An integrated thermal management system

Abstract

This utility model provides an integrated thermal management system, comprising system components including an electric compressor, a condenser, first / second radiators, a fan, a plate heat exchanger, an electronic expansion valve, a solenoid shut-off valve, a refrigerant check valve, a first temperature and pressure sensor, a second temperature and pressure sensor, a gas-liquid separator, a PTC heater, first / second water pumps, first to fourth water temperature sensors, a controller, a high-voltage junction box, and a low-voltage junction box; it also includes a frame assembly; the frame assembly includes a frame constructed from welded profiles and perforated panels located on the lower, front, rear, left, and right ends of the frame; the system components are all housed within the frame assembly. This system reduces the number of parts, increases integration, effectively improves vehicle space utilization, improves vehicle assembly efficiency, and reduces overall component costs; it also improves heat exchange efficiency and enhances system structural strength and seismic resistance.

Description

Technical Field

[0001] This utility model relates to the field of thermal management systems for commercial vehicles and engineering vehicles, and in particular to an integrated thermal management system. Background Technology

[0002] In the commercial and engineering vehicle sectors, automotive thermal management liquid cooling units are typically independent, meaning the liquid cooling unit supplies either cooling or heating to the battery separately; the passenger compartment uses a separate air conditioning system; the motor uses a separate cooling system, and the hydraulic press also uses a separate cooling system. Such fragmented systems consume excessive energy; have too many components, leading to high costs; and result in complex assembly structures at the vehicle level, reducing efficiency. Utility Model Content

[0003] The purpose of this utility model is to provide an integrated thermal management system, which mainly solves the defects of the existing technology. It can reduce the number of system components, improve integration, effectively improve the space utilization of the whole vehicle, effectively improve the assembly efficiency of the whole vehicle, and reduce the overall component cost; it can also improve heat exchange efficiency and improve the structural strength and seismic resistance of the system.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] An integrated thermal management system is characterized in that it comprises system components consisting of an electric compressor, a condenser, a first radiator, a second radiator, a fan, a plate heat exchanger, an electronic expansion valve, a solenoid shut-off valve, a refrigerant check valve, a first temperature and pressure sensor, a second temperature and pressure sensor, a gas-liquid separator, a PTC heater, a first water pump, a second water pump, a first water temperature sensor, a second water temperature sensor, a third water temperature sensor, a fourth water temperature sensor, a controller, a high-voltage junction box, and a low-voltage junction box.

[0006] It also includes a frame assembly; the frame assembly includes a frame constructed of welded profiles and panels with vents disposed on the lower end face, front end face, rear end face, left end face, and right end face of the frame; wherein: all system components are disposed within the frame assembly; the fan is fixedly disposed at the top of the frame assembly, a first radiator and a second radiator are fixedly disposed below the fan, and a condenser is fixedly disposed below the first radiator and the second radiator; the remaining system components are arranged below the condenser.

[0007] The integrated thermal management system described above is characterized in that:

[0008] The electric compressor, condenser, plate heat exchanger, electronic expansion valve, electromagnetic shut-off valve, refrigerant check valve, first temperature and pressure sensor, second temperature and pressure sensor, and gas-liquid separator are all connected through air conditioning refrigerant pipes to form a refrigerant circulation closed loop connected to the HVAC air conditioning unit.

[0009] The plate heat exchanger, PTC heater, first water pump, first water temperature sensor, and second water temperature sensor are connected to the battery pack at the external demand end through water pipes to form a first water circulation closed loop.

[0010] The first radiator, the second water pump, and the third water temperature sensor are connected to the external motor and electrical control system at the external demand end through water pipes to form a second water circulation closed loop.

[0011] The second radiator and the fourth water temperature sensor are connected to the external third water pump and the hydraulic press at the demand end through water pipes to form a third water circulation closed loop.

[0012] The electric compressor, electronic expansion valve, electromagnetic shut-off valve, fan, first water pump, second water pump, third water pump, PTC heater, first temperature and pressure sensor, second temperature and pressure sensor, first water temperature sensor, second water temperature sensor, third water temperature sensor, fourth water temperature sensor, high voltage junction box, low voltage junction box, and electrical connection controller are described.

[0013] Below the condenser within the frame assembly are other components that constitute the refrigerant circulation closed loop, the first water circulation closed loop, the second water circulation closed loop, and the third water circulation closed loop, as well as the controller, high-voltage junction box, and low-voltage junction box.

