature will rise sharply due to the large amount of heat generated during the charging process. If the battery heat is not removed in time, it will affect the charging time at best and the battery life at worst. Therefore, as the battery capacity continues to increase, a battery cooling system is needed to maintain a suitable battery temperature at any ambient temperature.

[0004] The existing method is to use the cab air conditioner to keep the temperature in the cab space suitable, and use the motor cooling system to dissipate heat to the motor in time. However, since the cab air conditioner, battery cooling system and motor cooling system of pure electric trucks are independent, each component circulates separately and needs to be heated and cooled. When the battery is cooled at low temperature, turning on the water pump for self-circulation or forcing the compressor to turn on will not only affect the life of the compressor but also increase the power consumption of the vehicle. The independent arrangement of the cab air conditioning refrigeration, battery cooling, motor cooling system and PTC heater components has the following problems: ① The components are arranged in a scattered manner, occupying a large space in the vehicle and having high costs; ② At low ambient temperatures, the battery generates high heat when the vehicle is charged, the compressor cannot start, and the battery cannot reach the target temperature, affecting the charging efficiency and battery life; ③ At extremely low ambient temperatures, due to the low temperature of the battery cell, the battery discharge efficiency is reduced, affecting the vehicle's cruising range and increasing the PTC power consumption.

[0005] The Chinese patent document with the announcement number CN214564757U announced a thermal management system for a pure electric truck, which integrates the battery thermal management unit, the motor thermal management unit and the heating and cooling air conditioning unit. A first regulating valve and a second regulating valve are provided between the heating and cooling air conditioning unit and the motor thermal management unit. Through the first regulating valve and the second regulating valve, the heating and cooling air conditioning unit can use the cooling water after heat exchange in the motor thermal management unit for heating, or use the PTC heater in the heating and cooling air conditioning for heating, so as to switch between the two heating modes of air conditioning and heating. A third regulating valve and a fourth regulating valve are provided between the motor thermal management unit and the battery thermal management unit. Through the adjustment of the third regulating valve and the fourth regulating valve, under high temperature ambient temperature conditions, two motor radiators can simultaneously dissipate heat for the motor, and under low temperature ambient conditions, one motor radiator is used to cool the battery. However, this scheme requires the cooperation of two regulating valves at each adjustment, that is, the adjustment of different thermal management functions is relatively complicated. Utility Model Content

[0006] The utility model aims to provide an integrated thermal management system for a pure electric truck, so as to solve the problem of complex adjustment of different thermal management functions of the existing thermal management system.

[0007] To achieve the above purpose, the solution of the utility model includes:

[0008] The utility model discloses an integrated thermal management system for a pure electric truck, comprising a refrigeration branch and a heat dissipation branch for dissipating heat to an external environment. The refrigeration branch is connected in series with a first expansion valve and then connected in series with an HVAC assembly to form a cab air conditioning circulation loop. The refrigeration branch is connected in series with a second expansion valve and then connected in series with a refrigerant side of a battery cooler to form a battery refrigeration circulation loop. The heat dissipation branch is connected in series with a first water pump and a motor heat exchanger and then connected with two ends of a four-way valve to form a motor liquid cooling branch. The remaining two ends of the four-way valve are also connected in series with the liquid cooling side of the battery cooler, a second water pump and a battery heat exchanger to form a battery liquid cooling branch. The four-way valve is used to realize that the two ends of the motor liquid cooling branch are connected to form a motor liquid cooling self-circulation, or the two ends of the battery liquid cooling branch are connected to form a battery liquid cooling self-circulation, or the motor liquid cooling branch and the battery liquid cooling branch are connected to each other to form a liquid cooling common circulation.

[0009] Furthermore, the motor heat exchanger includes a motor controller heat exchanger and a motor body heat exchanger connected in parallel.

[0010] Furthermore, the refrigeration branch includes a condenser, a compressor and a gas-liquid separator connected in series in sequence, the outlet of the condenser is respectively connected to the first expansion valve and the second expansion valve, and the inlet of the gas-liquid separator is respectively connected to the outlet of the HVAC assembly and the outlet of the refrigerant side of the battery cooler.

[0011] Furthermore, the heat dissipation branch includes a heat sink equipped with a heat dissipation fan.

