A thermal management system, an electric energy device, and a vehicle
By placing the electrical modules in the liquid cooling circuit within the thermal management system and using coolant for cooling, the problem of improper heat handling of the electrical modules is solved, thereby improving the stability and reliability of the system while reducing materials and costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANGHAI COOL AIR TRANSPORT REFRIGERATION EQUIP
- Filing Date
- 2025-05-29
- Publication Date
- 2026-07-07
AI Technical Summary
In existing thermal management systems, the heat generated by electrical modules is not effectively handled, leading to excessively high controller temperatures, which affects system stability and reliability, and also increases material costs.
The electrical module is placed in the liquid cooling circuit and cooled by coolant. Through the synergistic effect of the refrigeration circuit and the liquid cooling circuit, the temperature of the electrical module can be regulated, eliminating the need for a cooling fan.
It improves system stability and reliability, reduces material costs, and enhances system flexibility and adaptability.
Smart Images
Figure CN224472503U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of rail transit air conditioning technology, and in particular to a thermal management system, electrical equipment and vehicle. Background Technology
[0002] The efficient operation of thermal management systems is crucial for ensuring equipment performance and safety. With technological advancements, various battery thermal management systems are widely used in fields such as new energy vehicles to ensure that batteries operate within a suitable temperature range, thereby extending battery life and improving their performance.
[0003] Typically, these systems achieve battery temperature control through complex liquid cooling and refrigeration circuits, while requiring a controller system to coordinate the operation of various components. However, the controller itself generates heat during operation, which, if not properly managed, can lead to overheating and consequently affect its stability and reliability.
[0004] In the process of realizing this utility model, the inventors discovered that the prior art has at least the following problems: the common solution is to add a cooling fan to the controller, but this not only increases the demand for additional materials and accessories, but also leads to an increase in the number of controller ports, thereby increasing the complexity and cost of the system. Utility Model Content
[0005] The purpose of this application is to provide a thermal management system that, by placing electrical modules in a liquid cooling circuit and using coolant to cool them, effectively improves the problems of increased material usage, system complexity, and cost caused by adding cooling fans in the prior art, while also improving the system's stability and reliability. Another purpose of this application is to provide an electrical power device and vehicle.
[0006] To achieve the above objectives, this application provides a thermal management system, comprising:
[0007] The heat exchanger is equipped with refrigerant channels and coolant channels for heat exchange.
[0008] A refrigeration circuit is connected to the refrigerant flow channel, and refrigerant can circulate between the refrigeration circuit and the refrigerant flow channel;
[0009] A liquid cooling circuit is connected to the coolant flow channel, and coolant can circulate between the liquid cooling circuit and the coolant flow channel;
[0010] An electrical module is located on the coolant path formed by the connection between the liquid cooling circuit and the coolant flow channel, so that the coolant flows through the electrical module.
[0011] In some embodiments, the coolant channel is provided with an inlet end, and the electrical module is located in the direction from the liquid cooling circuit to the inlet end of the coolant channel.
[0012] In some embodiments, the liquid cooling circuit includes:
[0013] The liquid cooling branch is connected to the cooling liquid flow channel of the heat exchanger;
[0014] A dry cooling branch is provided in parallel with the liquid cooling branch. The first parallel node of the liquid cooling branch and the dry cooling branch is located upstream of the liquid inlet end of the coolant flow channel. The dry cooling branch is connected to a dry cooler.
[0015] The electrical module is located upstream of the first parallel node of the liquid-cooled branch and the dry-cooled branch.
[0016] In some embodiments, the liquid cooling circuit includes a return water main line and an outlet water main line, the return water main line being connected to a first parallel node of the liquid cooling branch line and the dry cooling branch line, and the outlet water main line being connected to a second parallel node of the liquid cooling branch line and the dry cooling branch line;
[0017] The main return water line is equipped with a return water temperature sensor, the main outlet water line is equipped with an outlet water temperature sensor, the liquid cooling branch line is equipped with a first control valve, and the dry cooling branch line is equipped with a second control valve.
[0018] When the thermal management system is in normal mode, the refrigeration circuit is working, the liquid cooling circuit is working, the first control valve is open, and the second control valve is closed.
[0019] When the thermal management system is in energy-saving mode, the refrigeration circuit stops working, the liquid cooling circuit works, the first control valve opens, the second control valve opens, and the opening degree of the first control valve and the second control valve is adjusted and controlled according to the temperature detected by the return water temperature sensor and the outlet water temperature sensor.
