New energy heavy truck integrated thermal management system

Abstract

The utility model relates to the technical field of heavy truck thermal management systems, and particularly discloses a new energy heavy truck integrated thermal management system which comprises a passenger compartment loop, a battery heating loop and an electric drive cooling loop, and energy distribution between the passenger compartment loop and the battery loop is adjusted through an electronic expansion valve. A four-way valve is arranged between the battery heating loop and the electric drive cooling loop; the passenger compartment loop comprises an HVAC system, the output end of the HVAC system is connected with a liquid-gas separator, the output end of the liquid-gas separator is connected with an electric compressor, and the output end of the electric compressor is connected with a condenser; the battery heating loop comprises a heat exchanger, the output end of the heat exchanger is connected with a four-way valve, the output end of the four-way valve is connected with a first PTC, the output end of the first PTC is connected with a battery, the output end of the battery is connected with a battery water pump, and the output end of the battery water pump is connected to the input end of the heat exchanger. The occupied space of the new energy heavy truck heat management system is reduced, overall truck layout is facilitated, and meanwhile energy consumption and manufacturing cost are reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of thermal management systems for new energy heavy trucks, and in particular to an integrated thermal management system for new energy heavy trucks. Background Art

[0002] With the rapid development of new energy vehicle technology, new energy heavy-duty trucks, as important equipment in the field of logistics and transportation, have a growing market demand. However, most of the current new energy heavy-duty trucks are redesigned from traditional fuel vehicles, while the design of traditional heavy-duty fuel vehicles is mainly based on fuel power, and its thermal management system mainly revolves around engine cooling and cab air conditioning. When this design is directly applied to new energy heavy-duty trucks, although basic temperature control requirements can be met, it can only simply use independent thermal management systems to control the passenger compartment, battery, and electric drive separately, which undoubtedly increases material costs and manufacturing complexity.

[0003] In addition, each of these independent thermal management systems requires independent hardware, control logic, and cooling circuits, which increases the space occupied by the interior layout and the weight of the vehicle. At the same time, it is difficult to provide sufficient installation space and heat dissipation channels within the limited vehicle body space. At the same time, due to the lack of synergy between systems, it may also lead to an increase in subsequent maintenance costs. Moreover, a separate thermal management system cannot achieve efficient use and recovery of energy, resulting in high energy consumption for the entire vehicle, which not only affects the vehicle's range, but also increases operating costs.

[0004] Therefore, in order to address the problems of high energy consumption, large space occupation and high manufacturing cost of the thermal management system of new energy heavy trucks, it is now necessary to provide an integrated thermal management system for new energy heavy trucks. Utility Model Content

[0005] The utility model aims to provide an integrated thermal management system for new energy heavy trucks, which reduces the occupied space of the thermal management system of new energy heavy trucks, facilitates the layout of the entire vehicle, and reduces energy consumption and manufacturing costs.

[0006] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0007] The utility model mainly uses a common compressor for cooling the battery and the passenger compartment, while reducing the number of fans used, and connects to the electric drive cooling circuit through a four-way valve, thereby combining the battery cooling unit with the passenger compartment, reducing the energy consumption of the entire vehicle while reducing the occupied space, and facilitating the layout of the entire vehicle. Specifically, it provides an integrated thermal management system for new energy heavy trucks, including a passenger compartment circuit, a battery heating circuit, and an electric drive cooling circuit. The energy distribution between the passenger compartment circuit and the battery circuit is adjusted by an electronic expansion valve; a four-way valve is provided between the battery heating circuit and the electric drive cooling circuit, and the heat of the electric drive cooling circuit is borrowed through the four-way valve for battery heating;

[0008] The passenger compartment circuit includes an HVAC system, the output end of the HVAC system is connected to a liquid-gas separator, the output end of the liquid-gas separator is connected to an electric compressor, the output end of the electric compressor is connected to a condenser, and the output end of the condenser is connected to the input end of the HVAC system;

[0009] It also includes a battery cooling circuit, the battery cooling circuit includes a heat exchanger, the output end of the heat exchanger is connected to the input end of the liquid-gas separator, and the input end of the heat exchanger is connected to the output end of the condenser;