[0012] Furthermore, both the first expansion valve and the second expansion valve are adjustable expansion valves.

[0013] The utility model discloses a pure electric truck, including an integrated thermal management system, which includes a refrigeration branch and a heat dissipation branch for dissipating heat to an external environment. The refrigeration branch is connected in series with a first expansion valve and then connected in series with an HVAC assembly to form a cab air conditioning circulation loop. The refrigeration branch is connected in series with a second expansion valve and then connected in series with a refrigerant side of a battery cooler to form a battery refrigeration circulation loop. The heat dissipation branch is connected in series with a first water pump and a motor heat exchanger and then connected to two ends of a four-way valve to form a motor liquid cooling branch. The remaining two ends of the four-way valve are also connected in series with the liquid cooling side of the battery cooler, a second water pump and a battery heat exchanger to form a battery liquid cooling branch. The four-way valve is used to realize that the two ends of the motor liquid cooling branch are connected to form a motor liquid cooling self-circulation, or the two ends of the battery liquid cooling branch are connected to form a battery liquid cooling self-circulation, or the motor liquid cooling branch and the battery liquid cooling branch are connected to each other to form a liquid cooling common circulation.

[0014] Furthermore, the motor heat exchanger includes a motor controller heat exchanger and a motor body heat exchanger connected in parallel.

[0015] Furthermore, the refrigeration branch includes a condenser, a compressor and a gas-liquid separator connected in series in sequence, the outlet of the condenser is respectively connected to the first expansion valve and the second expansion valve, and the inlet of the gas-liquid separator is respectively connected to the outlet of the HVAC assembly and the outlet of the refrigerant side of the battery cooler.

[0016] Furthermore, the heat dissipation branch includes a heat sink equipped with a heat dissipation fan.

[0017] Furthermore, both the first expansion valve and the second expansion valve are adjustable expansion valves.

[0018] Beneficial effects of the utility model:

[0019] The utility model is an improved invention, which provides an integrated thermal management system for a pure electric truck, including a refrigeration branch connected in series with a first expansion valve and then connected in series with an HVAC assembly to form a cab air conditioning circulation loop, wherein the cab is cooled only by opening the first expansion valve; a refrigeration branch connected in series with a second expansion valve and then connected in series with the refrigerant side of a battery cooler to form a battery refrigeration circulation loop, wherein the battery is cooled by opening the second expansion valve and a battery liquid cooling branch selected by a four-way valve; the cab and the battery are cooled simultaneously by simultaneously opening the first expansion valve, the second expansion valve and the battery liquid cooling branch selected by the four-way valve; a heat dissipation branch connected in series with a first water pump and a motor heat exchanger and then connected to both ends of the four-way valve to form a motor liquid cooling branch, wherein the four-way valve is connected in series with the first water pump and a motor heat exchanger to form a motor liquid cooling branch. The remaining two ends of the valve are also connected in series with the liquid-cooling side of the battery cooler, the second water pump and the battery heat exchanger to form a battery liquid-cooling branch; the four-way valve is selected to connect the two ends of the motor liquid-cooling branch to form a motor liquid-cooling self-circulation, so that the motor heat exchanger can dissipate heat for the motor, or the four-way valve is selected to connect the two ends of the battery liquid-cooling branch to form a battery liquid-cooling self-circulation, and cooperate with the second expansion valve to dissipate heat for the battery through the battery cooler and the battery heat exchanger, or the four-way valve is selected to connect the motor liquid-cooling branch and the battery liquid-cooling branch to form a liquid-cooling common circulation, so that the motor heat exchanger can dissipate heat or heat the battery; the utility model can adjust the four-way valve to adjust the four thermal management functions, and the adjustment of different thermal management functions is relatively simple. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a working principle diagram of the integrated thermal management system for a pure electric truck according to an embodiment of the utility model.