[0020] When the thermal management system is in hybrid mode, the refrigeration circuit is working, the liquid cooling circuit is working, the first control valve is open, and the second control valve is open. The opening degree of the first control valve and the second control valve is adjusted and controlled according to the temperature detected by the return water temperature sensor and the outlet water temperature sensor.
[0021] In some embodiments, the coolant flow channel has an outlet end; the liquid cooling branch is connected to one or more heaters, the heaters being located in the direction from the liquid cooling branch to the outlet end of the coolant flow channel.
[0022] In some embodiments, the plurality of heaters are arranged in parallel.
[0023] In some embodiments, the refrigeration circuit is connected to one or more first heat exchange structures, and the dry cooler includes one or more second heat exchange structures and a refrigeration fan.
[0024] The first heat exchange structure and the second heat exchange structure share the refrigeration fan.
[0025] In some embodiments, the plurality of first heat exchange structures are arranged in parallel, and the plurality of second heat exchange structures are arranged in parallel.
[0026] This application also provides an electrical power device, including the aforementioned thermal management system.
[0027] This application also provides a vehicle that includes the aforementioned electrical power equipment.
[0028] Compared to existing technologies, the thermal management system provided in this application mainly includes a heat exchanger, a refrigeration circuit, a liquid cooling circuit, and an electrical module. The heat exchanger is equipped with a refrigerant flow channel and a coolant flow channel for heat exchange. The refrigeration circuit is connected to the refrigerant flow channel, and refrigerant can circulate between the refrigeration circuit and the refrigerant flow channel. The liquid cooling circuit is connected to the coolant flow channel, and coolant can circulate between the liquid cooling circuit and the coolant flow channel. The electrical module is located on the coolant path formed by the connection between the liquid cooling circuit and the coolant flow channel, so that coolant flows through the electrical module.
[0029] In existing thermal management systems, electrical modules (such as controllers) generate heat during operation, and traditional cooling solutions typically involve adding cooling fans to these modules. This approach not only increases the demand for additional materials and components but also leads to an increase in the number of controller ports, thereby increasing system complexity and cost. Furthermore, cooling fans have relatively low reliability; if they fail, the electrical modules may overheat, affecting the normal operation of the entire thermal management system.
[0030] To address the aforementioned problems, the thermal management system provided in this application overcomes the deficiencies of existing technologies through an innovative design approach. This thermal management system mainly includes a heat exchanger, a refrigeration circuit, a liquid-cooled circuit, and an electrical module. The heat exchanger has refrigerant and coolant channels for heat exchange. The refrigeration circuit is connected to the refrigerant channel, where the refrigerant circulates to achieve a refrigeration cycle. The liquid-cooled circuit is connected to the coolant channel, where the coolant circulates to absorb and dissipate heat. Crucially, the electrical module is positioned on the coolant path formed by the connection between the liquid-cooled circuit and the coolant channel. As the coolant flows through the electrical module, it exchanges heat with it, thereby maintaining the module's temperature within a suitable range. Both heating and cooling can be achieved through coolant temperature regulation.
[0031] The advantage of this design lies in its efficient use of the temperature characteristics of the coolant in the liquid cooling circuit, rather than introducing additional heat dissipation components such as cooling fans. By rationally adjusting the position of the liquid cooling circuit's pipes, the coolant can flow through the electrical module, thereby regulating its temperature. This solution not only effectively addresses the issues of increased material usage, system complexity, and cost associated with adding cooling fans, but also improves system stability and reliability. Because it does not rely on additional cooling fans, the system has fewer potential points of failure and operates more stably. Furthermore, this design offers excellent flexibility and adaptability; the electrical module can be an integrated controller or other temperature-controlled electrical components, making it suitable for various application scenarios.
[0032] Based on the above structural and process descriptions, it can be seen that the thermal management system has at least the following beneficial effects: By placing the electrical modules in the liquid cooling circuit and using coolant to cool them, the thermal management system effectively improves the problems of increased material, increased system complexity, and increased costs caused by adding cooling fans in the prior art, while improving the stability and reliability of the system. Attached Figure Description
[0033] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.
[0034] Figure 1 A schematic diagram of a thermal management system provided in an embodiment of this application;
[0035] Figure 2 A schematic diagram of the liquid cooling circuit provided in an embodiment of this application;
[0036] Figure 3 A schematic diagram of a refrigeration circuit provided in an embodiment of this application;
[0037] Figure 4 Another schematic diagram of the thermal protection device provided in the embodiments of this application.
