Resistance grid heat dissipation system of hybrid rigid mine truck

Abstract

The utility model discloses a hybrid rigid mine truck resistance grid heat dissipation system, which relates to the technical field of engineering machinery and comprises a resistance grid, a battery, a battery heat management unit, a first three-way valve and a second three-way valve. The appearance of the battery thermal management unit is a box body, and a controller and an electronic water pump are arranged in the box body; a water inlet and a water outlet are formed in the box body; wherein one end of the first three-way valve is connected with a water outlet of the battery heat management unit through a pipeline, and the other two ends are respectively connected with a battery and a water inlet on the resistance grid core through pipelines; one end of the second three-way valve is connected with the water inlet of the battery heat management unit, and the other two ends are respectively connected with the battery and the water outlet on the resistance grid core body to form a water circulation loop; cooling liquid is contained in the pipeline, exists in the whole loop and is used for conducting liquid cooling heat dissipation on the resistance grid through the battery heat management unit. The battery heat management unit is adopted to replace a heat dissipation fan to dissipate heat for the resistance grid, the cost of the whole vehicle can be reduced, and the space utilization rate is improved.

Description

Technical Field

[0001] This utility model relates to the field of engineering machinery technology, and in particular to a hybrid rigid mining truck resistor grid heat dissipation system. Background Technology

[0002] The statements in this section merely refer to the background technology related to this utility model and do not necessarily constitute prior art.

[0003] Range-extended rigid mining trucks rely solely on their engines to generate electricity, which powers the entire vehicle. However, these trucks have high fuel consumption and operating costs. Therefore, hybrid rigid mining trucks have been developed to address this issue. These hybrid trucks use smaller engines to generate electricity, which, in conjunction with a battery, powers the entire vehicle. This significantly reduces fuel consumption, and the hybrid system recovers kinetic energy during downhill driving to recharge the battery.

[0004] The power system of hybrid rigid mining trucks currently on the market mainly includes a generator set consisting of an engine, a generator, and a controller, and a battery system. The generator outputs electricity to the converter cabinet, which rectifies the input three-phase electricity and inverts the rectified DC electricity and the DC electricity input from the battery system, thereby controlling the wheel-side motors of the truck and driving the truck to move.

[0005] The hybrid rigid mining truck operates differently under different working conditions. In no-load or light-load conditions, only the engine drives the generator to rotate and generate electricity, which is then input into the converter cabinet. The battery management system controls the battery to not supply power. The rectifier unit in the converter cabinet rectifies the generated electricity into DC power. The DC power has two paths: the first is that the DC power charges the battery, and the battery management system controls whether to charge the battery or how much current to use based on the battery's charge level. The second is that the controller inverts the DC power into AC power to control the motor, thereby enabling the rigid truck to work. These two situations can exist independently or simultaneously, that is, driving the motor to move while charging the battery.

[0006] Under heavy or full load conditions, the generator set and battery supply power simultaneously to drive the wheel-side motors at full power. When going downhill, the wheel-side motors convert kinetic energy into electrical energy, which is then used to charge the battery through the converter cabinet and battery management system.

[0007] When the energy fed back by the wheel-side motor exceeds the energy required for battery charging, the extra energy is input into the resistor grid, converting electrical energy into heat energy for dissipation and preventing battery overcharging. Since the resistor grid generates a significant amount of heat when consuming electrical energy, it requires air cooling, powered by the converter cabinet.

[0008] However, currently, for hybrid rigid mining trucks, the main method of using cooling fans for resistor grid cooling is too costly and reduces the utilization rate of the overall vehicle space. Furthermore, the airflow direction of the cooling fans needs to be considered to prevent hot air from blowing onto other components and causing overheating. The original battery cooling system in hybrid rigid mining trucks is also not being fully utilized, resulting in a waste of system resources. Utility Model Content

[0009] To address the shortcomings of existing technologies, this utility model provides a hybrid rigid mining truck resistor grid heat dissipation system. The entire vehicle eliminates the cooling fan and uses a battery thermal management unit to replace the cooling fan for heat dissipation of the resistor grid, thereby reducing the overall vehicle cost and improving space utilization.