[0021] Description of reference numerals:

[0022] 1. Compressor; 2. Gas-liquid separator; 3. Heat dissipation module; 4. Condenser; 5. Radiator; 6. Cooling fan; 7. First expansion valve; 8. HVAC assembly; 9. Blower; 10. Cold core; 11. Warm core; 12. Four-way water valve; 13. Second expansion valve; 14. Battery cooler; 15. Battery water pump; 16. First expansion water tank; 17. Second expansion water tank; 18. Motor water pump; 19. Battery heat exchanger; 20. Motor controller heat exchanger; 21. Motor body heat exchanger. DETAILED DESCRIPTION

[0023] In order to solve the problems in the background technology, the utility model provides an integrated thermal management system for a pure electric truck, specifically, only the first expansion valve is opened to cool the cab, the battery is cooled by opening the second expansion valve and the battery liquid cooling branch selected by the four-way valve, and the cab and the battery are cooled at the same time by opening the first expansion valve, the second expansion valve and the battery liquid cooling branch selected by the four-way valve at the same time; the two ends of the motor liquid cooling branch are connected by the four-way valve to form a motor liquid cooling self-circulation, and the motor heat exchanger is used to dissipate heat for the motor, or the two ends of the battery liquid cooling branch are connected by the four-way valve to form a battery liquid cooling self-circulation, and the second expansion valve is used to dissipate heat for the battery through the battery cooler and the battery heat exchanger, or the motor liquid cooling branch and the battery liquid cooling branch are connected by the four-way valve to form a liquid cooling common circulation, and the motor heat exchanger is used to dissipate heat or heat for the battery; the utility model can adjust the four-way valve to adjust the four thermal management functions, and the adjustment of different thermal management functions is relatively simple.

[0024] In order to make the purpose, technical solutions and advantages of the utility model more clear, the utility model is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0025] An embodiment of an integrated thermal management system for a pure electric truck:

[0026] A pure electric truck integrated thermal management system includes a refrigeration branch and a heat dissipation branch for dissipating heat to the external environment. The refrigeration branch is connected in series with a first expansion valve and then connected in series with an HVAC assembly to form a cab air conditioning circulation loop. The refrigeration branch is connected in series with a second expansion valve and then connected in series with the refrigerant side of a battery cooler to form a battery refrigeration circulation loop; the heat dissipation branch is connected in series with a first water pump (motor water pump) and a motor heat exchanger and then connected to the two ends of a four-way valve to form a motor liquid cooling branch. The liquid cooling side of the battery cooler, the second water pump (battery water pump) and the battery heat exchanger are connected in series and then connected to the remaining two ends of the four-way valve to form a battery liquid cooling branch. The four-way valve is used to connect the two ends of the motor liquid cooling branch to realize motor liquid cooling self-circulation or connect the two ends of the battery liquid cooling branch to realize battery liquid cooling self-circulation or connect the motor liquid cooling branch and the battery liquid cooling branch to each other to realize liquid cooling common circulation.

[0027] Specifically, the motor heat exchanger includes a motor controller heat exchanger and a motor body heat exchanger connected in parallel.

[0028] Specifically, the refrigeration branch includes a condenser, a compressor and a gas-liquid separator connected in series in sequence. The outlet of the condenser is respectively connected to the first expansion valve and the second expansion valve, and the inlet of the gas-liquid separator is respectively connected to the outlet of the HVAC (Heating, Ventilation and Air Conditioning) assembly and the outlet on the refrigerant side of the battery cooler.

[0029] Specifically, the heat dissipation branch includes a heat sink equipped with a heat dissipation fan.

[0030] Specifically, both the first expansion valve and the second expansion valve are adjustable expansion valves.

[0031] Specifically, the working principle of the integrated thermal management system of the pure electric truck is as follows: Figure 1 As shown, there are mainly the following working modes:

[0032] ① Air conditioning and refrigeration: The high-temperature and high-pressure refrigerant from the compressor 1 passes through the condenser 4 in the heat dissipation module 3 and enters the first expansion valve 7. After being throttled by the first expansion valve 7, it enters the cold core 10 in the HVAC air conditioning box (HVAC assembly 8), absorbs heat in the cold core 10 and evaporates into low-temperature and low-pressure gas, and then passes through the gas-liquid separator 2 and returns to the compressor 1; the air that has absorbed heat in the cold core 10 is blown into the cab by the blower 9 in the HVAC assembly 8 for air conditioning and refrigeration;