[0014] The integrated thermal management system is characterized in that: below the condenser are arranged the following components to form a refrigerant circulation closed loop: an electric compressor, a plate heat exchanger, an electronic expansion valve, an electromagnetic shut-off valve, a refrigerant check valve, a first temperature and pressure sensor, a second temperature and pressure sensor, and an air conditioning refrigerant pipe connection; a plate heat exchanger, a PTC heater, a first water pump, a first water temperature sensor, a second water temperature sensor, and a water pipe to form a first water circulation closed loop; a second water pump, a third water temperature sensor, and a water pipe to form a second water circulation closed loop; and a fourth water temperature sensor and a water pipe to form a third water circulation closed loop.

[0015] The integrated thermal management system is characterized in that: the inlet and outlet of the external battery pack on the first water circulation closed loop, the inlet, outlet, and replenishment port of the external motor and electronic control system on the second water circulation closed loop, and the inlet, outlet, and replenishment port of the external hydraulic press on the third water circulation closed loop are all located relatively outward within the frame assembly.

[0016] The integrated thermal management system is characterized in that: the refrigerant is charged in the closed-loop refrigerant circulation system; the high-pressure, high-temperature refrigerant formed by the electric compressor enters the condenser after passing through the second temperature and pressure sensor; after heat exchange with the air through the first radiator, the second radiator, and the fan installed on the condenser, it forms a high-pressure, medium-temperature refrigerant; one path passes through the electronic expansion valve to form a low-pressure, low-temperature refrigerant; in the plate heat exchanger, it exchanges heat with the water coolant in the plate heat exchanger to form a low-pressure, medium-temperature refrigerant; after passing through the first temperature and pressure sensor and the gas-liquid separator, it returns to the electric compressor; the other path passes through the electromagnetic shut-off valve to the HVAC air conditioning unit, where it exchanges heat with the passenger compartment environment to form a low-pressure, medium-temperature refrigerant; then, it flows back to the gas-liquid separator through the refrigerant one-way valve, and then back to the electric compressor.

[0017] The integrated thermal management system is characterized in that: the first water circulation closed-loop water pipe is filled with ethylene glycol aqueous solution as a refrigerant, powered by a first water pump; the refrigerant undergoes convective heat exchange with the refrigerant in a plate heat exchanger; then the refrigerant is heated in a PTC heater; and finally, the refrigerant exchanges cooling or heating energy in the battery pack.

[0018] The integrated thermal management system is characterized in that: the water pipe of the second water circulation closed loop is filled with ethylene glycol aqueous solution as a refrigerant, which is powered by the second water pump. The refrigerant absorbs heat in the external motor and electronic control system, exchanges heat with the air through fan convection in the first radiator, reduces the temperature of the refrigerant, and returns to the external motor and electronic control system to form a closed loop.

[0019] The integrated thermal management system is characterized in that: the water pipe of the third water circulation closed loop is filled with ethylene glycol aqueous solution as a refrigerant, which is powered by an external third water pump. The refrigerant absorbs heat in an external hydraulic press, and exchanges heat with the air through fan convection in the second radiator to reduce the temperature of the refrigerant. It then returns to the external hydraulic press to form a closed loop.

[0020] The advantages of this utility model are:

[0021] 1. This utility model's integrated thermal management system completely integrates the battery thermal management system, passenger compartment air conditioning system, motor cooling system, and hydraulic press system into one unit. This correspondingly reduces the number of components in the passenger compartment, such as the electric compressor, air conditioning refrigerant pipes, and water pipes, effectively improving the utilization rate of the system's electric compressor, increasing the energy efficiency ratio, enhancing system performance, reducing power consumption, and indirectly increasing battery range. It also improves overall vehicle system integration, increases assembly efficiency, and reduces overall costs.

[0022] 2. The integrated thermal management system of this utility model unifies the basic components of the thermal management system into a frame assembly, reducing the number of system parts, improving integration, effectively improving the space utilization of the whole vehicle, effectively improving the assembly efficiency of the whole vehicle, and reducing the overall parts cost; it can also improve heat exchange efficiency.

[0023] 3. This utility model uses a condenser, a first radiator, and a second radiator mounted on the frame assembly to exchange heat with the air through a fan, forming a structure in which air enters from the front, rear, left, right, and bottom, and exits from the top.

[0024] 4. The frame assembly in the integrated thermal management system of this utility model includes a frame made of welded profiles and perforated panels on the lower end, front end, rear end, left end and right end of the frame, which improves the structural strength and seismic resistance of the system. Attached Figure Description

[0025] Figure 1 This is a system schematic diagram of the integrated thermal management system of this utility model.

[0026] Figure 2 This is an exploded perspective view of the integrated thermal management system of this utility model.