[0010] A hybrid rigid mining truck resistive grid heat dissipation system includes: a resistive grid, a battery, a battery thermal management unit, a first three-way valve, and a second three-way valve;

[0011] The resistor grid includes a resistor grid core;

[0012] The battery thermal management unit has a box-like exterior, inside which is a controller and an electronic water pump; an expansion tank is connected to the outside of the box to supply water to the electronic water pump inside the box; the box has an inlet and an outlet.

[0013] One end of the first three-way valve is connected to the water outlet of the battery thermal management unit through a pipeline, and the other two ends are connected to the water inlets of the battery and the resistor grid core respectively through pipelines; one end of the second three-way valve is connected to the water inlet of the battery thermal management unit through a pipeline, and the other two ends are connected to the water outlet of the battery and the resistor grid core respectively through pipelines, forming a water circulation loop.

[0014] The pipeline contains coolant, which is present throughout the circuit, and is used to achieve liquid cooling of the battery and resistor grid through the battery thermal management unit.

[0015] Furthermore, the first three-way valve and the second three-way valve are used to control the flow of coolant in the pipeline connecting the resistor grid and the battery thermal management unit; this enables the battery thermal management unit to perform liquid cooling heat dissipation on the battery while also performing liquid cooling heat dissipation on the resistor grid.

[0016] Furthermore, the controller inside the battery thermal management unit is used to control the first three-way valve and the second three-way valve according to different operating conditions; the battery thermal management unit participates in vehicle communication.

[0017] Furthermore, the battery thermal management unit also includes a small air conditioning system inside its housing, specifically comprising a compressor, condenser, plate heat exchanger, and cooling fan, used to cool the coolant inside the battery thermal management unit.

[0018] Furthermore, the battery is composed of multiple battery packs, and the coolant flows into the battery packs to cool the battery.

[0019] Furthermore, when the battery starts working, it is heated according to the internal temperature requirements of the battery; the battery heating method adopts built-in diaphragm heating.

[0020] Furthermore, it also includes a battery management system, which is connected to the battery and controls the charging and discharging of the battery.

[0021] Furthermore, the battery management system also supplies high-voltage power to the battery thermal management unit and enables communication.

[0022] Furthermore, it also includes generator sets consisting of an engine and a generator, converter cabinets, and wheel-side motors;

[0023] The generator set is connected to the converter cabinet, which is connected to the wheel-side motor. The generator outputs electricity into the converter cabinet, which rectifies and inverts the input three-phase electricity to control the wheel-side motor of the steel car and drive the steel car to move.

[0024] Furthermore, the converter cabinet is also connected to the resistor grid. The generator rectifies the generated electricity into DC power through the converter cabinet, and the converter cabinet provides power to the resistor grid.

[0025] Compared with the prior art, the beneficial effects of this utility model are:

[0026] This utility model discloses a hybrid rigid mining truck resistor grid heat dissipation system, which eliminates the cooling fan in the whole vehicle and uses a battery thermal management unit to replace the cooling fan for heat dissipation of the resistor grid, thereby reducing the overall vehicle cost and improving space utilization.

[0027] This invention employs liquid cooling to add a three-way valve to the connection between the battery thermal management unit, the resistor grid, and the battery. By controlling the three-way valve, the flow of coolant in the pipeline is controlled according to different operating conditions. When the vehicle's kinetic energy is recovered, the battery needs to be charged, and the energy does not need to be consumed through the resistor grid. The branch of the three-way valve connected to the resistor grid can be closed, thus cooling only the battery and improving heat dissipation efficiency. When the battery is fully charged, the recovered energy needs to be completely consumed. The branch of the three-way valve connected to the battery can be closed, thus opening only the water path of the resistor grid. When the recovered energy exceeds the energy required for battery charging and needs to be consumed by the resistor grid, the three-way valve can be fully opened, simultaneously cooling both the resistor grid and the battery.

[0028] This invention can reduce the overall vehicle cost, improve space utilization, and increase the utilization rate of components. Attached Figure Description

[0029] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute an undue limitation of this application.

