Commercial vehicle pure electric heating management integration unit and system

Abstract

The utility model discloses a commercial vehicle pure electric heating management integration unit and system, which comprises a square fixed frame serving as a supporting structure of the whole heat management integration unit, and an electronic water pump, a PTC (Positive Temperature Coefficient) high-pressure heater, a gas-liquid separator, a high-pressure compressor, a valve terminal assembly, a battery heat exchanger and a water cooling condenser which are arranged in the fixed frame, a water side base plate support is installed above the fixing frame in an erected mode, and a water side base plate and a multi-way water valve are installed through the water side base plate support so that the water side base plate and the multi-way water valve can be arranged above the fixing frame. According to the utility model, the integration level is high, the structure is compact, a plurality of heat management key components are integrated in the fixed frame, the occupied space of the system is reduced, the pipeline connection is simplified, and the miniaturization and lightweight design of equipment is facilitated.

Description

Technical Field

[0001] This utility model relates to the field of thermal management technology, specifically, to an integrated unit and system for thermal management of pure electric vehicles in commercial vehicles. Background Technology

[0002] Thermal management is crucial in modern electronic devices, new energy vehicles, and other systems. With the increase in equipment power density and the growing demands for system compactness and reliability, traditional distributed thermal management components suffer from problems such as large footprint, complex piping connections, high control difficulty, and low thermal management efficiency.

[0003] Therefore, there is an urgent need for a thermal management integrated unit that is highly integrated, compact in structure, and has excellent thermal management performance. Utility Model Content

[0004] To address the aforementioned technical problems, the present invention aims to provide a commercial vehicle pure electric thermal management integrated unit and system. By optimizing the component layout and connection method, it achieves thermal management functions with high integration, high space utilization, high thermal management efficiency, and ease of installation and maintenance.

[0005] The present invention solves the above problems through the following technical solution:

[0006] A commercial vehicle pure electric thermal management integrated unit includes: a square fixed frame serving as the supporting structure for the entire thermal management integrated unit; an electronic water pump, a PTC high-pressure heater, a gas-liquid separator, a high-pressure compressor, a valve island assembly, a battery heat exchanger, and a water-cooled condenser are arranged within the fixed frame; a water-side base plate bracket is erected and installed above the fixed frame; and a water-side base plate and a multi-way water valve are installed through the water-side base plate bracket, so that the water-side base plate and the multi-way water valve are positioned above the fixed frame.

[0007] As a further improvement, the electronic water pump is located at the left rear of the fixed frame to drive the coolant to circulate within the thermal management integrated system.

[0008] And / or the PTC high-pressure heater is located at the front left of the fixed frame to heat the coolant in low-temperature environments or when rapid heating is required, providing heat to the thermal management integrated system.

[0009] As a further improvement, the high-pressure compressor is located at the front right of the fixed frame and is used to compress the refrigerant, thereby increasing the temperature and pressure of the refrigerant and providing power for the refrigeration cycle.

[0010] As a further improvement, the high-pressure compressor adopts a high-efficiency scroll or piston structure; and / or

[0011] The gas-liquid separator is located on the left side of the high-pressure compressor and is connected to the high-pressure compressor via a pipeline. It is used to separate the gas and liquid in the refrigerant and transfer the separated gaseous refrigerant to the high-pressure compressor.

[0012] As a further improvement, the water-cooled condenser is located at the right rear of the fixed frame. By exchanging heat with the external coolant or air, it cools and condenses the high-temperature and high-pressure gaseous refrigerant into a liquid state, releasing heat.

[0013] As a further improvement, the battery heat exchanger is located on the left side of the water-cooled condenser to realize heat exchange between the battery and the coolant, thereby cooling or heating the battery.

[0014] As a further improvement, the valve island assembly is mounted on the upper right side of the water-cooled condenser via an "n"-shaped valve island assembly bracket, and the valve island assembly integrates several solenoid valves and control valves to control the flow direction and flow rate of refrigerant or coolant.

[0015] As a further improvement, the water-side substrate support is erected and installed on the upper part of the fixed frame, the water-side substrate is embedded and installed on the water-side substrate support, and a number of multi-port water valves are arranged in a row on the water-side substrate support.

