A thermal management system and a hybrid vehicle

Abstract

The application relates to a heat management system and a hybrid automobile, and belongs to the technical field of automobiles. The heat management system comprises a water-cooling heat dissipation circuit, the water-cooling heat dissipation circuit comprises a first water pump, an electric drive component and a radiator which are connected in sequence to form a circulation through pipelines; an engine intake circuit, the engine intake circuit comprises an engine and a supercharger, and a water-cooled intercooler is connected in series on an intake pipeline between the supercharger and the engine; an intercooled heat exchange branch, the intercooled heat exchange branch is connected in parallel with the water-cooling heat dissipation circuit and exchanges heat with the engine intake circuit through the water-cooled intercooler, and a valve and a second water pump are connected in series on the intercooled heat exchange branch. The water-cooled intercooler is connected to the water-cooling heat dissipation circuit through the intercooled heat exchange branch, the valve opening degree and the second water pump duty cycle are adjusted, the temperature of the air after intercooling is controlled in real time, the problem of condensate water condensation and accumulation in the intake pipeline is solved, the engine combustion stability is improved, and the vehicle power is ensured.

Description

Technical Field

[0001] This application relates to the field of automotive technology, and in particular to a thermal management system and a hybrid vehicle. Background Technology

[0002] To meet increasingly stringent emission regulations and the need for low fuel consumption, automotive low-pressure EGR technology is highly effective in improving engine fuel economy and reducing emissions due to its ability to reduce pumping losses, suppress combustion rate, reduce knocking tendency, and lower exhaust temperature. Compared to air-cooled intercoolers, water-cooled intercoolers (WCAC) are smaller, more compact, and have higher heat exchange efficiency, making them the preferred intercooler for turbocharged engines in terms of miniaturization and energy saving / emission reduction.

[0003] In current technology, low-pressure EGR uses a water-cooled intercooler. This type of intercooler cannot control its cooling capacity in a closed-loop manner based on the intake air temperature. When fresh air mixes with EGR exhaust gas, it encounters the low-temperature walls within the intercooler. When the temperature is below the dew point, condensation forms and enters the engine cylinders along with the air-fuel mixture, affecting combustion stability and increasing fuel consumption. If a large amount of condensation accumulates at the bottom of the intake manifold, it can be instantly drawn into the cylinders, causing misfires. In severe cases, this can even lead to connecting rod bending and piston damage, rendering the engine unusable.

[0004] Therefore, it is necessary to research and improve existing technologies to provide a thermal management system and hybrid vehicle, in order to achieve a more practical purpose. Summary of the Invention

[0005] In view of any of the shortcomings or deficiencies mentioned in the background technology, this application provides a thermal management system and a hybrid vehicle, which can improve the condensation and accumulation of condensate in the intake manifold, improve engine combustion stability, and ensure the overall vehicle power performance.

[0006] In a first aspect, embodiments of this application provide a thermal management system, including:

[0007] A water-cooled heat dissipation circuit, comprising a first water pump, an electric drive component, and a radiator connected in sequence via pipes to form a circulation;

[0008] An engine intake circuit, comprising an engine and a turbocharger, and a water-cooled intercooler connected in series in the intake manifold between the turbocharger and the engine;

[0009] The intercooling heat exchange branch is connected in parallel with the water-cooled heat dissipation circuit and exchanges heat with the engine intake circuit through the water-cooled intercooler. A valve and a second water pump are connected in series on the intercooling heat exchange branch.

[0010] In some embodiments, the thermal management system further includes a controller and a temperature sensor located at the outlet of the water-cooled intercooler. The temperature sensor is used to detect the temperature of the cooled pressurized air. The temperature sensor, valve, and second water pump are all connected to the controller.

[0011] In some embodiments, the intercooling heat exchange branch includes a first pipeline connecting the outlet of the water-cooled intercooler and the inlet of the radiator, and a second pipeline connecting the outlet of the radiator and the inlet of the water-cooled intercooler, wherein the valve and the second water pump are connected in series on the second pipeline.

[0012] In one aspect, in some embodiments, the supercharger includes a compressor and a turbine, the outlet of the compressor being connected to the inlet of a water-cooled intercooler, and the inlet of the turbine being connected to the exhaust port of the engine.

[0013] In one aspect, in some embodiments, the air inlet of the compressor is connected to an air filter, and the exhaust outlet of the turbine is connected to a catalytic converter.

