Integrated thermal management system for large-tonnage hybrid mine car

Abstract

The utility model relates to an integrated thermal management system for a large-tonnage hybrid mine car. The integrated thermal management system comprises a first refrigerant refrigeration branch and a second refrigerant refrigeration branch which are respectively provided with a compressor and a condenser and are mutually independent, the first refrigerant refrigeration branch, a first expansion valve and an evaporation core body used for refrigerating a cab form a cab refrigerant circulation loop, and the first refrigerant refrigeration branch, a second expansion valve and the refrigerant side of a first heat exchanger serving as an evaporator form an external refrigerant circulation loop; the second refrigerant refrigeration branch, a third expansion valve and the refrigerant side of a second heat exchanger serving as an evaporator form a part refrigerant circulation loop; the liquid cooling side of the first heat exchanger and the liquid cooling side of the second heat exchanger are connected in series and then connected with a part liquid cooling pipeline for cooling one, two or three of a power battery, a driving motor and a motor controller.

Description

TECHNICAL FIELD

[0001] The utility model relates to a kind of large-tonnage hybrid mine car integrated thermal management system, belong to new energy vehicle thermal management technical field. BACKGROUND

[0002] New energy of mine car belongs to an important trend of transformation in recent years, compared with traditional vehicle, new energy mine car is heavy, load is heavy, and mine slope is steep, often need to face extreme working conditions such as heavy load climbing and heavy load downhill, power battery needs to bear large current output and large current kinetic energy recovery conditions, therefore, new energy mine car needs to carry out high-power refrigeration cooling, heating temperature rise to battery and motor in addition to cold and warm control to driving area, so that power battery can always work in suitable temperature range.

[0003] With the development trend of new energy industry, new energy mine car needs a set of efficient, highly integrated, cost-optimized vehicle thermal management system.

[0004] At present, the air conditioning of pure electric and hybrid mine car, battery thermal management, motor and motor controller are independent systems, and are independently controlled. The independent cab air conditioning system and independent battery thermal management system commonly used in current pure electric mine car are as shown in Figure 1 , motor and motor driver adopt forced liquid cooling mode, and cooling fan is shared. And for large-tonnage large-cooling capacity demand, battery thermal management system needs two or more independent battery thermal management units to support the cooling demand of battery. The existing scheme has low integration degree and large unit space occupation, and also has the disadvantages of low component utilization rate and high cost. UTILITY MODEL CONTENT

[0005] The utility model aims at providing a kind of large-tonnage hybrid mine car integrated thermal management system to solve the problem of low component utilization rate of existing scheme.

[0006] To achieve the above-mentioned purpose, the scheme of the utility model includes:

[0007] The technical scheme of a kind of large-tonnage hybrid mine car integrated thermal management system of the utility model, including first refrigerant refrigeration branch and second refrigerant refrigeration branch with compressor and condenser respectively and independent of each other;The first refrigerant refrigeration branch and first expansion valve, evaporative core for refrigerating cab constitute cab refrigerant circulation loop, and also form external refrigerant circulation loop with second expansion valve, the refrigerant side of first heat exchanger as evaporator;The second refrigerant refrigeration branch and third expansion valve, the refrigerant side of second heat exchanger as evaporator form component refrigerant circulation loop;The liquid cooling side of first heat exchanger, second heat exchanger is connected with component liquid cooling pipeline in series, for cooling one, two or three of power battery, drive motor and motor controller.

[0008] Further, the zero-part liquid cooling pipeline comprises a six-way water valve, a battery module heat exchange part, a water pump and a liquid cooling side of a first heat exchanger and a second heat exchanger are connected in series between a valve port E and a valve port F of the six-way water valve; a driving motor heat exchange part and a water pump are connected in series between a valve port A and a valve port D of the six-way water valve; an external radiator for heat exchange with the external environment is connected in series between a valve port B and a valve port C of the six-way water valve.

[0009] Further, an electric control liquid cooling circulation loop is further included, and the electric control liquid cooling circulation loop comprises a water pump, a motor controller heat exchange part and a motor radiator for heat exchange with the external environment connected in series.