[0038] in:
[0039] Thermal Management System 1000
[0040] Thermal protection device 100, electrical module 200,
[0041] Refrigeration circuit 1
[0042] Liquid cooling circuit 2, liquid cooling branch 201, heater branch 2011, return water sub-branch 2012, outlet water sub-branch 2013, dry cooling branch 202, return water main line 203, outlet water main line 204.
[0043] Heat exchanger 3, refrigerant flow channel 301, coolant flow channel 302, liquid inlet 3021, liquid outlet 3022
[0044] Dry cooler 4, second heat exchange structure 401, refrigeration fan 402,
[0045] 5. Return water temperature sensor
[0046] Water outlet temperature sensor 6
[0047] First control valve 7
[0048] Second control valve 8
[0049] Heater 9
[0050] First heat exchange structure 10
[0051] Compressor 11
[0052] Gas-liquid separator 12
[0053] Low-pressure sensor 13
[0054] Inhalation temperature sensor 14
[0055] First fluoride nozzle 15
[0056] One-way valve 16
[0057] Exhaust temperature sensor 17
[0058] Second fluoride nozzle 18
[0059] High pressure sensor 19
[0060] High pressure switch 20
[0061] Third fluoride nozzle 21
[0062] Filter 22
[0063] Sight glass 23
[0064] Electronic expansion valve 24
[0065] Circulating pump 25
[0066] Automatic air vent valve 26
[0067] Expansion tank 27
[0068] Liquid injection port 28.
[0069] Return water pressure sensor 29
[0070] Impurity filter 30
[0071] Drainage port 31.
[0072] Water pressure sensor 32. Detailed Implementation
[0073] 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, and 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.
[0074] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.
[0075] Please refer to Figures 1 to 3 ,in, Figure 1 This is a schematic diagram of a thermal management system provided in an embodiment of this application. Figure 2 This is a schematic diagram of the liquid cooling circuit provided in an embodiment of this application. Figure 3 This is a schematic diagram of a refrigeration circuit provided in an embodiment of this application.
[0076] like Figure 1 As shown, the thermal protection device 100 mainly includes a refrigeration circuit 1, a liquid cooling circuit 2, and a heat exchanger 3. The thermal protection device 100 achieves precise control of the coolant temperature through the synergistic effect of the refrigeration circuit 1, the liquid cooling circuit 2, and the heat exchanger 3. Specifically, the refrigeration circuit 1 is a compression refrigeration circuit.
[0077] Refrigeration circuit 1 provides refrigeration by transferring heat through refrigerant circulation; liquid cooling circuit 2 circulates coolant to provide stable temperature control for the equipment requiring cooling; heat exchanger 3 acts as a bridge between the two, facilitating heat exchange between the refrigerant and coolant, thereby ensuring that the coolant maintains a suitable temperature in liquid cooling circuit 2. This structure allows the thermal protection device 100 to flexibly adjust the coolant temperature under different operating conditions, meeting the thermal management needs of the equipment.
[0078] In some cases, the two ends of the liquid cooling circuit 2 are connected to two interfaces of the battery cabinet. The battery cabinet, for example, is the power battery cabinet of a new energy vehicle.
[0079] like Figure 1As shown, the thermal management system 1000 mainly includes a thermal protection device 100 and an electrical module 200. The thermal protection device 100 achieves precise control of the coolant temperature through the coordinated action of the refrigeration circuit 1, the liquid cooling circuit 2 and the heat exchanger 3, while the electrical module 200 is set in the liquid cooling circuit 2 and uses the coolant to regulate its temperature.
[0080] In a first specific embodiment, the thermal management system 1000 provided in this application mainly includes a heat exchanger 3, a refrigeration circuit 1, a liquid cooling circuit 2, and an electrical module 200. The heat exchanger 3 is provided with a refrigerant flow channel 301 and a coolant flow channel 302 for heat exchange. The refrigeration circuit 1 is connected to the refrigerant flow channel 301, and refrigerant can circulate between the refrigeration circuit 1 and the refrigerant flow channel 301. The liquid cooling circuit 2 is connected to the coolant flow channel 302, and coolant can circulate between the liquid cooling circuit 2 and the coolant flow channel 302. The electrical module 200 is located on the coolant path formed by the connection between the liquid cooling circuit 2 and the coolant flow channel 302, so that the coolant flows through the electrical module 200 to remove the heat from the electrical module 200.