[0030] Figure 1 This is a structural diagram of the conventional hybrid rigid mining truck power system in Embodiment 1 of this utility model;

[0031] Figure 2 This is a structural diagram of a hybrid rigid mining truck resistor grid heat dissipation system according to Embodiment 1 of this utility model;

[0032] Figure 3 A schematic diagram of the structural distribution of a hybrid rigid mining truck resistor grid heat dissipation system according to Embodiment 1 of this utility model;

[0033] Figure 4 A schematic diagram of the battery thermal management unit according to Embodiment 1 of this utility model.

[0034] Among them, 1. Generator set, 2. Converter cabinet, 3. Battery management system, 4. Battery, 5. Resistor grid, 6. Battery thermal management unit, 7. Expansion tank, 8. High voltage power supply interface of battery thermal management unit, 9. Low voltage communication interface, 10. Water inlet, 11. Water outlet. Detailed Implementation

[0035] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0036] It should be noted that this utility model is a structural solution. As for the individual devices involved, the specific structures for realizing their respective functions already exist in the prior art, as do the protocols, software, or programs involved in their operation. Those skilled in the art are fully aware of this. This utility model does not make any improvements to the individual devices, and therefore does not involve software content. Instead, it relies on the organic integration and consolidation of the components into a whole, that is, it provides a structural solution.

[0037] Example 1

[0038] To address the aforementioned issues, this utility model provides a hybrid rigid mining truck resistor grid heat dissipation system, comprising: a resistor grid, a battery, a battery thermal management unit, a first three-way valve, and a second three-way valve;

[0039] The resistor grid includes a resistor grid core;

[0040] The battery thermal management unit has a box-like exterior, inside which is a controller and an electronic water pump; an expansion tank is connected to the outside of the box to supply water to the electronic water pump inside the box; the box has an inlet and an outlet.

[0041] One end of the first three-way valve is connected to the water outlet of the battery thermal management unit through a pipeline, and the other two ends are connected to the water inlets of the battery and the resistor grid core respectively through pipelines; one end of the second three-way valve is connected to the water inlet of the battery thermal management unit through a pipeline, and the other two ends are connected to the water outlet of the battery and the resistor grid core respectively through pipelines, forming a water circulation loop.

[0042] The pipeline contains coolant, which is present throughout the circuit, and is used to achieve liquid cooling of the battery and resistor grid through the battery thermal management unit.

[0043] In the traditional structure of a conventional hybrid rigid mining truck power system, the heat dissipation of the resistor grid is mainly achieved through a cooling fan. For example... Figure 1 As shown, Figure 1 This is a structural diagram of a conventional hybrid rigid mining truck power system: the engine and generator are connected to form a generator set, the generator is connected to a converter cabinet, and the converter cabinet is connected to the wheel-side motors. The generator inputs the generated electricity into the converter cabinet, which rectifies and inverts the input three-phase electricity to control the wheel-side motors of the rigid truck, thereby driving the truck to move and operate.

[0044] The converter cabinet is connected to the battery management system (BMS), which in turn connects to the battery and controls its charging and discharging. Specifically, the generator rectifies the generated electricity into direct current (DC) through the converter cabinet (which contains hardware modules such as rectifiers) to charge the battery. The BMS controls whether to charge the battery and the amount of current used for charging based on the battery's charge level.

[0045] However, when the hybrid truck is under heavy or full load, the generator set and battery will supply power simultaneously to drive the wheel-side motors at full power. When going downhill, the wheel-side motors will convert kinetic energy into electrical energy, which will then charge the battery through the converter cabinet and battery management system.

[0046] Therefore, when the electrical energy fed back by the wheel-side motor exceeds the energy required for battery charging, the extra energy is input into the resistor grid, converting electrical energy into heat energy for dissipation and preventing battery overcharging. Since the resistor grid generates a significant amount of heat when consuming electrical energy, heat dissipation measures are necessary.

[0047] like Figure 1 As shown in the lower part, the converter cabinet is connected to the resistor grid and the cooling fan respectively, and the cooling fan cools the resistor grid.