[0010] Further, the motor radiator and the external radiator share the same fan.

[0011] Further, a cab liquid cooling pipeline for heating the cab is further included and connected in series, and the cab liquid cooling pipeline comprises a water heating PTC connected in series.

[0012] Further, a first valve port and a second valve port of a three-way valve are further connected in series on the cab liquid cooling pipeline, a second valve port and a third valve port of the three-way valve are further connected in series in an engine liquid cooling circulation pipeline, the cab liquid cooling pipeline is connected with the engine liquid cooling circulation pipeline at the second valve port of the three-way valve; the three-way valve can be switched between the first valve port and the second valve port in communication or the first valve port and the third valve port in communication, so as to realize heating the cab by the water heating PTC or heating the cab by the engine waste heat.

[0013] Further, the first expansion valve and the second expansion valve are electronic expansion valves; and the third expansion valve is a thermal expansion valve.

[0014] Further, the first heat exchanger and the second heat exchanger are plate heat exchangers.

[0015] The utility model discloses the beneficial effects are:

[0016] Compared with the prior art battery, driving air conditioner and motor cooling are independent systems and partially integrated thermal management systems, the integrated thermal management system of the large-tonnage hybrid mine vehicle of the utility model realizes the maximum integration of the whole vehicle thermal management, realizes the maximum commonality of the parts, improves the utilization efficiency of the parts, reduces the procurement and operation cost of the whole vehicle while meeting the cooling efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 It is the system principle drawing of the independent air conditioner + independent battery thermal management scheme of the prior art mine truck;

[0018] Figure 2It is a large tonnage hybrid mine car integrated thermal management system schematic diagram of the utility model;

[0019] Figure 3 It is a large tonnage hybrid mine car integrated thermal management system battery refrigeration mode circulating flow path schematic diagram of the utility model;

[0020] Figure 4 It is a large tonnage hybrid mine car integrated thermal management system cab refrigeration + battery refrigeration + motor heat dissipation mode circulating flow path schematic diagram of the utility model;

[0021] Figure 5 It is a large tonnage hybrid mine car integrated thermal management system cab refrigeration mode circulating flow path schematic diagram of the utility model;

[0022] Figure 6 It is a large tonnage hybrid mine car integrated thermal management system low-temperature battery heat dissipation mode circulating flow path schematic diagram of the utility model;

[0023] Figure 7 It is a large tonnage hybrid mine car integrated thermal management system low-temperature battery heat dissipation + motor heat dissipation mode circulating flow path schematic diagram of the utility model;

[0024] Figure 8 It is a large tonnage hybrid mine car integrated thermal management system cab heating mode circulating flow path schematic diagram of the utility model.

[0025] The figure includes: compressor ①, condenser 1 ②, EXV1 ③, evaporative core ④, EXV2 ⑤, chiller ⑥, gas-liquid separator ⑦, condenser 2 ⑧, TXV ⑨, compressor ⑯, chiller ⑰, warm air core ⑩, water heating PTC ⑪, water pump ⑫, two-way water valve ⑬, three-way water valve ⑭, six-way water valve ⑮. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical scheme and advantages of the utility model more clear and explicit, the utility model is clearly and completely explained in detail below by combining with the drawings and examples.

[0027] The utility model provides a whole vehicle thermal management system that can simultaneously satisfy large tonnage hybrid, battery cooling, heating of pure electric mine car, cab temperature reduction, temperature rise, motor and motor controller heat dissipation, engine heat dissipation and preheating. The system can not only satisfy the cooling / temperature reduction or temperature rise demand of single component or space, but also can simultaneously satisfy the cooling / temperature reduction or temperature rise demand of different components and cab.

[0028] The concept is to combine the original independent cab refrigerant cooling system for cooling the cab with the battery refrigerant system for cooling the battery. The liquid-cooled ends of the heat exchangers of the two refrigerant cooling systems, which act as evaporators and exchange heat with the coolant, are connected in series. This allows the two refrigerant cooling systems to work together to cool the three electric systems of the heavy-duty mining truck. This reduces the capacity of the original refrigerant cooling system used for cooling the three electric systems, lowers costs, and improves system integration.