[0081] During use, the coolant flows through the liquid cooling circuit 2 and the coolant flow channel 302, while the electrical module 200 is located on the coolant path formed by the connection between the liquid cooling circuit 2 and the coolant flow channel 302, and the coolant also flows through the electrical module 200.
[0082] It should be noted that the electrical module 200 in this embodiment is not limited to a specific electrical component; for example, it may be a controller module.
[0083] In some cases, electrical module 200 is a controller module and includes a controller / controller system / control system for thermal protection device 100, which is equivalent to the controller of battery thermal management system.
[0084] In the existing thermal management system 1000, electrical modules 200 (such as controllers) generate heat during operation, and traditional heat dissipation solutions typically involve adding cooling fans to the electrical modules 200. This approach not only increases the demand for additional materials and accessories but also leads to an increase in the number of controller ports, thereby increasing system complexity and cost. Furthermore, the reliability of cooling fans is relatively low; if a failure occurs, the electrical module 200 may overheat, thus affecting the normal operation of the entire thermal management system 1000.
[0085] To address the aforementioned problems, the thermal management system 1000 provided in this application effectively solves the deficiencies of the prior art through an innovative design concept. The thermal management system 1000 mainly includes a heat exchanger 3, a refrigeration circuit 1, a liquid-cooled circuit 2, and an electrical module 200. The heat exchanger 3 is equipped with a refrigerant flow channel 301 and a coolant flow channel 302 for heat exchange. The refrigeration circuit 1 is connected to the refrigerant flow channel 301, where the refrigerant circulates to achieve a refrigeration cycle. The liquid-cooled circuit 2 is connected to the coolant flow channel 302, where the coolant circulates to absorb and dissipate heat. Crucially, the electrical module 200 is positioned on the coolant path formed by the connection between the liquid-cooled circuit 2 and the coolant flow channel 302. When the coolant flows through the electrical module 200, it can exchange heat with it, thereby maintaining the temperature of the electrical module 200 within a suitable temperature range. Both heating and cooling can be achieved through temperature regulation of the coolant.
[0086] The advantage of this design lies in its efficient use of the temperature characteristics of the coolant in the liquid-cooled circuit 2, without introducing additional heat dissipation components such as cooling fans. By rationally adjusting the position of the liquid pipes in the liquid-cooled circuit 2, the coolant can flow through the electrical module 200, thereby regulating the temperature of the electrical module 200. This solution not only effectively addresses the issues of increased material usage, system complexity, and cost associated with adding cooling fans, but also improves system stability and reliability. Because it does not rely on additional cooling fans, the number of potential failure points is reduced, resulting in more stable operation. Furthermore, this design offers excellent flexibility and adaptability; the electrical module 200 can be an integrated controller or other electrical components requiring temperature control, making it suitable for various application scenarios.
[0087] Based on the above structural and process descriptions, it can be seen that the thermal management system 1000 has at least the following beneficial effects: By placing the electrical module 200 in the liquid cooling circuit 2 and using coolant to cool it, the thermal management system 1000 effectively improves the problems of increased material, increased system complexity, and increased cost caused by adding a cooling fan in the prior art, while improving the stability and reliability of the system.
[0088] In some cases, the liquid cooling circuit 2 is shipped without coolant. Of course, it is also possible that coolant is added after shipment, which should also fall within the scope of this embodiment. The relationship between the refrigeration circuit 1 and the refrigerant is similar to the relationship between the liquid cooling circuit 2 and the coolant, and will not be described again here.
[0089] In some embodiments, the coolant flow channel 302 is provided with an inlet end 3021, and the electrical module 200 is located in the direction of the liquid cooling circuit 2 leading to the inlet end 3021 of the coolant flow channel 302.
[0090] In this embodiment, this layout design is based on a thorough consideration of the temperature regulation requirements of the electrical module 200. During operation, the electrical module 200 generates heat or needs to be maintained within a certain temperature range. After the liquid cooling circuit 2 exchanges heat with the battery cabinet, the coolant will carry a certain amount of residual cold or heat. This residual cold or heat can be effectively utilized to regulate the temperature of the electrical module 200.