[0027] Figure 3 This is a three-dimensional composite diagram of the integrated thermal management system of this utility model. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0029] Please see Figure 1-3 This utility model discloses an integrated thermal management system. As shown in the figure, it includes an electric compressor 1, a condenser 2, a first radiator 3, a second radiator 4, a fan 5, a plate heat exchanger 6, an electronic expansion valve 10, an electromagnetic shut-off valve 11, a refrigerant check valve 13, a first temperature and pressure sensor 141, a second temperature and pressure sensor 142, a gas-liquid separator 15, a PTC heater 7, a first water pump 81, a second water pump 82, a first water temperature sensor 161, a second water temperature sensor 162, a third water temperature sensor 163, a fourth water temperature sensor 164, a controller 17, a high-voltage junction box 18, and a low-voltage junction box 19. These are the basic components constituting the integrated thermal management system. The purpose of this utility model is to rationally arrange these components within a frame assembly 20 to achieve the purpose of the utility model.

[0030] The following is combined first Figure 1This utility model introduces an integrated thermal management system and its functions:

[0031] The electric compressor 1, condenser 2, plate heat exchanger 6, electronic expansion valve 10, electromagnetic shut-off valve 11, refrigerant check valve 13, first temperature and pressure sensor 141 (low-pressure temperature and pressure sensor), second temperature and pressure sensor 142 (high-pressure temperature and pressure sensor), and gas-liquid separator 15 are all connected by air conditioning refrigerant pipes to form a refrigerant circulation closed loop. The refrigerant circulation closed loop is filled with refrigerant. The high-pressure, high-temperature refrigerant compressed by the electric compressor 1 enters the condenser 2 after passing through the second temperature and pressure sensor 142. It then exchanges heat with the air through the first radiator 3, second radiator 4, and fan 5 on the condenser 2, forming a high-pressure, medium-temperature refrigerant. This refrigerant then passes through the electronic expansion valve 10, forming a low-pressure, low-temperature refrigerant. In the plate heat exchanger 6, it exchanges heat with the water coolant in the plate heat exchanger 6, forming a low-pressure, medium-temperature refrigerant. Finally, it passes through the first temperature and pressure sensor 141 and the gas-liquid separator 15 before returning to the electric compressor 1. Another path leads through the electromagnetic shut-off valve 11 to the HVAC air conditioning unit 100, where it exchanges heat with the passenger compartment environment to form a low-pressure, medium-temperature refrigerant. Then, it flows back through the refrigerant check valve 13 to the gas-liquid separator 15, and then back to the electric compressor 1.

[0032] The plate heat exchanger 6, PTC heater 7, first water pump 81, first water temperature sensor 161, and second water temperature sensor 162 are connected to the battery pack 200 at the external demand end via water pipes, forming a first water circulation closed loop. The water pipes of the first water circulation closed loop are filled with an ethylene glycol aqueous solution as a refrigerant, powered by the first water pump 81. The refrigerant undergoes convective heat exchange with the refrigerant in the plate heat exchanger 6, followed by heating in the PTC heater 7. Finally, the refrigerant exchanges cooling or heating energy within the battery pack 200.

[0033] The first radiator 3, the second water pump 82, and the third water temperature sensor 163 are connected to the external motor and electronic control system 300 at the external demand end via water pipes, forming a second water circulation closed loop. The water pipes of the second water circulation closed loop are filled with an ethylene glycol aqueous solution as a refrigerant. Powered by the second water pump 82, the refrigerant absorbs heat in the external motor and electronic control system 300, exchanges heat with the air in the first radiator 3 through convection via the fan 5, lowers the refrigerant temperature, and returns to the external motor and electronic control system 300, forming a closed loop.

[0034] The second radiator 4 and the fourth water temperature sensor 164 are connected to the external third water pump 83 and the demand-side hydraulic press 400 via water pipes, forming a third water circulation closed loop. The water pipes of the third water circulation closed loop are filled with an ethylene glycol aqueous solution as a refrigerant, powered by the external third water pump 83. The refrigerant absorbs heat in the external hydraulic press 400, and then exchanges heat with the air through convection with the fan 5 in the second radiator 4, reducing the refrigerant temperature. It then returns to the external hydraulic press 400, forming a closed loop.

[0035] The electric compressor 1, electronic expansion valve 10, electromagnetic shut-off valve 11, fan 5, first water pump 81, second water pump 82, third water pump 83, PTC heater 7, first temperature and pressure sensor 141, second temperature and pressure sensor 142, first water temperature sensor 161, second water temperature sensor 162, third water temperature sensor 163, fourth water temperature sensor 164, high-voltage junction box 18, low-voltage junction box 19 are electrically connected to controller 17.