[0016] As a further improvement, a fixed bracket assembly is provided within the fixed frame via connectors to support the installation of the electronic water pump, PTC high-pressure heater, gas-liquid separator, high-pressure compressor, water-cooled condenser, and battery heat exchanger.

[0017] Furthermore, this utility model also solves the above problems through the following technical solutions:

[0018] A commercial vehicle pure electric thermal management integrated system, comprising:

[0019] Refrigeration circuit: It has a gas-liquid separator, a high-pressure compressor, a water-cooled condenser, a valve island assembly and a battery heat exchanger connected in sequence to form a circuit;

[0020] Heating circuit: It has a first electronic water pump, a water-cooled condenser, a PTC high-pressure heater, a warm air core, a first multi-way water valve, a second electronic water pump, a battery liquid cooling plate, a second multi-way water valve and a three-way valve connected in sequence to form a circuit, wherein a battery heat exchanger is connected between the first multi-way water valve and the second multi-way water valve.

[0021] The first and second electronic water pumps are integrated into an electronic water pump, the first multi-way water valve and the second multi-way water valve are integrated into a multi-way water valve, the PTC high-pressure heater, the gas-liquid separator, the high-pressure compressor, the valve island assembly, the water-cooled condenser and the battery heat exchanger are installed through the fixed frame and fixed bracket assembly of the commercial vehicle pure electric thermal management integrated unit as described above.

[0022] Compared with the prior art, this utility model has the following advantages and beneficial effects:

[0023] (1) This utility model has a high degree of integration and a compact structure: it integrates multiple key thermal management components such as electronic water pump, PTC high-pressure heater, high-pressure compressor, water-cooled condenser, and battery heat exchanger into a fixed frame, which reduces the space occupied by the system, simplifies the pipeline connection, and is conducive to the miniaturization and lightweight design of the equipment.

[0024] (2) The present invention has high thermal management efficiency: by rationally arranging the components and using efficient heat exchange and control components, it achieves precise control and efficient heat exchange of coolant and refrigerant, can quickly respond to changes in system heat load, effectively improve thermal management efficiency, and ensure that the components in the system work in a suitable temperature environment.

[0025] (3) This utility model is easy to install and maintain: It adopts a modular design, the installation position of each component in the fixed frame is clear, the connection method is simple, and it is easy to install and disassemble the whole. At the same time, the integrated components such as the valve island assembly facilitate fault diagnosis and repair and replacement, reducing maintenance costs and difficulties. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of a commercial vehicle pure electric thermal management integrated unit according to the present invention;

[0027] Figure 2 This is an exploded view of an integrated unit for pure electric thermal management in commercial vehicles according to the present invention.

[0028] Figure 3 This is a schematic diagram of the installation of the multi-way water valve, water-side base plate, and water-side base plate support of this utility model;

[0029] Figure 4 This is a schematic diagram showing the fit between the fixed bracket assembly of this utility model and the components installed on it;

[0030] Figure 5 This is a schematic diagram of the installation inside the fixed frame of this utility model;

[0031] Figure 6 This is a schematic diagram of the installation of the upper part of the fixed frame of this utility model;

[0032] Figure 7This is a connection diagram of a commercial vehicle pure electric thermal management integrated system according to the present invention.

[0033] Reference numerals: 1. Electronic water pump; 2. Fixed frame; 3. PTC high-pressure heater; 4. Water-side substrate support; 5. Water-side substrate; 6. Multi-way water valve; 7. Gas-liquid separator; 8. High-pressure compressor; 9. Valve island assembly; 91. Valve island assembly support; 10. Water-cooled condenser; 11. Battery heat exchanger; 12. Fixed support assembly; 13. Connector; 14. Warm air core; 15. Battery liquid cooling plate; 16. Three-way valve; 17. Evaporator core. Detailed Implementation

[0034] 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.

[0035] Example 1:

[0036] See attached document Figure 1-6 A commercial vehicle pure electric thermal management integrated unit includes: a square fixed frame 2, which serves as the supporting structure for the entire unit and provides an installation base for other components. Preferably, the fixed frame 2 is made of high-strength metal material, possessing good mechanical strength and stability, and capable of withstanding the weight of each component as well as vibration and stress during operation. The fixed frame 2 houses an electric water pump 1, a PTC high-pressure heater 3, a gas-liquid separator 7, a high-pressure compressor 8, a valve island assembly 9, and a water-cooled condenser 10. A water-side base plate bracket 4 is erected and installed above the fixed frame 2, and a water-side base plate 5 and a multi-way water valve 6 are installed through the water-side base plate bracket 4, so that the water-side base plate 5 and the multi-way water valve 6 are positioned above the fixed frame.