[0014] In one aspect, in some embodiments, an EGR cooler is connected between the exhaust port of the turbine and the intake port of the compressor, and the exhaust port of the EGR cooler is connected to the intake pipeline via an EGR valve.

[0015] In one aspect, in some embodiments, the engine intake circuit further includes a throttle valve connected in series in the intake manifold between the engine and the water-cooled intercooler.

[0016] In one aspect, in some embodiments, the electric drive component includes at least one of a battery pack, a drive motor, and a generator.

[0017] In one aspect, in some embodiments, the water-cooled heat dissipation circuit further includes an electrically driven kettle connected in series between the radiator and the electric drive component.

[0018] Secondly, embodiments of this application provide a hybrid vehicle:

[0019] The hybrid vehicle is equipped with any of the thermal management systems described above.

[0020] The beneficial effects of the technical solution provided in this application include:

[0021] This application provides a thermal management system and a hybrid vehicle. The water-cooled heat dissipation circuit includes a first water pump, an electric drive component, and a radiator connected in sequence through pipes to form a circulation. The engine intake circuit includes an engine and a turbocharger, as well as a water-cooled intercooler connected in series on the intake pipe between the turbocharger and the engine. The intercooler heat exchange branch is connected in parallel with the water-cooled heat dissipation circuit and exchanges heat with the engine intake circuit through the water-cooled intercooler. A valve and a second water pump are connected in series on the intercooler heat exchange branch.

[0022] Therefore, by connecting the water-cooled intercooler to the water-cooled heat dissipation circuit through the intercooling heat exchange branch, the heat generated by the electric drive components in the water-cooled heat dissipation circuit is exchanged between the water side of the water-cooled intercooler and the air side of the engine intake circuit. With the adjustment of the valve opening and the duty cycle of the second water pump, the temperature of the boosted air after intercooling can be precisely maintained within the set range. This can effectively reduce the accumulation of condensate in the intake manifold, ensure stable engine operation at high EGR rates, improve combustion stability, and ensure the overall vehicle power performance. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the thermal management system according to an embodiment of this application.

[0025] The attached diagram lists the components represented by each number as follows:

[0026] 1. Water-cooled heat dissipation circuit; 11. First water pump; 12. Electric drive components; 121. Battery pack; 122. Drive motor; 123. Generator; 13. Radiator; 14. Electric drive water tank;

[0027] 2. Engine intake circuit; 21. Engine; 22. Turbocharger; 221. Compressor; 222. Turbine; 23. Water-cooled intercooler; 24. Air filter; 25. Catalytic converter; 26. Throttle valve;

[0028] 3. Intercooling heat exchange branch; 31. Valve; 32. Second water pump; 4. Controller; 5. Temperature sensor; 6. EGR cooler; 7. EGR valve. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0030] In response to any of the shortcomings or deficiencies mentioned in the background technology, this application provides a thermal management system and a hybrid vehicle that can improve the condensation and accumulation of condensate in the intake manifold, enhance engine combustion stability, and ensure the overall vehicle power performance.

[0031] See Figure 1 As shown, a first aspect of this application provides a thermal management system, including:

[0032] Water-cooled heat dissipation circuit 1, which includes a first water pump 11, an electric drive component 12, and a radiator 13 connected in sequence through pipes to form a circulation;

[0033] Engine intake circuit 2, which includes engine 21 and turbocharger 22, and water-cooled intercooler 23 connected in series in the intake pipe between turbocharger 22 and engine 21.

[0034] Intercooling heat exchange branch 3 is connected in parallel with water cooling heat dissipation circuit 1, and exchanges heat with engine intake circuit 2 through water-cooled intercooler 23. A valve 31 and a second water pump 32 are connected in series on intercooling heat exchange branch 3.

[0035] The thermal management system of this application embodiment connects the water-cooled intercooler 23 to the water-cooled heat dissipation circuit 1 through the intercooling heat exchange branch 3. The heat generated by the electric drive component 12 in the water-cooled heat dissipation circuit 1 is used to exchange heat with the air side of the engine intake circuit 2 through the water side of the water-cooled intercooler 23.