[0010] The battery heating circuit includes a heat exchanger, the output end of the heat exchanger is connected to a four-way valve, the output end of the four-way valve is connected to a first PTC, the output end of the first PTC is connected to a battery, the output end of the battery is connected to a battery water pump, and the output end of the battery water pump is connected to the input end of the heat exchanger;

[0011] The electric drive cooling circuit includes a low-temperature radiator and an electronic fan connected to the output end of the four-way valve, the output ends of the low-temperature radiator and the electronic fan are connected to a water pump, the output end of the water pump is connected to an electronically controlled motor, and the output end of the electronically controlled motor is connected to the input end of the four-way valve.

[0012] The principles and advantages of this solution are:

[0013] By sharing the battery cooling, electric compressor, condenser and passenger compartment, and using the low-temperature radiator fan of the front electric drive cooling of the vehicle as the electronic fan, the battery cooling unit and the passenger compartment are combined into one and modularly integrated, reducing the overall space occupied by the thermal management system, reducing the number of equipment used, and increasing the system coordination ability and improving thermal management efficiency. At the same time, the electric drive cooling circuit is connected through a four-way valve, and the control system can be adjusted through the electric drive cooling circuit to cool or heat. At different ambient temperatures, the battery can use the front radiator to dissipate heat or use the waste heat of the electronic control motor to heat the battery and the passenger compartment, realizing modular integrated management.

[0014] Using this solution has the following advantages:

[0015] 1. The battery and passenger compartment cooling share the same electric compressor, which greatly improves the compressor utilization rate, reduces the use of connectors, effectively reduces the risk of water ingress, and improves driving safety.

[0016] 2. The battery electronic fan directly uses the low-temperature radiator fan at the front end of the vehicle, which reduces the number of fans used, reduces manufacturing costs, reduces manufacturing complexity, and saves material costs.

[0017] 3. The electric drive cooling circuit is introduced into the battery and passenger compartment. The electric drive cooling circuit controls the system for cooling or heating, making full use of the front low-temperature radiator and electric drive waste heat to reduce the energy consumption of the whole vehicle and improve energy utilization.

[0018] 4. Integrate the battery cooling unit with the passenger compartment to reduce the space occupied by the system and facilitate the layout of the entire vehicle. At the same time, through the modular design structure, it can adapt to different vehicle models by replacing parts, which does not affect the layout of the entire vehicle while improving adaptability and versatility. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic diagram of the structure of an integrated thermal management system for a new energy heavy truck of the utility model;

[0020] Figure 2 This is a schematic diagram of the structure of a passenger compartment circuit and a battery cooling circuit of an integrated thermal management system for a new energy heavy truck of the utility model;

[0021] Figure 3 This is a schematic diagram of the structure of a battery heating circuit of an integrated thermal management system for a new energy heavy truck of the utility model;

[0022] Figure 4 This is a schematic diagram of the structure of an electric drive cooling circuit and an electric drive waste heat battery heating circuit of an integrated thermal management system for a new energy heavy truck of the utility model;

[0023] Figure 5 The utility model is a schematic diagram of the structure of the passenger compartment heating bypass of the integrated thermal management system of a new energy heavy truck. DETAILED DESCRIPTION

[0024] The following is further described in detail through specific implementation methods:

[0025] The reference numerals in the drawings of the specification include: condenser 1, low-temperature radiator and electronic fan 2, water pump 3, electronically controlled motor 4, four-way valve 5, first PTC 6, battery 7, battery water pump 8, heat exchanger 9, second expansion valve 10, liquid-gas separator 11, electric compressor 12, first expansion valve 13, HVAC system 14, water pump 15, second PTC 16, first expansion water tank 17, second expansion water tank 18, third expansion water tank 19.

[0026] The embodiment is basically as shown in the attached Figure 1 As shown: An integrated thermal management system for a new energy heavy truck includes a passenger compartment circuit, a battery heating circuit and an electric drive cooling circuit. An expansion valve (electronic expansion valve) is used to adjust energy distribution between the passenger compartment circuit and the battery circuit. The electric drive cooling circuit is connected to the battery heating circuit through a four-way valve 5.