[0029] Specifically, it can achieve the following: producing low-temperature refrigerant through compressor refrigeration, directly cooling the cab through the refrigerant and indirectly cooling the battery through a plate heat exchanger (chiller); heating the cab through a water-heated core; and cooling the battery through natural cooling when the ambient temperature is low.

[0030] Example 1:

[0031] This embodiment of an integrated thermal management system for a large-tonnage hybrid mining truck includes functions such as battery cooling and heating, cab cooling and heating, motor and motor controller heat dissipation, and engine waste heat utilization.

[0032] like Figure 2 As shown, the integrated thermal management system for a large-tonnage hybrid mining truck in this embodiment includes two major integrated systems: a refrigerant system and a water system.

[0033] The refrigerant system includes: compressor ①; condenser 1 ②; EXV1 ③ (first expansion valve); evaporator core ④; EXV2 ⑤ (second expansion valve); chiller ⑥ (first heat exchanger); gas-liquid separator ⑦; condenser 2 ⑧; TXV ⑨ (third expansion valve); compressor ⑯; chiller ⑰ (second heat exchanger); and refrigerant piping connecting these components. In this embodiment, the first and second expansion valves are electronic expansion valves, and the third expansion valve is a thermostatic expansion valve. The first and second heat exchangers are plate heat exchangers.

[0034] Specifically, compressor ① and condenser 1② are connected in series to form a refrigerant refrigeration branch (first refrigerant refrigeration branch). A gas-liquid separator ⑦ can also be connected in series before the inlet of compressor ① in the refrigerant refrigeration branch. The refrigerant refrigeration branch is connected to the evaporator core ④ of HVAC (heating, ventilation and air conditioning system for the cab) through EXV1③ to form a cab refrigerant circulation loop for cooling the cab. The first refrigerant refrigeration branch is also connected to the refrigerant side of chiiller ⑥ through EXV2⑤ to form an external refrigerant circulation loop for cooling other components such as vehicle battery, motor and electronic control. The refrigerant side of chiiller ⑥ constitutes the evaporator of the external refrigerant circulation loop.

[0035] The refrigerant side of the compressor 2, the condenser 3, the TXV 4 and the chiller 5 forms a component refrigerant circulation loop (electric component) for cooling the vehicle battery, motor and electric control and other components, wherein the compressor 2 and the condenser 3 form a second refrigerant refrigeration branch, and the refrigerant side of the chiller 5 constitutes an evaporator in the component refrigerant circulation loop.

[0036] The water system comprises: a heating core 6; a water heating PTC 7; a water pump 8 (including one engine water pump, two motor water pumps and a water pump connected in series with the battery module); a two-way water valve 9; a three-way water valve 10; a six-way water valve 11, and water pipes connecting these components.

[0037] Specifically, the water system is further divided into an engine liquid cooling pipe and a component liquid cooling pipe (electric component), the engine liquid cooling pipe comprises: a high-temperature radiator and an engine (engine liquid cooling part) to form an engine liquid cooling heat dissipation large circulation, and an expansion tank is further arranged on the engine liquid cooling heat dissipation large circulation. The engine liquid cooling inlet and outlet are connected in series with the two-way water valve 9, the engine water pump 8, the water heating PTC 7 and the heating core 6 of the HVAC (heating, ventilation and air conditioning system for the cab) in sequence. The three-way water valve 10 is further arranged at the engine liquid cooling inlet or outlet, for switching on or off the connection between the engine liquid cooling pipe and the heating core 6.