[0036] By adjusting the opening of valve 31 and the duty cycle of the second water pump 32, the temperature of the boosted air after intercooling can be precisely maintained within the set range, which can effectively reduce the accumulation of condensate in the intake manifold, ensure the stable operation of engine 21 at a high EGR rate, improve combustion stability, and ensure the power performance of the whole vehicle.

[0037] For example, valve 31 is preferably a controllable throttle valve, and the second water pump 32 is an electronic water pump. Both are controlled in real time by the vehicle controller 4. The vehicle controller 4 monitors the intake air temperature of engine 21 in real time, dynamically adjusts the throttle valve opening and the water pump duty cycle, and stably controls the temperature of the intercooled and boosted air at the target value (35°C to 40°C). This achieves precise closed-loop control of the intercooler temperature, significantly improves the problem of condensate accumulation in the intake pipe, optimizes the combustion stability of engine 21, and ensures the power performance of the vehicle.

[0038] It should be noted that in this application, the water-cooled intercooler 23 is connected to the water-cooled heat dissipation circuit 1 where the electric drive component 12 is located. Its heat source mainly comes from the battery pack 121, the drive motor 122 and the generator 123. The heat generated is much lower than the heat generated by the combustion of the engine 21, which enables the water-cooled heat dissipation circuit 1 to participate in the transfer of heat from the intake side of the engine 21, which is conducive to achieving precise temperature control.

[0039] Based on bench test results, when the temperature after intercooling is above 25°C, the condensate at the engine intake manifold is significantly reduced; when the temperature is further increased to above 35°C, the condensate almost completely disappears. This is because the temperature difference between the temperature after intercooling and the operating temperature of the turbocharger compressor (approximately 55°C) is reduced, effectively inhibiting the condensation of water vapor in the air, thereby preventing the accumulation of condensate in the intake manifold.

[0040] This application achieves precise temperature control through the coordinated optimization of hardware and control systems. A water-cooled intercooler is connected in parallel to the vehicle's electric drive circuit cooling system, with the water inlet directly connected to the outlet of the electric drive circuit radiator. A controllable throttle valve is added to the pipeline. The control system monitors the temperature after intercooling in real time and dynamically adjusts the throttle valve opening and water pump duty cycle to maintain the temperature stably within the range of 35℃ to 40℃.

[0041] This range ensures that condensation is minimized (avoiding the risk of liquid buildup due to low temperatures) and prevents engine overheating caused by excessively high temperatures, thereby ensuring the engine continues to operate stably under high EGR conditions and significantly improving combustion efficiency and vehicle power.

[0042] Firstly, in some alternative embodiments: see Figure 1 As shown in the figure, this application embodiment provides a thermal management system, which further includes a controller 4 and a temperature sensor 5 disposed at the air outlet of the water-cooled intercooler 23. The temperature sensor 5 is used to detect the temperature of the cooled pressurized air. The temperature sensor 5, valve 31 and second water pump 32 are all connected to the controller 4.

[0043] In this embodiment, the thermal management system monitors the intake air temperature after intercooling in real time through temperature sensor 5. Controller 4 achieves precise closed-loop control of the temperature after intercooling by dynamically adjusting the opening of valve 31 and the duty cycle of the second water pump 32, thereby significantly reducing condensate buildup in the intake pipe. For example, valve 31 is preferably a controllable throttle valve with adjustable fluid flow, the second water pump 32 is an electronic water pump, and controller 4 is an automotive electronic control unit (ECU).

[0044] Firstly, in some alternative embodiments: see Figure 1 As shown, this application embodiment provides a thermal management system. The intercooling heat exchange branch 3 of the thermal management system includes a first pipeline connecting the outlet of the water-cooled intercooler 23 and the inlet of the radiator 13, and a second pipeline connecting the outlet of the radiator 13 and the inlet of the water-cooled intercooler 23. A valve 31 and a second water pump 32 are connected in series on the second pipeline.

[0045] In this embodiment, the water side of the water-cooled intercooler 23 is connected to the water-cooled heat dissipation circuit 1 via a first pipe and a second pipe. The first pipe and the second pipe are respectively connected to the inlet and outlet of the radiator 13 via a three-way valve. The radiator 13 releases heat from the intercooler intake side to the outside. The radiator 13 can work with a fan for heat dissipation, thus optimizing the pipe layout. The valve 31 and the second water pump 32 are arranged at the front end of the water-cooled intercooler 23 to ensure efficient heat exchange between the water-cooled intercooler 23 and the water-cooled heat dissipation circuit 1, improving the temperature control response speed and accuracy.