[0027] Among them, as attached Figure 2As shown, the passenger compartment circuit includes the passenger compartment HVAC (Heating, Ventilation and Air Conditioning) system 14, which is used to control the temperature, humidity and air quality inside the car. The output end of the HVAC system 14 is connected to a liquid-gas separator 11, the output end of the liquid-gas separator 11 is connected to an electric compressor 12, the output end of the electric compressor 12 is connected to a condenser 1, and the output end of the condenser 1 is connected to the input end of the HVAC system 14. The liquid-gas separator 11 separates and preserves the refrigerant liquid, accommodates the refrigerant part of the liquid return in the system, prevents liquid hammer on the electric compressor 12, and prevents excessive refrigerant from diluting the compressor oil.

[0028] Also includes battery cooling circuit, such as attached Figure 2 As shown, the battery cooling circuit includes a heat exchanger 9 , the output end of the heat exchanger 9 is connected to the input end of the liquid-gas separator 11 , and the input end of the heat exchanger 9 is connected to the output end of the condenser 1 .

[0029] A first expansion valve 13 is provided between the output end of the condenser 1 and the input end of the HVAC system 14, and a second expansion valve 10 is provided between the output end of the condenser 1 and the input end of the heat exchanger 9. In this embodiment, the first expansion valve 13 and the second expansion valve 10 are both electronic expansion valves.

[0030] As attached Figure 3 As shown, the battery heating circuit includes a heat exchanger 9 shared with the battery cooling circuit, the output end of the heat exchanger 9 is connected to a four-way valve 5, the output end of the four-way valve 5 is connected to a first PTC 6 (Positive Temperature Coefficient, i.e., thermistor), the output end of the first PTC 6 is connected to a battery 7, the output end of the battery 7 is connected to a battery water pump 8, and the output end of the battery water pump 8 is connected to the input end of the heat exchanger 9. The heat generated by the battery is exchanged out through heat exchange through the shared heat exchanger 9.

[0031] At the same time, the electric drive cooling circuit is also connected through the four-way valve 5, as shown in the attached Figure 4As shown, the electric drive cooling circuit includes a low-temperature radiator and an electronic fan 2 connected to the output end of the four-way valve 5, and the output ends of the low-temperature radiator and the electronic fan 2 are connected to a water pump 3, and the output end of the water pump 3 is connected to an electronically controlled motor 4, and the output end of the electronically controlled motor 4 is connected to the input end of the four-way valve 5. The heat of the electric drive cooling circuit is used to heat the battery to realize the battery heating function. In this embodiment, the low-temperature radiator and the electronic fan 2 directly use the front low-temperature radiator fan, and the low-temperature radiator and the electronic fan are integrated into one, reducing the number of fans used. At the same time, the battery and the passenger compartment are introduced into the electric drive cooling circuit, making full use of the front low-temperature radiator fan and the electric drive waste heat, and reducing the energy consumption of the whole vehicle. In this embodiment, the opening of the four-way valve 5 is adjusted according to the PID to realize the replacement of cooling and heating drives, improve the intelligent control, and reduce the amount of equipment to realize the integrated management system.

[0032] In this embodiment, as shown in the attached Figure 5 As shown, it also includes a passenger compartment heating bypass, which includes an HVAC system 14. A water pump 15 is connected to the output end of the HVAC system 14, and a second PTC 16 is connected to the output end of the water pump 15. The output end of the second PTC 16 is connected to the input end of the HVAC system 14, and the heating of the passenger compartment is controlled through the passenger compartment heating bypass.

[0033] In this embodiment, a water replenishment and degassing circuit is also included, as shown in the attached Figure 1 As shown, the water replenishment and degassing circuit includes a first water replenishment and degassing circuit, a second water replenishment and degassing circuit and a third water replenishment and degassing circuit. The first water replenishment and degassing circuit is connected to the low-temperature radiator and the low-temperature radiator end of the electronic fan 2, and includes a third expansion water tank 19. The input end of the third expansion water tank 19 is connected to the output end of the low-temperature radiator and the front end of the water pump 3, and is used to participate in the water replenishment and degassing operations of the low-temperature radiator and the electronic fan 2.