[0033] ② Battery cooling: The high-temperature and high-pressure refrigerant from the compressor 1 passes through the condenser 4 in the heat dissipation module 3 and enters the second expansion valve 13. After being throttled by the second expansion valve 13, it enters the refrigerant side of the battery cooler 14. In the battery cooler 14, it absorbs the heat in the battery water circuit and evaporates into low-temperature and low-pressure gas, and then passes through the gas-liquid separator 2 and returns to the compressor 1; the cold water that absorbs heat on the liquid cooling side of the battery cooler 14 flows into the battery heat exchanger 19 through the battery water pump (second water pump) 15 for battery cooling, thereby ensuring that the battery is within a certain temperature range. At this time, AC and BD in the four-way water valve 12, which serves as a four-way valve, are respectively turned on;

[0034] ③ Air conditioning and battery cooling at the same time: The high-temperature and high-pressure refrigerant coming out of the compressor 1 passes through the condenser 4 in the heat dissipation module 3, is cooled, and then enters the first expansion valve 7 and the second expansion valve 13 respectively. After throttling, it enters the cold core 10 and the battery cooler 14 in the HVAC air conditioning box (HVAC assembly 8), absorbs heat and evaporates into low-temperature and low-pressure gas, and then passes through the gas-liquid separator 2 to return to the compressor 1; the air that has absorbed heat in the cold core 10 is blown into the cab by the blower 9 for air conditioning and cooling; the cold water that has absorbed heat in the battery cooler 14 flows into the battery heat exchanger 19 through the battery water pump 15 for battery cooling, thereby ensuring that the battery is within a certain temperature range. At this time, AC and BD in the four-way water valve 12 are respectively turned on;

[0035] ④ Motor heat dissipation: AC and BD in the four-way water valve 12 are respectively turned on, and the hot water on the motor body heat exchanger 21 side flows through the radiator 5 in the heat dissipation module 3, and dissipates heat to the environment under the action of the cooling fan 6. The cooled water enters the motor controller heat exchanger 20 and the motor body heat exchanger 21 through CA of the four-way water valve 12 and the motor water pump 18 to cool it down, and then the hot water circulates through the radiator 5 again;

[0036] ⑤Battery low-temperature cooling: When the ambient temperature is low, the battery will also release a lot of heat when charging, and the battery needs to be cooled. At this time, the four-way water valve 12 is switched to AD and BC to connect respectively, and the battery water pump 15 and the motor water pump 18 are turned on. The water system on the motor side is used to cool the battery. According to the demand, it is confirmed whether to turn on the cooling fan 6 in the heat dissipation module 3 to meet the battery cooling demand. The water circuit cycle is radiator 5-four-way water valve 12C-B-battery cooler 14-battery water pump 15-battery heat exchanger 19-four-way water valve 12D-A-motor water pump 18-motor controller heat exchanger 20 / motor body heat exchanger 21 and then returns to the radiator 5;

[0037] ⑥ Battery heating (motor waste heat utilization): When the ambient temperature is extremely low and the vehicle starts running, the battery needs to be heated to a certain temperature to ensure maximum power output. At this time, the four-way water valve 12 is switched to AD and BC to connect respectively, and the battery water pump 15 and the motor water pump 18 are turned on to use the hot water on the motor side to heat the battery. The water circuit circulation is motor controller heat exchanger 20 / motor body heat exchanger 21-radiator 5-four-way water valve 12C-B-battery cooler 14-battery water pump 15-battery heat exchanger 19-four-way water valve 12D-A-motor water pump 18-and then returns to the motor body heat exchanger 21 / motor controller heat exchanger 20.

[0038] The first expansion water tank 16 and the second expansion water tank 17 are used to balance the amount of water in the integrated thermal management system of the pure electric truck when the ambient temperature changes.

[0039] The heat dissipation module 3 includes a condenser 4, a radiator 5, and a heat dissipation fan 6 for accelerating the heat dissipation speed of the radiator 5. The heat dissipation fan 6 can also accelerate the condensation speed of the condenser 4.

[0040] The HVAC assembly 8 includes a blower 9 , a cold core 10 and a warm core 11 .