[0037] The electronic water pump 1 is located at the rear left of the fixed frame 2 and is used to drive the coolant to circulate within the thermal management integrated system to achieve heat transfer. The electronic water pump 1 has an adjustable speed function, enabling precise control of the coolant flow rate according to the thermal load requirements of the thermal management integrated system. It features high efficiency, energy saving, and low noise. The electronic water pump 1 is controlled by PWM duty cycle: the vehicle sends a duty cycle request, the electronic water pump receives the duty cycle request signal, and controls and adjusts the pump current to achieve different speeds.

[0038] The PTC high-pressure heater 3 is located at the front left of the fixed frame. In low-temperature environments or when rapid heating is required, the PTC high-pressure heater 3 can quickly heat the coolant, providing heat for the thermal management integrated system. It uses a positive temperature coefficient thermistor material, which has the advantages of high heating efficiency, fast response speed, and good safety.

[0039] The high-pressure compressor 8, located at the front right of the fixed frame, is a key component of the refrigeration cycle. It compresses the refrigerant, increasing its temperature and pressure to power the refrigeration cycle. The high-pressure compressor 8 employs a high-efficiency scroll or piston structure, featuring high compression ratio, large cooling capacity, and high reliability.

[0040] The gas-liquid separator 7 is installed within a fixed frame and located to the left of the high-pressure compressor 8. The gas-liquid separator 7 is connected to the high-pressure compressor 8 through a pipeline. It is used to separate the gas and liquid in the refrigerant and transfer the separated gaseous refrigerant to the high-pressure compressor 8. This prevents liquid refrigerant from entering the high-pressure compressor and causing liquid slugging, protects the high-pressure compressor for normal operation, and improves the stability and efficiency of the refrigeration system.

[0041] The water-cooled condenser 10 is located at the right rear of the fixed frame. It cools and condenses the high-temperature, high-pressure gaseous refrigerant into a liquid state by exchanging heat with the external coolant or air, thus releasing heat. The water-cooled condenser 10 adopts a high-efficiency finned tube structure or microchannel structure, which has the advantages of large heat exchange area and high heat exchange efficiency.

[0042] The battery heat exchanger 11 is located to the left of the water-cooled condenser 10 within the fixed frame. It facilitates heat exchange between the battery and the coolant, cooling or heating the battery to ensure it operates within a suitable temperature range, thereby improving its performance and lifespan. The battery heat exchanger 11 employs a plate-fin or brazed plate structure, featuring a compact and highly efficient heat exchange characteristic.

[0043] The valve island assembly 9 is mounted on the upper right side of the water-cooled condenser 10 within a fixed frame via an "n"-shaped valve island assembly bracket 91. It integrates multiple solenoid valves and control valves, precisely controlling the flow direction and flow rate of refrigerant or coolant to switch between various thermal management modes such as cooling, heating, and defrosting, as well as the rational distribution of heat across different parts of the system. The valve island assembly 9 adopts a modular design, facilitating maintenance and functional expansion.

[0044] In this embodiment, as an optional solution, a fixing bracket assembly 12 is installed within the fixing frame 2 using bolts, screws, or other connectors. This fixing bracket assembly supports the installation of the electronic water pump 1, PTC high-pressure heater 3, gas-liquid separator 7, high-pressure compressor 8, water-cooled condenser 10, and battery heat exchanger 11. The valve island assembly bracket 91, which houses the valve island assembly 9, is mounted on the fixing bracket assembly 12 using bolts, screws, or other connectors. Preferably, the fixing brackets for the electronic water pump 1, PTC high-pressure heater 3, gas-liquid separator 7, high-pressure compressor 8, and water-cooled condenser 10 are each individually installed, while the battery heat exchanger 11 is mounted between two fixing brackets. The fixing bracket assembly 12 assists in fixing other components, enhancing the structural stability of the entire thermal management integrated unit and ensuring that no components shift or loosen during operation.