[0034] The second water replenishment and degassing circuit is connected to the HVAC system 14 end, and includes a first expansion water tank 17 . The first expansion water tank 17 is connected to the input end of the HVAC system 14 and is used to participate in the water replenishment and degassing operations of the HVAC system 14 .

[0035] The third water replenishment and degassing circuit is connected to the end of the battery 7 , and includes a second expansion water tank 18 . The second expansion water tank 18 is connected to the input end of the battery 7 and is used to participate in the water replenishment and degassing operations of the battery 7 .

[0036] The specific implementation process is as follows:

[0037] 1. When the passenger compartment and the battery need to be cooled at the same time

[0038] 1) Refrigerant cooling: In a high temperature environment, adjust the opening of the four-way valve 5 to 0, turn off the heating drive circuit for the battery, and open the second expansion valve 10 and the first expansion valve 13 at the same time. The opening of the second expansion valve 10 and the first expansion valve 13 is adjusted according to PID. The duty cycle of the low-temperature radiator and the electronic fan 2 is based on the outlet temperature of the low-temperature radiator and the electronic fan's cooling water tank to perform fan superposition logic. At the same time, the battery water pump 8 is adjusted according to the temperature difference between the battery inlet and outlet water, and the speed of the electric compressor 12 is adjusted according to the pressure. Heat exchange is performed through the heat exchanger 9 to achieve cooling of the passenger compartment and the battery.

[0039] 2) The battery is cooled by a radiator. In a low-temperature environment, the opening of the four-way valve 5 is adjusted to 100, the electric drive cooling circuit is opened, and the second expansion valve 10 is closed at the same time, and the first expansion valve 13 is opened. The opening of the first expansion valve 13 is adjusted according to PID, and the low-temperature radiator and the electronic fan 2 are turned on. The duty cycle of the electronic fan in the low-temperature radiator and the electronic fan 2 is adjusted according to the system pressure, and the speed of the electric compressor 12 is adjusted according to the temperature and pressure to achieve a cooling effect and reduce energy consumption.

[0040] 2. When the passenger compartment needs to be heated

[0041] When the passenger compartment needs to be heated, the water pump 15 and the second PTC 16 connected to the HVAC system 14 are turned on, and the power is adjusted according to the gear position and the set temperature.

[0042] 3. When the battery needs to be heated

[0043] When the battery needs to be heated during driving, the opening of the four-way valve 5 is adjusted to 100, the electric drive cooling circuit is connected, the water pump 3 and the battery water pump 8 are turned on at the same time, the low-temperature radiator and the electronic fan 2 are turned off, and the battery 7 is heated by the waste heat of the electronic control motor 4 through the electric drive cooling circuit. At the same time, when the waste heat of the electronic control motor 4 is insufficient, the second PTC6 can be turned on, and the power of the second PTC6 can be adjusted according to the temperature difference to meet the heating demand for the battery.

[0044] In this embodiment, by sharing the electric compressor for cooling the battery and the passenger compartment, the utilization rate of the electric compressor is greatly improved, while the amount of compressors used is reduced, the use of connectors is effectively reduced, and the risk of water ingress is reduced. At the same time, the electronic fan directly borrows the fan of the low-temperature radiator at the front end of the vehicle and is integrated into a group of fans, thereby reducing the number of fans used. While ensuring the purpose of the fan, the cost of equipment use is reduced, thereby integrating the battery and the passenger compartment into a thermal management system, improving the overall coordination of the system, reducing the space occupied, reducing the weight of the vehicle, and facilitating the layout of the vehicle. The battery and the passenger compartment introduce an electric drive cooling circuit to make full use of the front low-temperature radiator and the waste heat of the electric drive, improve energy utilization efficiency, and reduce the energy consumption of the vehicle and reduce operating costs. At the same time, through modular design, different models can be adapted by replacing some parts without affecting the use of the overall thermal management system, improving the versatility and adaptability of the thermal management system, and greatly reducing manufacturing costs.