[0048] Therefore, in the traditional hybrid rigid mining truck power system structure, the battery thermal management system is used to dissipate heat from the battery, and the cooling fan is used to dissipate heat from the resistor grid. However, the cost of using a cooling fan to dissipate heat from the resistor grid is too high, and it reduces the utilization rate of the overall vehicle space. At the same time, the airflow direction of the cooling fan needs to be considered to prevent hot air from blowing onto other components and causing overheating. Furthermore, the original battery thermal management system in the hybrid rigid mining truck is not fully utilized, which also leads to a waste of system resources.

[0049] Therefore, in this embodiment, in Figure 1 Based on the conventional steel truck power system shown, the cooling fan has been removed, and a battery thermal management unit has been used instead of the cooling fan to dissipate heat from the resistor grid.

[0050] Specifically, such as Figure 2 and Figure 3 As shown, the engine and generator are connected to form generator set 1. Generator set 1 is connected to converter cabinet 2, and converter cabinet 2 is connected to wheel-side motor. The generator outputs electricity into the converter cabinet, which rectifies and inverts the input three-phase electricity to control the wheel-side motor of the steel truck, thereby driving the steel truck to move.

[0051] Converter cabinet 2 is connected to battery management system 3, and battery management system 3 is connected to battery 4. The generator rectifies the generated electricity into DC power through converter cabinet 2 (which contains hardware modules such as rectifiers) to charge battery 4. Battery management system 3 controls whether to charge battery 4 and the amount of current used for charging based on the battery 4's charge level.

[0052] Battery 4 consists of multiple battery packs.

[0053] Converter cabinet 2 is also connected to resistor grid 5. The generator rectifies the generated electricity into DC through converter cabinet 2 (which has hardware modules such as rectifiers), and converter cabinet 2 provides power to resistor grid.

[0054] In this embodiment, the cooling fan is removed, and a battery thermal management unit 6 is used to cool the resistor grid 5. The battery thermal management unit 6 is connected to the battery 4 and the resistor grid 5 via three-way valves.

[0055] The three-way valve specifically includes a first three-way valve and a second three-way valve.

[0056] The resistor grid 5 includes the resistor grid core.

[0057] The battery thermal management unit 6 has a cabinet exterior, inside which are a controller, an electric water pump, and a small air conditioning unit. An expansion tank is connected to the outside of the cabinet to replenish the coolant to the electric water pump inside. Figure 3As shown, the expansion tank 7 is positioned at the highest point of the entire system (above battery 4) for convenient coolant replenishment. The expansion tank 7 is connected to the pipeline at the highest point of the system via a standard tee connector, and this pipeline connects to the electronic water pump within the system to replenish the entire system's coolant supply. This standard tee connector lacks a solenoid valve and is not controlled by the system.

[0058] In this embodiment, the coolant is water.

[0059] In this embodiment, as Figure 4 As shown, the battery thermal management unit is equipped with a water inlet 10 and a water outlet 11 on its casing, and also includes a high-voltage power supply interface 8 and a low-voltage communication interface 9.

[0060] One end of the first three-way valve is connected to the water outlet of the battery thermal management unit through a pipeline composed of rubber hoses and steel pipes, and the other two ends are also connected to the water inlets on the battery and the resistor grid core respectively through pipelines composed of rubber hoses and steel pipes; one end of the second three-way valve is connected to the water inlet of the battery thermal management unit through a pipeline, and the other two ends are connected to the water outlet on the battery and the resistor grid core respectively through pipelines, forming a water circulation loop.

[0061] In this embodiment, two three-way valves are used to control the flow of coolant in the pipeline connecting the resistor grid and the battery thermal management unit. The pipeline connecting the two three-way valves to the inlet and outlet of the battery thermal management unit is the main pipeline, and the pipeline connecting the two three-way valves to the outlet of the resistor grid core and the outlet of the battery are two branch pipelines.

