Dual-system large-cooling-capacity integrated heat management system for heavy truck

Abstract

A dual-system large-cooling-capacity integrated heat management system for a heavy truck is characterized in that a second compressor is connected with a second condenser, and an outlet of the second condenser is divided into two paths: one path is connected with a gas-liquid separator through a cold core body and is connected to the other end of the second compressor through the gas-liquid separator; the other path is connected with a second cell panel heat exchanger which is connected to the other end of the second compressor through a gas-liquid separator; the system further comprises a first compressor, the first compressor is connected with a first condenser, the first condenser is connected with a first cell panel heat exchanger, and the first cell panel heat exchanger is connected to the other end of the first compressor. After being connected in parallel, the first battery panel heat exchanger and the second battery panel heat exchanger are connected in series in a refrigerating and heating pipeline of the power battery, and a liquid PTC (Positive Temperature Coefficient) and a battery water pump are arranged in the refrigerating and heating pipeline of the power battery. The high-efficiency heat dissipation requirement of the new energy heavy truck is met, the operation is more stable, the energy efficiency is lower, and the reliability is higher.

Description

Technical Field

[0001] This utility model relates to a dual-system large-capacity integrated thermal management system for heavy-duty trucks, which is mainly applied to pure electric heavy-duty trucks, but can also be extended to pure electric mining trucks, light trucks, sanitation vehicles and engineering machinery vehicles, etc. Background Technology

[0002] Pure electric heavy-duty trucks are a relatively new type of new energy vehicle. Based on pure electric vehicles and combined with traditional heavy-duty truck products, they replace the engine with a battery-powered system. Since batteries require a specific temperature range during operation, cooling of the battery pack is necessary. Current pure electric heavy-duty trucks typically use liquid cooling to improve internal temperature uniformity in their battery thermal management systems. This requires a refrigeration cycle, including a compressor, condenser, expansion valve, and evaporator. However, existing single-unit refrigeration systems are limited by installation space, wiring and piping layout, and cost, and cannot meet the increasing heat dissipation demands of new energy heavy-duty trucks.

[0003] like Figure 1 As shown, the high-temperature, high-pressure refrigerant gas from the compressor is cooled by the external heat exchanger, then throttled by the electronic expansion valve before entering the plate heat exchanger. In the plate heat exchanger, the low-temperature refrigerant exchanges heat with the battery-side circulating water. Afterward, the refrigerant gas returns to the compressor via a gas-liquid separator. The low-temperature circulating water, having undergone heat exchange in the plate heat exchanger, is pumped to the battery cold plates for further heat exchange with the battery.

[0004] Existing single-cell battery cooling systems have limited cooling capacity due to the performance constraints of individual components. To meet the increasing heat dissipation demands of new energy heavy-duty trucks, current technology proposes a dual-cooling system approach, where the two systems work together to enhance cooling capacity. This solution offers advantages such as stable operation, high reliability, high energy efficiency, and strong cooling capacity. Therefore, the dual-cooling system approach represents a significant optimization direction for the thermal management of new energy heavy-duty trucks. Utility Model Content

[0005] The technical problem to be solved by this utility model is: how to meet the increasing heat dissipation requirements of new energy heavy trucks, and to provide a dual-system large-capacity integrated thermal management system for heavy trucks.

[0006] To solve the above problems, this utility model is achieved through the following technical solution:

[0007] A dual-system large-capacity integrated thermal management system for heavy-duty trucks includes a second compressor connected to a second condenser. The outlet of the second condenser is divided into two paths: one path is connected to a gas-liquid separator through a cold core, and then connected to the other end of the second compressor through the gas-liquid separator; the other path is connected to a second solar panel heat exchanger, and the second solar panel heat exchanger is connected to the other end of the second compressor through the gas-liquid separator.

[0008] It also includes a first compressor, which is connected to a first condenser, which is connected to a first solar panel heat exchanger, and the first solar panel heat exchanger is connected to the other end of the first compressor.

[0009] Furthermore, the first and second solar panel heat exchangers are connected in parallel and then connected in series in the cooling and heating pipeline of the power battery. Liquid PTC and a battery water pump are installed in the cooling and heating pipeline of the power battery.

[0010] The outlet of the second condenser is connected to the cold core via the first solenoid valve, and to the second solar panel heat exchanger via the second solenoid valve.

[0011] The first condenser is connected to the first solar panel heat exchanger via a thermal expansion valve.