[0046] Firstly, in some alternative embodiments: see Figure 1 As shown in the figure, this application embodiment provides a thermal management system. The supercharger 22 of the thermal management system includes a compressor 221 and a turbine 222. The outlet of the compressor 221 is connected to the inlet of the water-cooled intercooler 23, and the inlet of the turbine 222 is connected to the exhaust port of the engine 21.

[0047] In this embodiment, the direct connection between the compressor 221 and the water-cooled intercooler 23 optimizes the cooling path of the pressurized air, improves cooling efficiency, and ensures that the temperature after intercooling remains stable within the target range.

[0048] Firstly, in some alternative embodiments: see Figure 1 As shown in the figure, this application embodiment provides a thermal management system in which the air inlet of the compressor 221 is connected to an air filter 24 and the exhaust outlet of the turbine 222 is connected to a catalytic converter 25.

[0049] In this embodiment, the integrated design of the air filter 24 and the catalyst 25 is used to ensure intake air cleanliness and exhaust treatment efficiency, respectively, and to synergistically improve the combustion stability and emission performance of the engine 21.

[0050] Firstly, in some alternative embodiments: see Figure 1 As shown, this application embodiment provides a thermal management system in which an EGR cooler 6 is connected between the exhaust port of the turbine 222 and the intake port of the compressor 221, and the exhaust port of the EGR cooler 6 is connected to the intake pipeline through an EGR valve 7.

[0051] In this embodiment, the EGR cooler 6 and the water-cooled intercooler 23 work together to effectively reduce the exhaust gas temperature, reduce the formation of condensate in the mixed gas, and support stable operation at high EGR rates.

[0052] Specifically, step one, such as Figure 1 As shown, a second water pump 32 and a valve 31 are arranged at the front end of the water-cooled intercooler 23. The outlet of the water-cooled intercooler 23 is connected to the inlet of the radiator 13, and the inlet of the water-cooled intercooler 23 is connected to the outlet of the radiator 13 through the second water pump 32 and the valve 31.

[0053] Step 2: Monitor the intake air temperature of engine 21 and the opening status of EGR valve 7;

[0054] Step 3: When it is detected that the engine 21 is not in EGR condition, the control function is not activated. At this time, the valve 31 is fully open normally, and the second water pump 32 is turned on as needed.

[0055] Step 4: When the engine 21 is detected to be in EGR mode, the intake air temperature after intercooling of the engine 21 is monitored. The target value of the intake air temperature after intercooling is set to 35°C to 40°C. When the temperature after intercooling is lower than 35°C, the opening of valve 31 in the pipeline where the water-cooled intercooler 23 is located and the duty cycle of the second water pump 32 are controlled to reduce the cooling capacity so that the temperature after intercooling reaches the target value.

[0056] Step 5: When the temperature after intercooling is at the target value, maintain the throttle valve opening and the duty cycle of the intercooler pump;

[0057] Step 6: When EGR valve 7 is detected to be closed and the closing time exceeds a certain threshold, the throttle valve opening is released to reduce the temperature after intercooling and improve the combustion environment.

[0058] It should be noted that existing solutions cannot control the temperature after the intercooler in real time, leading to potential misfires due to prolonged EGR operation and excessive condensation in the intake manifold, ultimately causing vehicle malfunctions and affecting vehicle use. This proposed solution improves condensation buildup in the intake manifold by controlling the temperature after the intercooler in real time, thereby enhancing engine combustion stability and ensuring overall vehicle performance.

[0059] Firstly, in some alternative embodiments: see Figure 1As shown in the figure, this application embodiment provides a thermal management system, the engine intake circuit 2 of which further includes a throttle valve 26 connected in series in the intake pipe between the engine 21 and the water-cooled intercooler 23.

[0060] In this embodiment, the throttle valve 26 is used to provide precise control of intake airflow and is linked with the intercooled temperature control system formed by the controller 4 to optimize the combustion efficiency and stability of the engine 21 under all operating conditions.

[0061] Firstly, in some alternative embodiments: see Figure 1 As shown, this application embodiment provides a thermal management system, the electric drive component 12 of which includes at least one of a battery pack 121, a drive motor 122, and a generator 123.