[0036] Please see Figure 2 , 3This utility model unifies the basic components constituting the thermal management system into a frame assembly 20. The frame assembly 20 includes a frame 201 constructed from welded profiles and a panel 202 with vents on the lower, front, rear, left, and right ends of the frame 201. The following components are all housed within the frame assembly 20: electric compressor 1, condenser 2, first radiator 3, second radiator 4, fan 5, plate heat exchanger 6, electronic expansion valve 10, electromagnetic shut-off valve 11, refrigerant check valve 13, first temperature and pressure sensor 141, second temperature and pressure sensor 142, gas-liquid separator 15, PTC heater 7, first water pump 81, second water pump 82, first water temperature sensor 161, second water temperature sensor 162, third water temperature sensor 163, fourth water temperature sensor 164, controller 17, high-voltage junction box 18, and low-voltage junction box 19. The fan 5 is fixedly mounted at the top of the frame assembly 20. Below the fan 5, a first radiator 3 and a second radiator 4 are fixedly mounted. Below the first radiator 3 and the second radiator 4, a condenser 2 is fixedly mounted. Below the condenser 2, other components constituting the refrigerant circulation closed loop, the first water circulation closed loop, the second water circulation closed loop, and the third water circulation closed loop, as well as a controller 17, a high-pressure junction box 18, and a low-pressure junction box 19, are arranged. For example, the components constituting the refrigerant circulation closed loop include an electric compressor 1, a plate heat exchanger 6, an electronic expansion valve 10, an electromagnetic shut-off valve 11, a refrigerant check valve 13, a first temperature and pressure sensor 141 (low-pressure temperature and pressure sensor), a second temperature and pressure sensor 142 (high-pressure temperature and pressure sensor), and air conditioning refrigerant pipe connections. The components constituting the first water circulation closed loop include a plate heat exchanger 6, a PTC heater 7, a first water pump 81, a first water temperature sensor 161, a second water temperature sensor 162, and water pipes. The second water pump 82, the third water temperature sensor 163, and the water pipe constitute the second water circulation closed loop. The fourth water temperature sensor 164 and the water pipe constitute the third water circulation closed loop.

[0037] In addition, the inlet and outlet of the external battery pack 200 on the first water circulation closed loop, the inlet, outlet and replenishment port of the external motor and electronic control system 300 on the second water circulation closed loop, and the inlet, outlet and replenishment port of the external hydraulic press 400 on the third water circulation closed loop are all located relatively outward within the frame assembly 20 for easy connection.

[0038] The advantages of the aforementioned integrated thermal management system are:

[0039] 1) By unifying the basic components of the thermal management system into a single frame assembly, the number of system parts is reduced, the integration is improved, the overall space utilization of the vehicle is effectively improved, the overall vehicle assembly efficiency is improved, and the overall parts cost is reduced; it can also improve heat exchange efficiency.

[0040] 2) The condenser, first radiator, and second radiator installed on the frame assembly exchange heat with the air through the fan, forming a structure in which air enters from the front, rear, left, right, and bottom, and exits from the top.

[0041] 3) The frame assembly includes a frame made of welded profiles and perforated panels on the lower, front, rear, left, and right ends of the frame, which improves the structural strength and seismic resistance of the system.

[0042] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. An integrated thermal management system, characterized by: It includes system components consisting of an electric compressor, a condenser, a first radiator, a second radiator, a fan, a plate heat exchanger, an electronic expansion valve, a solenoid shut-off valve, a refrigerant check valve, a first temperature and pressure sensor, a second temperature and pressure sensor, a gas-liquid separator, a PTC heater, a first water pump, a second water pump, a first water temperature sensor, a second water temperature sensor, a third water temperature sensor, a fourth water temperature sensor, a controller, a high-voltage junction box, and a low-voltage junction box. It also includes a frame assembly; the frame assembly includes a frame constructed of welded profiles and panels with vents disposed on the lower end face, front end face, rear end face, left end face, and right end face of the frame; wherein: all system components are disposed within the frame assembly; the fan is fixedly disposed at the top of the frame assembly, a first radiator and a second radiator are fixedly disposed below the fan, and a condenser is fixedly disposed below the first radiator and the second radiator; the remaining system components are arranged below the condenser.