[0091] By positioning the electrical module 200 at the liquid inlet 3021 of the liquid cooling circuit 2, it is effectively ensured that the coolant, after passing through the battery cabinet, first exchanges heat with the battery cabinet, absorbing or releasing heat to regulate the battery cabinet's temperature. The remaining cold or heat in the coolant can then be further used to regulate the temperature of the electrical module 200. This design allows the liquid cooling circuit 2 to efficiently utilize the remaining cold or heat to maintain the temperature of the electrical module 200, achieving both heating and cooling through coolant temperature regulation.
[0092] It should be noted that in practical applications, the positional relationship between the electrical module 200 and the liquid cooling circuit 2 may change due to equipment layout or installation space limitations. By adjusting the piping position of the liquid cooling circuit 2, these changes can be better accommodated, effectively ensuring that the liquid cooling circuit 2 first acts on the battery cabinet and then further acts on the electrical module 200. This design not only improves the overall efficiency of the system but also enhances its stability and reliability, providing reliable temperature regulation for both the electrical module 200 and the battery cabinet.
[0093] like Figure 2 As shown, the liquid cooling circuit 2 includes a liquid cooling branch 201 and a dry cooling branch 202.
[0094] In some embodiments, the liquid cooling circuit 2 includes:
[0095] The liquid cooling branch 201 is connected to the coolant flow channel 302 of the heat exchanger 3;
[0096] Dry cooling branch 202 is connected in parallel with liquid cooling branch 201, and dry cooling branch 202 is connected to dry cooler 4.
[0097] In this embodiment, the liquid cooling branch 201, as the part of the liquid cooling circuit 2 that is connected to the coolant flow channel 302 of the heat exchanger 3, is also connected in parallel with the dry cooling branch 202, while the dry cooling branch 202 is not connected to the coolant flow channel 302 of the heat exchanger 3.
[0098] The thermal protection device 100 of the thermal management system 1000 further expands its functionality by introducing a dry cooling branch 202, which is connected in parallel with the liquid cooling branch 201, providing more flow direction options and functional options for the coolant. The dry cooling branch 202 is connected to the dry cooler 4, and together with the liquid cooling branch 201, they constitute the core part of the thermal protection device 100. The two work together to meet the thermal protection needs under different operating conditions, including both cooling and heating.
[0099] Furthermore, the first parallel node of the liquid cooling branch 201 and the dry cooling branch 202 is located upstream of the liquid inlet 3021 of the coolant flow channel 302, wherein the electrical module 200 is located upstream of the first parallel node of the liquid cooling branch 201 and the dry cooling branch 202.
[0100] In this embodiment, the first parallel node of the liquid-cooled branch 201 and the dry-cooled branch 202 is located upstream of the inlet end 3021 of the coolant flow channel 302. This layout design allows the liquid-cooled branch 201 to be directly connected to the coolant flow channel 302 of the heat exchanger 3, while the dry-cooled branch 202 is not directly connected to the coolant flow channel 302. This structural arrangement provides two options: liquid-cooled branch 201-heat exchanger 3 and dry-cooled branch 202-dry cooler 4. As a parallel branch, the dry-cooled branch 202 provides an additional flow direction option for the coolant, further enhancing the flexibility and adaptability of the system.
[0101] The electrical module 200 is located upstream of the first parallel node of the liquid-cooled branch 201 and the dry-cooled branch 202. This means that the coolant only enters the liquid-cooled branch 201 and the dry-cooled branch 202 for branching after flowing through the electrical module 200. This layout ensures that the coolant flowing through the electrical module 200 is a concentrated flow before branching; that is, the coolant has not yet been branched when passing through the electrical module 200, thus carrying more heat or cold energy for heat exchange with the electrical module 200. This design not only effectively ensures that the electrical module 200 can regulate its temperature under a more stable coolant flow rate but also improves the efficiency of the coolant in regulating the temperature of the electrical module 200. In this way, the system can further optimize the temperature control of the electrical module 200 while ensuring the temperature regulation of the battery cabinet, effectively ensuring its operation within a suitable temperature range.
[0102] like Figure 2 As shown, the liquid cooling circuit 2 includes a liquid cooling branch 201, a return water main 203, and an outlet water main 204.
[0103] In some cases, the return water main line 203 is connected to the first interface of the battery cabinet, and the outlet water main line 204 is connected to the second interface of the battery cabinet.