[0062] The piping contains coolant, which is present throughout the entire circuit. This is used to achieve liquid cooling of the resistor grid via the battery thermal management unit. For example... Figure 2 As shown by the arrows, the coolant in the battery thermal management unit flows through the connected pipes into the battery and the resistor grid for heat dissipation. After heat dissipation, it flows back to the battery thermal management unit through the outlets of the battery and the resistor grid via the branch of the second three-way valve.

[0063] Since batteries are prone to heat generation during use, and the resistor grid also generates heat during operation, the battery thermal management unit can be used to remove the heat from the battery by allowing coolant to flow into the battery, while simultaneously using the coolant in the battery thermal management unit to cool the resistor grid.

[0064] When battery charging is required and heat dissipation of the resistor grid is not needed, the branches of the two three-way valves connected to the resistor grid can be closed, thus dissipating heat only from the battery and improving heat dissipation efficiency. When heat dissipation of the resistor grid is required, the branch of the two three-way valves connected to the battery can be closed, thus opening only the branch of the resistor grid for heat dissipation. When both battery and resistor grid heat dissipation are required, both branches of the three-way valves can be fully opened, dissipating heat from both the resistor grid and the battery simultaneously.

[0065] The battery thermal management unit was originally only used for cooling the battery. In this example, by designing a three-way valve, the battery thermal management unit is connected to both the resistor grid and the battery, forming a common water circulation loop. This allows the battery thermal management unit to provide liquid cooling for both the battery and the resistor grid, thus avoiding resource waste.

[0066] In this embodiment, the battery thermal management unit also includes a small air conditioning unit, specifically including a compressor, condenser, plate heat exchanger and cooling fan, for cooling the coolant in the battery thermal management unit.

[0067] The working principle of the battery thermal management unit is as follows: The small air conditioning unit first compresses the refrigerant through the compressor, and the refrigerant absorbs heat through evaporation. Then, a plate heat exchanger is used to cool the coolant inside the battery thermal management unit. Finally, an electric water pump is used to transport the coolant to the battery and resistor grid through pipelines made of steel pipes, hoses, etc. to cool the battery and resistor grid. The cooled coolant will be circulated back to the battery thermal management unit for cooling again. This process is repeated. The expansion tank is used to replenish the coolant and to monitor whether the coolant level in the system is appropriate.

[0068] In this embodiment, the battery is also electrically connected to the battery thermal management unit, and the battery management system is electrically connected to the battery. The battery management system supplies high-voltage power to the battery thermal management unit and communicates with it.

[0069] In this embodiment, the battery may need to be heated before it starts working.

[0070] Maintaining a suitable internal temperature for battery operation is crucial. Excessive heat reduces battery life, while excessive cold affects efficiency. Therefore, controlling the internal temperature is essential. The optimal operating temperature for a battery is generally 20℃-25℃.

[0071] The battery heating method uses a built-in diaphragm heating system, which has high heating efficiency.

[0072] In extremely cold environments, batteries need to be heated to a suitable temperature before operation. Therefore, a diaphragm heating method is used, which has the advantages of high efficiency and rapid temperature rise. However, when the battery reaches the suitable temperature for operation, battery discharge will cause the battery to heat up further. Therefore, the diaphragm heating function is turned off, and the battery thermal management unit is used to cool the battery.

[0073] In this embodiment, by connecting the battery thermal management unit and the resistor grid through a liquid cooling pipeline and controlling their on / off state via a three-way valve, the problem of excessively high heat dissipation cost of the resistor grid and the need to consider the airflow direction of the cooling fan to avoid overheating of other components is solved. At the same time, the utilization rate of the vehicle space is reduced, allowing the battery thermal management unit to be fully utilized and avoiding waste of system resources.

[0074] The specific working principle of the hybrid rigid mining truck resistor grid heat dissipation system disclosed in this paper is as follows:

[0075] The flow of coolant to the resistor grid is controlled by a three-way valve.

[0076] When the vehicle recovers kinetic energy, the battery needs to be charged. If the energy does not need to be consumed through the resistor grid, the three-way valve can close the water path of the resistor grid, thereby cooling only the battery and improving the cooling efficiency.