[0038] The component liquid cooling pipe comprises: through the switching of the connection state between different valve ports of the six-way water valve 11, the switching between different liquid cooling heat dissipation modes of the battery module (power battery), the drive motor and the motor controller is realized. Specifically, the liquid cooling side of the chiller 6 and the liquid cooling side of the chiller 5 are connected in series, and the battery module (liquid cooling heat exchange part for heat exchange with the battery module) and the water pump 8 (water pump connected in series with the battery module) are further connected in series to form a battery module heat dissipation branch, and the two ends of the battery module heat dissipation branch are connected with the valve port F and the valve port E of the six-way water valve 11; between the valve port B and the valve port C of the six-way water valve 11, the motor radiator for heat exchange with the outside air is connected, and the motor radiator further connects the motor controller (liquid cooling heat exchange part for heat exchange with the motor controller) and the motor water pump 8 to form an electric control liquid cooling circulation loop; the drive motor (liquid cooling heat exchange part for heat exchange with the drive motor) is connected in series with the motor water pump 8 to form a motor cooling branch, and in this embodiment, an expansion tank is connected in series on the motor cooling branch, and the two ends of the motor cooling branch are connected with the valve port A and the valve port D of the six-way water valve 11. In the electric control liquid cooling circulation loop, a three-way valve is connected in series before the water inlet of the motor water pump 8 (upstream of the liquid cooling circulation); in the motor cooling branch, a three-way valve is also connected in series before the water inlet of the motor water pump 8 (upstream of the liquid cooling circulation), and the third port of the three-way valve in the electric control liquid cooling circulation loop is connected with the third port of the three-way valve in the motor cooling branch, so as to realize the sharing of the expansion tank in the motor cooling branch by the electric control liquid cooling circulation loop and the motor cooling branch.

[0039] The integrated thermal management system for a large-tonnage hybrid mining truck in this embodiment can achieve the following six working modes.

[0040] 1. Battery-Only Cooling Mode: This mode is for situations where the battery requires cooling. The external refrigerant circulation loop operates to create a refrigerant (coolant) circulation, with the refrigerant circulating in the compressor ①, condenser 1 ②, EXV2 ⑤, chiller ⑥, gas-liquid separator ⑦, and corresponding refrigerant lines. Simultaneously, the component refrigerant circulation loop operates to create a refrigerant circulation, with the refrigerant circulating in the compressor ⑯, condenser 2 ⑧, TXV ⑨, chiller ⑰, and corresponding refrigerant lines. The valve ports F and E of the six-way water valve ⑮ are connected internally, forming a coolant circulation between the battery module and the liquid-cooled side of chiller ⑥ and chiller ⑰ via the water pump ⑫. The chiller exchanges heat through its internal liquid-cooled water lines and refrigerant lines, thus achieving battery cooling. The specific circulation path is as follows: Figure 3 As shown.

[0041] As another implementation method, when the cooling demand of the battery module is not high, only one of the external refrigerant circulation loop and the component refrigerant circulation loop needs to be started to work, so as to achieve the purpose of energy saving.

[0042] 2. Cab Cooling + Battery Cooling + Motor Heat Dissipation Mode: This mode is for situations where the cab requires cooling, and both the battery and motor require cooling. The external refrigerant circulation loop and the cab refrigerant circulation loop operate simultaneously to form a refrigerant circulation. The refrigerant exits from compressor ① and condenser 1②, then passes through EXV2⑤, chiller ⑥, and gas-liquid separator ⑦, and then through EXV1③, evaporator core ④, and gas-liquid separator ⑦ before returning to compressor ①. Simultaneously, the component refrigerant circulation loops operate to form a refrigerant circulation, with the refrigerant circulating in compressor ⑯, condenser 2⑧, TXV⑨, chiller ⑰, and the corresponding refrigerant piping. The cab refrigerant circulation loop operates, with the evaporator core ④ acting as an evaporator to cool the cab via HVAC. The external refrigerant circulation loop operates, with the refrigerant side of the chiller ⑥ acting as an evaporator to absorb heat from the liquid-cooled side of the chiller ⑥. The distribution of cooling intensity between the cab and external refrigerant circulation loops can be adjusted by the opening of EXV1③ and EXV2⑤. The component refrigerant circulation loop operates, with the refrigerant side of the chiller ⑰ acting as an evaporator to absorb heat from the liquid-cooled side of the chiller ⑰. The six-way water valve ⑮'s ports E and F are open, forming a coolant circulation between the battery module and the liquid-cooled sides of the chiller ⑰ and chiller ⑥ via the water pump ⑫. Simultaneously, the cooling capacity of the chillers ⑰ and ⑥ is used to cool and lower the battery module. The valve ports A and B, and valve ports C and D of the six-way water valve ⑮ are also connected inside the six-way water valve ⑮. The motor cooling branch is connected to the motor radiator. A liquid cooling cycle is formed between the drive motor and the motor radiator through the motor water pump ⑫ in the motor cooling branch. The condenser fan of the motor radiator runs, carrying the heat of the drive motor to the outside of the vehicle for dissipation, thereby achieving the purpose of using the low temperature of the outside environment to cool the drive motor. At the same time, a liquid cooling cycle is formed between the motor controller and the motor radiator through the motor water pump ⑫ in the electronic control liquid cooling cycle, thereby achieving the purpose of using the low temperature of the outside environment to cool the motor controller. The specific circulation path is as follows: Figure 4 As shown.