[0104] In some embodiments, the liquid cooling circuit 2 includes a return water main line 203 and an outlet water main line 204. The return water main line 203 is connected to a first parallel node of the liquid cooling branch line 201 and the dry cooling branch line 202, and the outlet water main line 204 is connected to a second parallel node of the liquid cooling branch line 201 and the dry cooling branch line 202.
[0105] In this embodiment, the dry cooling branch 202 and the liquid cooling branch 201 are connected in parallel between the return water main line 203 and the outlet water main line 204. This design allows the coolant to select different paths according to actual needs when flowing through the thermal management system 1000.
[0106] The advantage of this parallel configuration is that the liquid cooling branch 201 and the dry cooling branch 202 can work independently or collaboratively according to different operating conditions and needs. For example, when the ambient temperature is low, the dry cooling branch 202 can be used first for cooling to save energy; while when the ambient temperature is high or rapid cooling is required, the liquid cooling branch 201 and the dry cooling branch 202 can work simultaneously to provide a stronger cooling effect.
[0107] Furthermore, the main return water line 203 is equipped with a return water temperature sensor 5, the main outlet water line 204 is equipped with an outlet water temperature sensor 6, the liquid cooling branch line 201 is equipped with a first control valve 7, and the dry cooling branch line 202 is equipped with a second control valve 8.
[0108] In this embodiment, the thermal management system 1000 achieves precise control of the coolant temperature and flexible adjustment under different operating conditions by installing a return water temperature sensor 5 and an outlet water temperature sensor 6 on the return water main line 203 and the outlet water main line 204, respectively, and by installing a first control valve 7 and a second control valve 8 on the liquid cooling branch line 201 and the dry cooling branch line 202, respectively. This design allows the system to select different operating modes according to actual needs, thereby optimizing energy utilization and improving the overall efficiency of the system.
[0109] When the thermal management system 1000 is in normal mode, both the refrigeration circuit 1 and the liquid cooling circuit 2 operate normally. At this time, the first control valve 7 is open, allowing coolant to flow through the liquid cooling branch 201, while the second control valve 8 is closed, and the dry cooling branch 202 does not participate in coolant circulation. This mode is suitable for operating conditions requiring a stable cooling effect from the refrigeration circuit 1. The temperature of the coolant is regulated through the liquid cooling branch 201, effectively ensuring efficient system operation.
[0110] When the thermal management system 1000 is in energy-saving mode, refrigeration circuit 1 stops working, while liquid cooling circuit 2 continues to operate. At this time, both the first control valve 7 and the second control valve 8 are open, allowing coolant to be distributed between the liquid cooling branch 201 and the dry cooling branch 202. The opening degree of the first control valve 7 and the second control valve 8 is adjusted and controlled based on the temperatures detected by the return water temperature sensor 5 and the outlet water temperature sensor 6. This mode is suitable for operating conditions with low ambient temperatures or low cooling demands. By utilizing the low ambient temperature through the dry cooling branch 202 to lower the coolant temperature, energy is saved and the system's economy is improved.
[0111] When the thermal management system 1000 is in hybrid mode, refrigeration circuit 1 and liquid cooling circuit 2 operate simultaneously. At this time, both the first control valve 7 and the second control valve 8 are open, and coolant is distributed between the liquid cooling branch 201 and the dry cooling branch 202. Similarly, the opening degree of the first control valve 7 and the second control valve 8 is adjusted and controlled according to the temperatures detected by the return water temperature sensor 5 and the outlet water temperature sensor 6. This mode is suitable for operating conditions requiring rapid cooling or where the ambient temperature changes significantly. Through the synergistic action of refrigeration circuit 1 and the dry cooling branch 202, rapid regulation of the coolant temperature is achieved, ensuring stable system operation under complex conditions.
[0112] In some embodiments, the coolant flow channel 302 is provided with an outlet end 3022; the liquid cooling branch 201 is connected to one or more heaters 9, and the heaters 9 are located in the direction from the liquid cooling branch 201 to the outlet end 3022 of the coolant flow channel 302.
[0113] In this embodiment, by installing a heater 9 in the liquid cooling branch 201, the system can heat the coolant when needed, thereby meeting the temperature requirements under different operating conditions. For example, in scenarios where the ambient temperature is low or the coolant needs to be preheated, the heater 9 can effectively increase the coolant temperature. This temperature regulation capability enables the thermal management system 1000 to not only perform cooling functions but also provide heating functions when necessary, enhancing the system's versatility and adaptability.