[0045] The above is only an embodiment of the utility model, and the common knowledge such as the known specific technical solutions and / or characteristics in the solution is not described in detail here. It should be pointed out that for those skilled in the art, several deformations and improvements can be made without departing from the technical solution of the utility model, which should also be regarded as the protection scope of the utility model, and these will not affect the effect of the implementation of the utility model and the practicality of the patent. The scope of protection required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.

Claims

1. An integrated thermal management system for a new energy heavy truck, characterized by: It includes a passenger compartment circuit, a battery heating circuit and an electric drive cooling circuit. The energy distribution between the passenger compartment circuit and the battery circuit is adjusted by an expansion valve. A four-way valve is provided between the battery heating circuit and the electric drive cooling circuit. The heat of the electric drive cooling circuit is used for battery heating through the four-way valve. The passenger compartment circuit includes an HVAC system, the output end of the HVAC system is connected to a liquid-gas separator, the output end of the liquid-gas separator is connected to an electric compressor, the output end of the electric compressor is connected to a condenser, and the output end of the condenser is connected to the input end of the HVAC system; It also includes a battery cooling circuit, the battery cooling circuit includes a heat exchanger, the output end of the heat exchanger is connected to the input end of the liquid-gas separator, and the input end of the heat exchanger is connected to the output end of the condenser; The battery heating circuit includes a heat exchanger, the output end of the heat exchanger is connected to a four-way valve, the output end of the four-way valve is connected to a first PTC, the output end of the first PTC is connected to a battery, the output end of the battery is connected to a battery water pump, and the output end of the battery water pump is connected to the input end of the heat exchanger; The electric drive cooling circuit includes a low-temperature radiator and an electronic fan connected to the output end of the four-way valve, the output ends of the low-temperature radiator and the electronic fan are connected to a water pump, the output end of the water pump is connected to an electronically controlled motor, and the output end of the electronically controlled motor is connected to the input end of the four-way valve.

2. The integrated thermal management system for new energy heavy trucks according to claim 1 is characterized by: A first expansion valve is also provided between the output end of the condenser and the input end of the HVAC system; and a second expansion valve is also provided between the output end of the condenser and the input end of the heat exchanger.

3. The integrated thermal management system for new energy heavy trucks according to claim 1 is characterized by: It also includes a passenger compartment heating bypass, which includes an HVAC system, a water pump is connected to the output end of the HVAC system, the output end of the water pump is connected to a second PTC, and the output end of the second PTC is connected to the input end of the HVAC system.

4. The integrated thermal management system for new energy heavy trucks according to claim 1 is characterized by: It also includes a water replenishment and degassing circuit for participating in water replenishment and degassing, and the water replenishment and degassing circuit includes a first water replenishment and degassing circuit, a second water replenishment and degassing circuit and a third water replenishment and degassing circuit; the first water replenishment and degassing circuit is arranged at the low-temperature radiator end, the second water replenishment and degassing circuit is arranged at the HVAC system end, and the third water replenishment and degassing circuit is arranged at the battery end.

5. The integrated thermal management system for new energy heavy trucks according to claim 4 is characterized by: The first water replenishment and degassing circuit includes a third expansion water tank, and an input end of the third expansion water tank is connected to an output end of the low-temperature radiator and a front end of a water pump.

6. The integrated thermal management system for new energy heavy trucks according to claim 4 is characterized by: The second water replenishment and degassing circuit includes a first expansion water tank connected to an input end of the HVAC system.

7. The integrated thermal management system for new energy heavy trucks according to claim 4 is characterized by: The third water replenishment and degassing circuit includes a second expansion water tank, and the second expansion water tank is connected to the input end of the battery.

8. The integrated thermal management system for new energy heavy trucks according to claim 1 is characterized by: The opening degree of the four-way valve is 0-100; the expansion valve adjusts energy distribution according to PID.

9. The integrated thermal management system for new energy heavy trucks according to claim 1 is characterized by: The power adjustment range of the first PTC is 0-8KW.

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