[0012] Both the first and second compressors are variable frequency compressors.

[0013] A first exhaust temperature sensor and a first high-pressure sensor are installed on the exhaust side of the first compressor; a second exhaust temperature sensor and a second high-pressure sensor are installed on the exhaust side of the second compressor; and a low-pressure sensor is installed on the return side of the second compressor.

[0014] The cooling and heating pipelines of the power battery are equipped with outlet water temperature sensors and return water temperature sensors.

[0015] The cooling core is equipped with a blower and is located in an HVAC system, where an interior temperature sensor is installed.

[0016] A first outlet temperature sensor is installed on the pipeline from the cold core to the gas-liquid separator, and a second outlet temperature sensor is installed on the pipeline from the second solar panel heat exchanger to the gas-liquid separator.

[0017] Compared with existing technologies, this utility model has the following advantages: It employs a dual-cooling system for the battery to manage the thermal performance of the entire vehicle system. The main cooling system is responsible for cooling the cab and the battery side, while the auxiliary cooling system cools the battery side. Compared to traditional single-cooling systems, the dual-cooling system not only meets the high-efficiency heat dissipation requirements of new energy heavy-duty trucks, but also operates more stably, with lower energy efficiency and higher reliability. Attached Figure Description

[0018] Figure 1 Here is a circulation diagram of the existing battery cooling unit for new energy heavy-duty trucks;

[0019] Figure 2 This is a schematic diagram of the integrated thermal management system for heavy-duty trucks with dual systems and large cooling capacity. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] In the description of this utility model, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model 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. Therefore, they should not be construed as limitations on this utility model.

[0022] like Figure 1 As shown, a dual-system large-capacity integrated thermal management system for heavy-duty trucks adds an auxiliary cooling system to the existing battery cooling system.

[0023] A dual-system large-capacity integrated thermal management system for heavy-duty trucks includes a second compressor 2, which is connected to a second condenser 4. The outlet of the second condenser 4 is divided into two paths: one path is connected to a gas-liquid separator 7 through a cold core 11, and then connected to the other end of the second compressor 2 through the gas-liquid separator 7; the other path is connected to a second solar panel heat exchanger 6, and the second solar panel heat exchanger 6 is connected to the other end of the second compressor 2 through the gas-liquid separator 7.

[0024] The present invention also includes a first compressor 1, the first compressor 1 is connected to a first condenser 3, the first condenser 3 is connected to a first solar panel heat exchanger 5, and the first solar panel heat exchanger 5 is connected to the other end of the first compressor 1.

[0025] Furthermore, the first solar panel heat exchanger 5 and the second solar panel heat exchanger 6 are connected in parallel and then connected in series in the cooling and heating pipeline of the power battery 8. A liquid PTC 9 and a battery water pump 10 are installed in the cooling and heating pipeline of the power battery 8.

[0026] Furthermore, the outlet of the second condenser 4 is divided into two paths: one path is connected to the cold core 11 through the first solenoid valve 12, and the other path is connected to the second solar panel heat exchanger 6 through the second solenoid valve 13.

[0027] Furthermore, the first condenser 3 is connected to the first solar panel heat exchanger 5 via a thermal expansion valve 14.

[0028] Furthermore, both the first compressor 1 and the second compressor 2 are variable frequency compressors. More preferably, a first exhaust temperature sensor 15 and a first high-pressure sensor 16 are provided on the exhaust side of the first compressor 1; a second exhaust temperature sensor 17 and a second high-pressure sensor 18 are provided on the exhaust side of the second compressor 2; and a low-pressure sensor 19 is provided on the return side of the second compressor 2.

[0029] Furthermore, an outlet water temperature sensor 21 and a return water temperature sensor 22 are installed in the cooling and heating pipeline of the power battery 8.

[0030] Furthermore, the cooling core 11 is equipped with a blower 23, and the cooling core 11 is located in an HVAC system, where an interior temperature sensor is installed.

[0031] Furthermore, a first outlet temperature sensor 24 is installed on the pipeline from the cold core 11 to the gas-liquid separator 7, and a second outlet temperature sensor 25 is installed on the pipeline from the second solar panel heat exchanger 6 to the gas-liquid separator 7.