[0043] As another implementation method, in cases where the cooling demand of the battery module is not large but the cooling demand of the cab is large, only the refrigerant circulation loop in the cab and the refrigerant circulation loop in the components can be used. All the refrigerant passing through the compressor ① and condenser 1② passes through EXV1③ and undergoes a phase change in the evaporator core ④, absorbing heat, and is used entirely for cooling the cab. The external refrigerant circulation loop does not work. The liquid cooling circulation in the battery module heat dissipation branch only uses the cooling capacity of the component refrigerant circulation loop at the chiller 10 to cool and lower the battery module.

[0044] 3. Independent Cab Cooling Mode: This mode is for situations where the cab requires cooling. The cab refrigerant circulation loop operates, with the refrigerant circulating through the compressor ①, condenser 1 ②, EXV1 ③, evaporator core ④, gas-liquid separator ⑦, and corresponding refrigerant piping. The blower in the HVAC system blows the cooling energy generated by the low-temperature refrigerant phase change through the evaporator core ④ into the cab, thereby achieving the purpose of cooling the cab. The specific circulation path is as follows: Figure 5 As shown.

[0045] 4. Low-Temperature Battery Cooling Mode: The battery requires heat dissipation. When the external ambient temperature is low, the refrigerant circulation stops to achieve energy saving. The valve ports E and B, and C and F of the six-way water valve ⑮ are connected inside the valve ⑮. The battery module cooling branch is connected to the motor radiator. A liquid cooling circulation is formed between the battery module and the motor radiator via the water pump ⑫. The condenser fan of the motor radiator operates, carrying the battery heat outside the vehicle for dissipation, thus utilizing the low external temperature to cool the battery. The specific circulation path is as follows: Figure 6 As shown.

[0046] 5. Low-Temperature Battery Cooling + Motor Cooling Mode: The battery and motor require heat dissipation. When the external ambient temperature is low, the refrigerant circulation stops working to achieve energy saving. The six-way water valve ⑮ has ports E and A connected to port B, and port C connected to ports D and F. Both the motor cooling branch and the battery module cooling branch are connected to the motor radiator. A liquid cooling cycle is formed between the battery module and the motor radiator via water pump ⑫. A liquid cooling cycle is also formed between the drive motor and the motor radiator via the motor water pump ⑫ in the motor cooling branch. The condenser fan of the motor radiator operates, carrying the heat from the battery module and drive motor outside the vehicle for dissipation. Simultaneously, a liquid cooling cycle is formed between the motor controller and the motor radiator via the motor water pump ⑫ in the electronic control liquid cooling cycle, thus utilizing the low external temperature to cool the motor controller. The specific circulation path is as follows: Figure 7 As shown.