2. The integrated thermal management system according to claim 1, characterized in that: The electric compressor, condenser, plate heat exchanger, electronic expansion valve, electromagnetic shut-off valve, refrigerant check valve, first temperature and pressure sensor, second temperature and pressure sensor, and gas-liquid separator are all connected through air conditioning refrigerant pipes to form a refrigerant circulation closed loop connected to the HVAC air conditioning unit. The plate heat exchanger, PTC heater, first water pump, first water temperature sensor, and second water temperature sensor are connected to the battery pack at the external demand end through water pipes to form a first water circulation closed loop. The first radiator, the second water pump, and the third water temperature sensor are connected to the external motor and electrical control system at the external demand end through water pipes to form a second water circulation closed loop. The second radiator and the fourth water temperature sensor are connected to the external third water pump and the hydraulic press at the demand end through water pipes to form a third water circulation closed loop. The electric compressor, electronic expansion valve, electromagnetic shut-off valve, fan, first water pump, second water pump, third water pump, PTC heater, first temperature and pressure sensor, second temperature and pressure sensor, first water temperature sensor, second water temperature sensor, third water temperature sensor, fourth water temperature sensor, high voltage junction box, low voltage junction box, and electrical connection controller are described. Below the condenser within the frame assembly are other components that constitute the refrigerant circulation closed loop, the first water circulation closed loop, the second water circulation closed loop, and the third water circulation closed loop, as well as the controller, high-voltage junction box, and low-voltage junction box.

3. The integrated thermal management system according to claim 2, characterized in that: Below the condenser are arranged the following components: an electric compressor, a plate heat exchanger, an electronic expansion valve, an electromagnetic shut-off valve, a refrigerant check valve, a first temperature and pressure sensor, a second temperature and pressure sensor, and an air conditioning refrigerant pipe connection, forming a refrigerant circulation closed loop; a plate heat exchanger, a PTC heater, a first water pump, a first water temperature sensor, a second water temperature sensor, and water pipes, forming a first water circulation closed loop; a second water pump, a third water temperature sensor, and water pipes, forming a second water circulation closed loop; and a fourth water temperature sensor and water pipes, forming a third water circulation closed loop.

4. The integrated thermal management system of claim 3, wherein: The inlet and outlet of the external battery pack on the first water circulation closed loop, the inlet, outlet, and replenishment port of the external motor and electronic control system on the second water circulation closed loop, and the inlet, outlet, and replenishment port of the external hydraulic press on the third water circulation closed loop are all located relatively outward within the frame assembly.

5. The integrated thermal management system of claim 2 or 3 or 4, wherein: The refrigerant is charged in a closed-loop refrigerant circulation system. The high-pressure, high-temperature refrigerant formed by the electric compressor enters the condenser after passing through the second temperature and pressure sensor. After heat exchange with the air through the first radiator, the second radiator, and the fan on the condenser, it becomes a high-pressure, medium-temperature refrigerant. One path passes through the electronic expansion valve to become a low-pressure, low-temperature refrigerant. In the plate heat exchanger, it exchanges heat with the water coolant in the plate heat exchanger to become a low-pressure, medium-temperature refrigerant. After passing through the first temperature and pressure sensor and the gas-liquid separator, it returns to the electric compressor. The other path passes through the electromagnetic shut-off valve to the HVAC unit, where it exchanges heat with the passenger compartment environment to become a low-pressure, medium-temperature refrigerant. Then, it flows back to the gas-liquid separator through the refrigerant check valve and back to the electric compressor.

6. The integrated thermal management system of claim 2 or 3 or 4, wherein: The first water circulation closed-loop water pipe is filled with ethylene glycol aqueous solution as a refrigerant, powered by the first water pump. The refrigerant undergoes convective heat exchange with the refrigerant in the plate heat exchanger, and is then heated in the PTC heater. Finally, the refrigerant exchanges cold or heat in the battery pack.

7. The integrated thermal management system of claim 2 or 3 or 4, wherein: The second water circulation closed-loop water pipe is filled with ethylene glycol aqueous solution as a coolant, powered by a second water pump. The coolant absorbs heat in the external motor and electronic control system, and exchanges heat with the air through fan convection in the first radiator to reduce the temperature of the coolant. It then returns to the external motor and electronic control system, forming a closed loop.

8. The integrated thermal management system according to claim 2, 3, or 4, characterized in that: The third water circulation closed loop is filled with ethylene glycol aqueous solution as a refrigerant, powered by an external third water pump. The refrigerant absorbs heat in an external hydraulic press, and exchanges heat with the air through fan convection in the second radiator to reduce the temperature of the refrigerant. It then returns to the external hydraulic press, forming a closed loop.

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