[0062] In this embodiment, the electric drive component 12 serves as a heat source, with its heat source mainly coming from the battery pack 121, drive motor 122, and generator 123. The heat generated is far lower than the heat generated by the combustion of the engine 21, which allows the radiator 13 to participate in the heat dissipation of the intercooler intake side while meeting the heat dissipation requirements of the electric drive component 12, which is beneficial for achieving precise temperature control.

[0063] Firstly, in some alternative embodiments: see Figure 1 As shown, this application embodiment provides a thermal management system, the water cooling circuit 1 of which further includes an electric water tank 14 connected in series between the radiator 13 and the electric drive component 12.

[0064] In this embodiment, the pressure and retention of the fluid in the water-cooled heat dissipation circuit 1 are controlled by the electric water-driven kettle 14, so that the fluid in the water-cooled heat dissipation circuit 1 has a stable flow rate and appropriate pressure, preventing cavitation and flow fluctuations, and enhancing the reliability and long-term operating performance of the thermal management system.

[0065] See Figure 1 As shown, a second aspect of this application provides a hybrid vehicle:

[0066] The hybrid vehicle is equipped with a thermal management system according to any of the above embodiments.

[0067] After the hybrid vehicle of this application embodiment is equipped with the thermal management system of the above-described thermal embodiment, the problem of condensation in the intake manifold can be significantly improved, the combustion stability of the engine 21 can be enhanced, and the power and reliability of the whole vehicle under high EGR rate can be ensured.

[0068] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0069] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0070] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A thermal management system, characterized in that, include: Water-cooled heat dissipation circuit (1), the water-cooled heat dissipation circuit (1) includes a first water pump (11), an electric drive component (12), and a radiator (13) connected in sequence through pipelines to form a circulation. Engine intake circuit (2), the engine intake circuit (2) includes engine (21) and turbocharger (22), and water-cooled intercooler (23) connected in series on the intake pipe between turbocharger (22) and engine (21). Intercooling heat exchange branch (3), the intercooling heat exchange branch (3) is connected in parallel with the water cooling heat dissipation circuit (1), and exchanges heat with the engine intake circuit (2) through the water cooling intercooler (23). A valve (31) and a second water pump (32) are connected in series on the intercooling heat exchange branch (3).

2. The thermal management system as described in claim 1, characterized in that: The thermal management system also includes a controller (4) and a temperature sensor (5) located at the outlet of the water-cooled intercooler (23). The temperature sensor (5) is used to detect the temperature of the pressurized air after cooling. The temperature sensor (5), valve (31), and second water pump (32) are all connected to the controller (4).

3. The thermal management system as described in claim 1, characterized in that: The intercooling heat exchange branch (3) includes a first pipeline connecting the outlet of the water-cooled intercooler (23) and the inlet of the radiator (13), and a second pipeline connecting the outlet of the radiator (13) and the inlet of the water-cooled intercooler (23). The valve (31) and the second water pump (32) are connected in series on the second pipeline.

4. The thermal management system as described in claim 1, characterized in that: The supercharger (22) includes a compressor (221) and a turbine (222). The outlet of the compressor (221) is connected to the inlet of the water-cooled intercooler (23), and the inlet of the turbine (222) is connected to the exhaust port of the engine (21).

5. The thermal management system as described in claim 4, characterized in that: The air inlet of the compressor (221) is connected to an air filter (24), and the exhaust outlet of the turbine (222) is connected to a catalyst (25).

6. The thermal management system as described in claim 5, characterized in that: An EGR cooler (6) is connected between the exhaust port of the turbine (222) and the intake port of the compressor (221), and the exhaust port of the EGR cooler (6) is connected to the intake pipeline through an EGR valve (7).

7. The thermal management system as described in claim 1, characterized in that: The engine intake circuit (2) also includes a throttle valve (26) connected in series in the intake pipe between the engine (21) and the water-cooled intercooler (23).

8. The thermal management system as described in claim 1, characterized in that: The electric drive component (12) includes at least one of a battery pack (121), a drive motor (122), and a generator (123).

9. The thermal management system as described in claim 1, characterized in that: The water-cooled heat dissipation circuit (1) also includes an electric water tank (14) connected in series between the radiator (13) and the electric drive component (12).

10. A hybrid vehicle, characterized in that: The hybrid vehicle is equipped with a thermal management system as described in any one of claims 1 to 9.

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