[0047] 6. Cab Heating Mode: This mode is for situations where the cab requires heating. If the engine coolant temperature is higher than the set temperature, the three-way water valve 14 switches so that valve port a and valve port b are connected internally. Driven by the engine water pump 12, a large coolant circulation is formed between the HVAC heater core 10 and the engine. At this time, the water-cooled PTC 11 does not work, utilizing engine waste heat to heat the cab. If the hybrid system engine is not working or the engine coolant temperature is lower than the set temperature, the three-way water valve 14 switches so that valve port a and valve port c are connected internally. At this time, the water-cooled PTC 11 heats the coolant, forming a small coolant circulation between the heater core 10 and the water-cooled PTC 11, utilizing the water-cooled PTC 11 to heat the cab. The specific circulation path is as follows: Figure 8 As shown.

[0048] This utility model discloses an integrated thermal management system for large-tonnage hybrid mining trucks. Compared with the current mainstream mining truck independent air conditioning and independent battery thermal management systems, it has significant advantages in terms of overall vehicle space occupation, reduces costs, and has a high utilization rate of heat dissipation system components.

Claims

1. An integrated thermal management system for large-tonnage hybrid mining trucks, characterized in that, It includes a first refrigerant refrigeration branch and a second refrigerant refrigeration branch, each with a compressor and a condenser, and are independent of each other. The first refrigerant refrigeration branch, together with the first expansion valve and the evaporator core used for cooling the cab, forms a cab refrigerant circulation loop, and also forms an external refrigerant circulation loop with the second expansion valve and the refrigerant side of the first heat exchanger, which serves as an evaporator. The second refrigerant refrigeration branch, together with the third expansion valve and the refrigerant side of the second heat exchanger, which serves as an evaporator, forms a component refrigerant circulation loop. The liquid-cooled sides of the first and second heat exchangers are connected in series and then connected to the component liquid-cooled pipeline for cooling one, two, or three of the power battery, drive motor, and motor controller.

2. The integrated thermal management system for large-tonnage hybrid mining trucks according to claim 1, characterized in that, The liquid cooling pipeline of the component includes a six-way water valve. The battery module heat exchange section, water pump, and the liquid cooling side of the first heat exchanger and the second heat exchanger are connected in series between valve port E and valve port F of the six-way water valve. The drive motor heat exchange section and water pump are connected in series between valve port A and valve port D of the six-way water valve. An external radiator for heat exchange with the external environment is connected in series between valve port B and valve port C of the six-way water valve.

3. The integrated thermal management system for large-tonnage hybrid mining trucks according to claim 1, characterized in that, It also includes an electrically controlled liquid cooling circulation loop, in which a water pump, a heat exchange section of a motor controller, and a motor radiator for heat exchange with the external environment are connected in series.

4. The integrated thermal management system for large-tonnage hybrid mining trucks according to claim 3, characterized in that, The motor radiator and the external radiator share the same fan.

5. The integrated thermal management system for large-tonnage hybrid mining trucks according to claim 1, characterized in that, It also includes a cab liquid cooling pipeline connected in series for heating the cab, and a water-cooled PTC is connected in series in the cab liquid cooling pipeline.

6. The integrated thermal management system for large-tonnage hybrid mining trucks according to claim 5, characterized in that, The cab liquid cooling pipeline is also connected in series with a first valve port and a second valve port of a three-way valve. The second valve port and the third valve port of the three-way valve are also connected in series in the engine liquid cooling circulation pipeline. At the second valve port of the three-way valve, the cab liquid cooling pipeline is connected to the engine liquid cooling circulation pipeline. The three-way valve can switch between connecting the first valve port and the second valve port, or between connecting the first valve port and the third valve port, so as to realize the use of water heating PTC to heat the cab or the use of engine waste heat to heat the cab.

7. The integrated thermal management system for large-tonnage hybrid mining trucks according to claim 1, characterized in that, The first and second expansion valves are electronic expansion valves; the third expansion valve is a thermostatic expansion valve.

8. The integrated thermal management system for large-tonnage hybrid mining trucks according to claim 1, characterized in that, The first and second heat exchangers are plate heat exchangers.

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