[0077] When the battery is fully charged, the recovered energy needs to be completely consumed. The three-way valve can then close the battery cooling circuit, leaving only the resistor grid's cooling circuit open. When the recovered energy exceeds the energy required for battery charging, and the resistor grid needs to dissipate this energy, the three-way valve can be fully opened, simultaneously cooling both the resistor grid and the battery.

[0078] The three-way valve is controlled by a controller within the battery thermal management unit. The battery thermal management unit participates in vehicle communication and controls the three-way valve to perform different operations according to different operating conditions.

[0079] The battery thermal management unit (BTM) uses liquid cooling to maintain the battery at a suitable temperature during charging and discharging. The BTM cools the coolant through an internal air conditioning unit, which then flows into the battery pack to cool the batteries. The resistor grids also generate heat during operation, so the coolant from the BTM can also be used to cool them.

[0080] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A hybrid rigid mining truck resistor grid heat dissipation system, characterized in that, Includes: resistor grid, battery, battery thermal management unit, first three-way valve and second three-way valve; The resistor grid includes a resistor grid core; The battery thermal management unit has a box-like exterior, inside which is a controller and an electronic water pump; an expansion tank is connected to the outside of the box to supply water to the electronic water pump inside the box; the box has an inlet and an outlet. One end of the first three-way valve is connected to the water outlet of the battery thermal management unit through a pipeline, and the other two ends are connected to the water inlets of the battery and the resistor grid core respectively through pipelines; one end of the second three-way valve is connected to the water inlet of the battery thermal management unit through a pipeline, and the other two ends are connected to the water outlet of the battery and the resistor grid core respectively through pipelines, forming a water circulation loop. The pipeline contains coolant, which is present throughout the entire circuit, and is used to achieve liquid cooling of the battery and resistor grid through the battery thermal management unit.

2. The hybrid rigid mining truck resistor grid heat dissipation system as described in claim 1, characterized in that, The first three-way valve and the second three-way valve are used to control the flow of coolant in the pipeline connecting the resistor grid and the battery thermal management unit; they are used to enable the battery thermal management unit to perform liquid cooling heat dissipation on the battery while also performing liquid cooling heat dissipation on the resistor grid.

3. The hybrid rigid mining truck resistor grid heat dissipation system as described in claim 1, characterized in that, The battery thermal management unit has a controller inside its housing for controlling the first three-way valve and the second three-way valve according to different operating conditions; the battery thermal management unit participates in vehicle communication.

4. The hybrid rigid mining truck resistor grid heat dissipation system as described in claim 1, characterized in that, The battery thermal management unit also includes a small air conditioning system, specifically a compressor, condenser, plate heat exchanger and cooling fan, used to cool the coolant inside the battery thermal management unit.

5. The hybrid rigid mining truck resistor grid heat dissipation system as described in claim 1, characterized in that, The battery consists of multiple battery packs, and the coolant flows into the battery packs to cool the battery.

6. The hybrid rigid mining truck resistor grid heat dissipation system as described in claim 1, characterized in that, When the battery starts working, it is heated according to the internal temperature requirements of the battery; the battery heating method uses built-in diaphragm heating.

7. The hybrid rigid mining truck resistor grid heat dissipation system as described in claim 1, characterized in that, It also includes a battery management system, which is connected to the battery and controls the charging and discharging of the battery.

8. The hybrid rigid mining truck resistor grid heat dissipation system as described in claim 7, characterized in that, The battery management system also supplies high-voltage power to the battery thermal management unit and enables communication.

9. The hybrid rigid mining truck resistor grid heat dissipation system as described in claim 1, characterized in that, It also includes generator sets consisting of an engine and a generator, converter cabinets, and wheel-side motors; The generator set is connected to the converter cabinet, which is connected to the wheel-side motor. The generator outputs electricity into the converter cabinet, which rectifies and inverts the input three-phase electricity to control the wheel-side motor of the steel car and drive the steel car to move.

10. The hybrid rigid mining truck resistor grid heat dissipation system as described in claim 9, characterized in that, The converter cabinet is also connected to the resistor grid. The generator rectifies the generated electricity into DC power through the converter cabinet, and the converter cabinet provides power to the resistor grid.

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