[0114] The liquid cooling branch 201 has both cooling and heating functions, and achieves precise regulation of the coolant temperature through components such as heater 9 and heat exchanger 3. The dry cooling branch 202 mainly provides cooling function, and achieves cooling of the coolant through dry cooler 4.
[0115] In some cases, the refrigeration process of the liquid cooling branch 201 typically involves heat exchange between the refrigerant and the coolant, which may be accompanied by a phase change (such as refrigerant vaporization or liquefaction). In contrast, the refrigeration process of the dry cooling branch 202 typically does not involve a phase change; it primarily achieves coolant cooling through heat exchange between the dry cooler 4 and the external environment. Furthermore, when the liquid cooling branch 201 needs to perform refrigeration, the dry cooling branch 202 can serve as a backup path, ensuring more flexible and efficient coolant temperature regulation.
[0116] Through this design, the thermal protection device 100 of the thermal management system 1000 can not only meet diverse temperature regulation needs, but also optimize energy utilization according to actual working conditions, thereby improving the overall performance and reliability of the system.
[0117] like Figure 2 As shown, the first control valve 7 and the heater 9 are located downstream of the liquid outlet 3022 of the heat exchanger 3 on the liquid cooling branch 201. The first parallel node of the liquid cooling branch 201 and the dry cooling branch 202 is located upstream of the liquid inlet 3021 of the heat exchanger 3. The second parallel node of the liquid cooling branch 201 and the dry cooling branch 202 is located downstream of the heater 9.
[0118] In some embodiments, a plurality of heaters 9 are arranged in parallel.
[0119] In this embodiment, the heaters 9 are arranged in parallel, meaning each heater 9 is located in a branch circuit, and these branches are connected in parallel. The key to this design is that by distributing the heaters 9 across multiple branches and giving each heater 9 independent control capabilities, the entire thermal management system 1000 can flexibly adjust the heating power according to actual needs. Specifically, the heating power of each heater 9 is Q, and the number of heaters 9 is N, where N is a positive integer greater than 1. This means that by controlling the operating states of different numbers of heaters 9, the heating power of the thermal management system 1000 can be adjusted in multiple levels within the range of 0 to NQ, specifically within the adjustment range {kQ|k=0,1,...,N}. For example, when only a lower heating power is needed, only one heater 9 can be activated; while when a higher heating power is needed, multiple heaters 9, or even all branches, can be activated simultaneously to meet different temperature requirements.
[0120] This multi-level adjustment capability allows the thermal management system 1000 to precisely adjust the heating power according to the actual temperature requirements of the coolant. Simultaneously, because the number N of heaters 9 is greater than 1, and each heater 9 can be controlled independently, other branches can still operate normally when some heaters 9 fail, thus providing a backup function and improving the system's stability and reliability. Furthermore, by flexibly selecting the number of heaters 9 according to actual needs, unnecessary energy consumption is effectively avoided, achieving energy-saving functionality and meeting energy conservation and environmental protection requirements.
[0121] In addition, the "heating power" in this embodiment does not refer to the rated power of heater 9, but to the working power of heater 9 when it is working, such as the power in the off state or the power in the running state. This embodiment does not limit the specific working state, and the heating power is not a calibrated value like the rated power.
[0122] Please refer to Figure 4 , Figure 4 Another schematic diagram of the thermal protection device provided in the embodiments of this application.
[0123] In some embodiments, the refrigeration circuit 1 is connected to one or more first heat exchange structures 10, and the dry cooler 4 includes one or more second heat exchange structures 401 and a refrigeration fan 402.
[0124] The first heat exchange structure 10 and the second heat exchange structure 401 share the refrigeration fan 402, that is, the two are arranged in the refrigeration space generated when the refrigeration fan 402 is working.
[0125] In this embodiment, the thermal management system 1000 further improves the cooling efficiency and energy utilization efficiency of the system by optimizing the structure of the refrigeration circuit 1 and the dry cooler 4. The refrigeration circuit 1 is connected to one or more first heat exchange structures 10, while the dry cooler 4 includes one or more second heat exchange structures 401 and a cooling fan 402. The first heat exchange structures 10 and the second heat exchange structures 401 are arranged in the cooling space generated when the cooling fan 402 is working. This design allows the cooling fan 402 to simultaneously provide cooling airflow to the first heat exchange structures 10 and the second heat exchange structures 401, thereby achieving efficient heat exchange.