[0032] The working principle of this utility model is as follows:

[0033] The high-temperature, high-pressure refrigerant gas from the first compressor 1 is cooled by the first condenser 3 (with forced heat dissipation to the environment by a condenser fan), and then throttled by the thermal expansion valve 14 before entering the first solar panel heat exchanger 5. In the first solar panel heat exchanger 5, the low-temperature refrigerant exchanges heat with the circulating water in the battery cold plate. Afterward, the refrigerant gas returns to the compressor via a gas-liquid separator. Under high-load conditions, a second refrigeration system is activated to assist in battery cooling. The two refrigeration systems operate on the same principle. The two streams of low-temperature circulating water, after heat exchange in the two solar panel heat exchangers, merge and are then sent to the power battery 8 by the battery water pump 10 for heat exchange. The circulating water at the drive motor, after heat exchange, is cooled at the battery cooling area and then returned to the drive motor via the motor water pump, thus completing the cycle.

[0034] In this invention, the speeds of the two compressors are adjusted according to the needs of the thermal management system and synchronized with two high-pressure sensors. The two refrigeration systems each use two compressors for pressurization. When the cooling demands of the battery and motor are normal, a single refrigeration system is activated for heat dissipation; when the battery and motor loads are high, both refrigeration systems are activated for heat dissipation. The cooling capacity of the dual refrigeration system fully meets the high heat dissipation requirements of new energy heavy-duty trucks operating under high loads.

[0035] The power battery is equipped with a liquid PTC 9. When there is a need for heating, defrosting, or defogging during the transitional season in winter, the system heating function can be turned on to meet the corresponding needs.

[0036] The above description is only a preferred embodiment of the present utility model. It should be noted that those skilled in the art can make several changes and improvements without departing from the overall concept of the present utility model, and these should also be considered within the protection scope of the present utility model.

Claims

1. A dual-system, high-capacity integrated thermal management system for heavy-duty trucks, characterized in that: Includes a second compressor (2), which is connected to a second condenser (4). The outlet of the second condenser (4) is divided into two paths: one path is connected to a gas-liquid separator (7) through a cold core (11), and is connected to the other end of the second compressor (2) through the gas-liquid separator (7); the other path is connected to a second solar panel heat exchanger (6), and is connected to the other end of the second compressor (2) through the gas-liquid separator (7). It also includes a first compressor (1), the first compressor (1) is connected to a first condenser (3), the first condenser (3) is connected to a first solar panel heat exchanger (5), and the first solar panel heat exchanger (5) is connected to the other end of the first compressor (1); Furthermore, the first solar panel heat exchanger (5) and the second solar panel heat exchanger (6) are connected in parallel and then connected in series in the cooling and heating pipeline of the power battery (8). Liquid PTC (9) and battery water pump (10) are installed in the cooling and heating pipeline of the power battery (8).

2. The heavy-duty truck dual-system large-capacity integrated thermal management system according to claim 1, characterized in that: The outlet of the second condenser (4) is connected to the cold core (11) through the first solenoid valve (12) and to the second solar panel heat exchanger (6) through the second solenoid valve (13).

3. The heavy-duty truck dual-system large-capacity integrated thermal management system according to claim 1, characterized in that: The first condenser (3) is connected to the first solar panel heat exchanger (5) via a thermal expansion valve (14).

4. The heavy-duty truck dual-system large-capacity integrated thermal management system according to claim 1, characterized in that: Both the first compressor (1) and the second compressor (2) are variable frequency compressors.

5. The heavy-duty truck dual-system large-capacity integrated thermal management system according to claim 1, characterized in that: A first exhaust temperature sensor (15) and a first high pressure sensor (16) are provided on the exhaust side of the first compressor (1); a second exhaust temperature sensor (17) and a second high pressure sensor (18) are provided on the exhaust side of the second compressor (2); and a low pressure sensor (19) is provided on the return side of the second compressor (2).

6. The heavy-duty truck dual-system large-capacity integrated thermal management system according to claim 1, characterized in that: A water outlet temperature sensor (21) and a water return temperature sensor (22) are installed in the cooling and heating pipeline of the power battery (8).

7. The heavy-duty truck dual-system large-capacity integrated thermal management system according to claim 1, characterized in that: The cold core (11) is equipped with a blower (23), and the cold core (11) is located in the HVAC, where an in-vehicle temperature sensor is installed.

8. The heavy-duty truck dual-system large-capacity integrated thermal management system according to claim 1, characterized in that: A first outlet temperature sensor (24) is installed on the pipeline from the cold core (11) to the gas-liquid separator (7), and a second outlet temperature sensor (25) is installed on the pipeline from the second solar panel heat exchanger (6) to the gas-liquid separator (7).

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