[0045] The fixed frame 2 has a notch on the front side, located between the gas-liquid separator 7 and the high-pressure compressor 8, to allow for structural clearance for maintenance of the compressor and the liquid receiver.

[0046] In a further preferred embodiment, the connection and mounting holes of each fixed bracket are oblong holes, so that adjustment can be made during installation and interference can be avoided.

[0047] The water-side substrate support 4 is erected and installed on the upper part of the fixed frame 2. The water-side substrate 5 is embedded and installed on the water-side substrate support 4. The water-side substrate support 4 is used to support and fix the water-side substrate 5. The water-side substrate 5 integrates some pipeline interfaces and installation structures, which facilitates the connection and integration between various water-side components and makes the water-side pipeline layout more compact and reasonable.

[0048] Several multi-way water valves 6 are arranged in a row on the water-side base plate support 4. The multi-way water valves 6 are installed in the water-side pipeline and work with components such as the electronic water pump 1, PTC high-pressure heater 3, water-cooled condenser 10, and battery heat exchanger 11 to control the flow direction and flow rate of coolant in different branches, thereby achieving precise thermal management of different components.

[0049] In this embodiment, preferably, bolts and clamps are used to fasten the connections between the components and fix the pipelines to ensure the sealing and reliability of the connections and prevent leakage of coolant or refrigerant.

[0050] Example 2:

[0051] See attached document Figure 7 A commercial vehicle pure electric thermal management integrated system includes: a cooling circuit and a heating circuit, wherein,

[0052] The refrigeration circuit includes, in sequence, a gas-liquid separator 7, a high-pressure compressor 8, a water-cooled condenser 10, a valve island assembly 9, and a battery heat exchanger 11. When the thermal management integrated system requires cooling, the high-pressure compressor 8 starts to compress the refrigerant, increasing its temperature and pressure. The high-temperature, high-pressure gaseous refrigerant enters the water-cooled condenser 10, where it exchanges heat with the external coolant or air, condensing into a liquid state. The liquid refrigerant, controlled by the valve island assembly 9, flows to components requiring cooling, such as the battery heat exchanger 11 or the evaporator core 17, absorbing heat and turning into a gaseous state. After passing through the gas-liquid separator 7 to separate the liquid refrigerant, it returns to the high-pressure compressor 8, completing the refrigeration cycle. Simultaneously, the electric water pump 1 in the heating circuit drives the coolant to circulate within the thermal management integrated system, carrying away heat from components such as the water-cooled condenser 10.

[0053] In this embodiment, the valve island of the valve island assembly 9 and the battery heat exchanger 11 are also connected in parallel to another valve island of the other valve island assembly 9 and the evaporator core or other components that need to be cooled.

[0054] The heating circuit includes: a first electronic water pump, a water-cooled condenser 10, a PTC high-pressure heater 3, a heater core 14, a first multi-way water valve, a second electronic water pump, a battery liquid cooling plate 15, a second multi-way water valve, and a three-way valve 16 connected in sequence to form the circuit. Components requiring cooling, such as a battery heat exchanger, are connected between the first and second multi-way water valves. When heating is required in a low-temperature environment, the PTC high-pressure heater 3 starts to heat the coolant. The electronic water pump 1 delivers the heated coolant to the components requiring heating, such as the battery heat exchanger 11, to achieve heat transfer. Simultaneously, the flow direction and flow rate of the coolant are adjusted by the valve island assembly 9 and several multi-way water valves 6 to meet the heating needs of different components.

[0055] In this embodiment, the first electronic water pump 1 and the second electronic water pump are integrated into an electronic water pump 1, the PTC high-pressure heater 3, the first multi-way water valve and the second multi-way water valve are integrated into a multi-way water valve 6, the gas-liquid separator 7, the high-pressure compressor 8, the valve island assembly 9, the water-cooled condenser 10, and the battery heat exchanger 11 are installed through the fixed frame 2 and the fixed bracket assembly 12 of the thermal management integrated unit in embodiment 1.

[0056] Although the present invention has been described herein with reference to illustrative embodiments, the above embodiments are merely preferred embodiments of the present invention, and the implementation of the present invention is not limited to the above embodiments. It should be understood that those skilled in the art can design many other modifications and implementations, which will fall within the scope and spirit of the principles disclosed in this application.