[0041] The utility model realizes multiple functional modes such as air conditioning refrigeration, battery refrigeration, air conditioning + battery refrigeration, motor heat dissipation, battery low-temperature refrigeration and motor waste heat utilization through the high integration of the refrigerant system and the water system, the opening / closing of the expansion valve and the reversing of the four-way water valve, meeting the operating conditions of pure electric trucks. Compared with the system in which the air conditioner / battery / motor are independently controlled and operated, the utility model only adds a four-way water valve to realize the independent operation and joint operation of the battery thermal management system and the electric drive heat dissipation system, realize the low-temperature heat dissipation of the battery and the heating of the battery at extremely low temperatures, and reduce the power consumption of the whole vehicle under the premise of ensuring that the battery operates within the optimal temperature range.

[0042] The utility model highly integrates the cab air conditioning system, battery thermal management system and motor electric drive cooling system; the utility model has the functions of cooling / heating / defrosting the whole vehicle, cooling and heating functions of the battery and heat dissipation function of the motor; the air conditioning system and battery thermal management system of the utility model share a compressor, which can reduce the battery temperature while realizing cabin cooling; the utility model adds a four-way water valve to connect the motor cooling system and the battery cooling system; when the ambient temperature is low, the motor cooling system can be used to cool the battery during the charging process of the whole vehicle to ensure that the battery core temperature is within a suitable range and improve the charging efficiency; the utility model is that when the ambient temperature is particularly low in winter and the battery needs to be heated, the hot water of the electric drive system can be used to increase the battery heat. Among them, the number of motor heat exchangers and the number of battery heat exchangers can be adjusted according to actual needs. Among them, the air conditioning and battery heat dissipation parts can be integrated or separated. Among them, different refrigerants can be used. Among them, the expansion valve can be an electronic expansion valve or a thermal expansion valve; the number of expansion water tanks can be adjusted according to actual needs.

[0043] The integrated thermal management system for pure electric trucks of the utility model includes cab air conditioning, battery cooling and heating, and heat dissipation of motors and electronic control components. The system can not only simultaneously realize the temperature regulation of the air conditioner, battery and motor, but also realize the waste heat utilization of the motor and low ambient temperature cooling of the battery on this basis, effectively matching the needs of various heat dissipation components of the whole vehicle and realizing efficient recycling of heat.

[0044] An embodiment of a pure electric truck:

[0045] A pure electric truck includes an integrated thermal management system, wherein the integrated thermal management system adopts a pure electric truck integrated thermal management system. The pure electric truck integrated thermal management system has been described in detail in an embodiment of a pure electric truck integrated thermal management system, and will not be described in detail here.

Claims

1. An integrated thermal management system for a pure electric truck, comprising a cooling branch and a heat dissipation branch for dissipating heat to the external environment, characterized in that: The refrigeration branch is connected in series with the first expansion valve and then with the HVAC assembly to form a cab air-conditioning circulation loop. The refrigeration branch is connected in series with the second expansion valve and then with the refrigerant side of the battery cooler to form a battery refrigeration circulation loop. The heat dissipation branch is connected in series with the first water pump and the motor heat exchanger and then connected to the two ends of the four-way valve to form a motor liquid cooling branch. The remaining two ends of the four-way valve are also connected in series with the liquid cooling side of the battery cooler, the second water pump and the battery heat exchanger to form a battery liquid cooling branch. The four-way valve is used to achieve the connection of the two ends of the motor liquid cooling branch to form a motor liquid cooling self-circulation, or the connection of the two ends of the battery liquid cooling branch to form a battery liquid cooling self-circulation, or the connection of the motor liquid cooling branch and the battery liquid cooling branch to form a liquid cooling common circulation.

2. The integrated thermal management system for pure electric trucks according to claim 1, characterized in that: The motor heat exchanger comprises a motor controller heat exchanger and a motor body heat exchanger connected in parallel.

3. The integrated thermal management system for pure electric trucks according to claim 1, characterized in that: The refrigeration branch includes a condenser, a compressor and a gas-liquid separator connected in series in sequence. The outlet of the condenser is respectively connected to the first expansion valve and the second expansion valve, and the inlet of the gas-liquid separator is respectively connected to the outlet of the HVAC assembly and the outlet on the refrigerant side of the battery cooler.

4. The integrated thermal management system for pure electric trucks according to claim 1, characterized in that: The heat dissipation branch includes a heat sink equipped with a heat dissipation fan.

5. The integrated thermal management system for pure electric trucks according to claim 1, characterized in that: The first expansion valve and the second expansion valve are both adjustable expansion valves.

Images