Claims

1. A pure electric thermal management integrated unit for commercial vehicles, characterized in that, Comprise: A square fixed frame as a whole thermal management integrated unit support structure, an electronic water pump, a PTC high-pressure heater, a gas-liquid separator, a high-pressure compressor, a valve island assembly, a battery heat exchanger and a water-cooled condenser are arranged in the fixed frame, a water side substrate support is installed on the top of the fixed frame, and a water side substrate and a multi-way water valve are installed through the water side substrate support, so that the water side substrate and the multi-way water valve are arranged above the fixed frame.

2. The integrated thermal management unit for a commercial vehicle according to claim 1, wherein, The electronic water pump is arranged at the left rear in the fixed frame, and is used to drive the circulation of the cooling liquid in the thermal management integrated system; And / or the PTC high-pressure heater is arranged at the left front in the fixed frame, and is used to heat the cooling liquid in a low-temperature environment or when rapid heating is needed, to provide heat for the thermal management integrated system.

3. The integrated thermal management unit for a commercial vehicle of claim 1, wherein, The high-pressure compressor is arranged at the right front in the fixed frame, and is used to compress the refrigerant to increase the temperature and pressure of the refrigerant, to provide power for the refrigeration cycle.

4. The commercial vehicle pure electric thermal management integrated unit according to claim 1 or 3, characterized in that: The high-pressure compressor adopts a high-efficiency scroll or piston structure; and / or The gas-liquid separator is located on the left side of the high-pressure compressor, and the gas-liquid separator and the high-pressure compressor are connected through pipelines, for separating gas and liquid in the refrigerant, and transmitting the separated gaseous refrigerant to the high-pressure compressor.

5. The integrated thermal management unit for a commercial vehicle of claim 1, wherein, The water-cooled condenser is arranged at the right rear in the fixed frame, and exchanges heat with external cooling liquid or air to cool and condense the high-temperature and high-pressure gaseous refrigerant into liquid state, to release heat.

6. The integrated thermal management unit for a commercial vehicle according to claim 1 or 5, characterized in that, The battery heat exchanger is arranged on the left side of the water-cooled condenser, and is used to exchange heat between the battery and the cooling liquid, to cool or heat the battery.

7. The integrated thermal management unit for a commercial vehicle of claim 1, wherein, The valve island assembly is arranged on the right upper side of the water-cooled condenser through an "n"-shaped valve island assembly support, and the valve island assembly integrates a plurality of electromagnetic valves and control valves, to control the flow direction and flow rate of the refrigerant or the cooling liquid.

8. The integrated thermal management unit for a commercial vehicle of claim 1, wherein, The water side substrate support is installed on the middle upper side of the fixed frame, the water side substrate is embedded and installed on the water side substrate support, and a plurality of multi-way water valves are arranged in rows on the water side substrate support.

9. The integrated thermal management unit for a commercial vehicle of claim 1, wherein, The fixed frame is provided with a fixed support assembly through a connecting piece, to install and support the electronic water pump, the PTC high-pressure heater, the gas-liquid separator, the high-pressure compressor, the water-cooled condenser and the battery heat exchanger through the fixed support assembly.

10. A pure electric thermal management integrated system for a commercial vehicle, characterized in that, Comprise: A refrigeration circuit: a gas-liquid separator, a high-pressure compressor, a water-cooled condenser, a valve island assembly and a battery heat exchanger connected in sequence to form a circuit; A heating circuit: a first electronic water pump, a water-cooled condenser, a PTC high-pressure heater, a warm air core, a first multi-way water valve, a second electronic water pump, a battery liquid cooling plate, a second multi-way water valve and a three-way valve connected in sequence to form a circuit, wherein the battery heat exchanger is connected between the first multi-way water valve and the second multi-way water valve; The first electronic water pump and the second electronic water pump are integrated into an electronic water pump, the first multi-way water valve and the second multi-way water valve are integrated into a multi-way water valve, the PTC high-pressure heater, the gas-liquid separator, the high-pressure compressor, the valve island assembly, the water-cooled condenser and the battery heat exchanger are installed through the fixing frame and the fixing support assembly of the commercial vehicle pure electric thermal management integrated unit according to any one of claims 1-9.

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