[0126] Specifically, the cooling fan 402 creates a cooling space during operation. The airflow within this space is cooled and used to lower the temperature of the first heat exchange structure 10 and the second heat exchange structure 401, transferring heat from the first heat exchange structure 10 and the second heat exchange structure 401 into the cooling space. Because the cooling airflow of the cooling fan 402 flows through both the first heat exchange structure 10 and the second heat exchange structure 401 simultaneously, it carries away the heat released by them, thereby achieving a highly efficient cooling process.
[0127] The advantage of this design lies in the shared cooling fan 402, which avoids configuring separate cooling equipment for the first heat exchange structure 10 and the second heat exchange structure 401, thereby reducing system complexity and energy consumption. By sharing the cooling fan 402, the thermal management system 1000 can not only improve cooling efficiency but also reduce equipment size and cost, while improving system reliability and ease of maintenance. In addition, this shared design can optimize space utilization, enabling the thermal management system 1000 to achieve efficient cooling function within a compact space.
[0128] In some cases, the first heat exchange structure 10 is equivalent to a condenser. The refrigeration fan 402 is equivalent to a condenser fan.
[0129] In some embodiments, a plurality of first heat exchange structures 10 are arranged in parallel, and a plurality of second heat exchange structures 401 are arranged in parallel.
[0130] In this embodiment, the thermal management system 1000 further optimizes the design of its heat exchange structure by using a parallel arrangement of multiple first heat exchange structures 10 and multiple second heat exchange structures 401, which significantly improves the overall performance and reliability of the system.
[0131] Specifically, multiple first heat exchange structures 10 are arranged in parallel in the refrigeration circuit 1. This design allows the refrigerant to exchange heat through multiple parallel heat exchange channels, thereby improving heat exchange efficiency. The parallel arrangement of the heat exchange structures can disperse the refrigerant flow, reduce the load on individual heat exchange structures, and make heat exchange more uniform and efficient. At the same time, this parallel design also increases the redundancy of the system. When one or more of the first heat exchange structures 10 fail, the other heat exchange structures can still operate normally, thereby ensuring the stable operation of the refrigeration circuit 1 and improving the reliability and stability of the system.
[0132] Similarly, multiple second heat exchange structures 401 are also arranged in parallel to work in conjunction with the refrigeration fan 402. This design not only improves the heat exchange efficiency of the dry cooler 4 but also enhances the redundancy and stability of the system. The parallel arrangement of the second heat exchange structures 401 ensures that heat is transferred more effectively to the refrigeration space when the coolant passes through the dry cooler 4, thereby achieving a better cooling effect. At the same time, this parallel design also provides a backup function for the system. When some heat exchange structures fail, the other heat exchange structures can continue to perform the heat exchange task, ensuring the normal operation of the dry cooler 4.
[0133] By employing this parallel configuration, the thermal management system 1000 not only improves heat exchange efficiency but also enhances system redundancy and stability. This design enables the thermal management system 1000 to maintain efficient and stable operation under complex conditions, while reducing the risk of system failure due to the malfunction of a single heat exchange structure, significantly improving system reliability and service life.
[0134] Please continue to refer to this. Figure 4 In one specific embodiment, the refrigeration circuit 1 of the thermal management system 1000 further includes a compressor 11, and the following components are disposed upstream of the compressor 11 and between the compressor 11 and the heat exchanger 3: a gas-liquid separator 12, a low-pressure sensor 13, a suction temperature sensor 14, and a first refrigerant inlet 15; the following components are disposed downstream of the compressor 11 and between the compressor 11 and the first heat exchange structure 10: a one-way valve 16, a discharge temperature sensor 17, a second refrigerant inlet 18, a high-pressure sensor 19, and a high-pressure switch 20; and the following components are disposed downstream of the compressor 11 and between the compressor 11 and the heat exchanger 3: a third refrigerant inlet 21, a filter 22, a sight glass 23, and an electronic expansion valve 24.
[0135] Under the driving force provided by the compressor 11, the refrigerant can achieve the following flow path: compressor 11 - first heat exchange structure 10 - electronic expansion valve 24 - refrigerant flow channel 301 of heat exchanger 3 - compressor 11, thereby realizing a refrigeration cycle. In addition, the refrigeration circuit 1 is equipped with a frequency converter, which is electrically connected to the compressor 11 to control the compressor 11 to operate at a variable frequency.
[0136] The liquid cooling circuit 2 of the thermal management system 1000 also includes a circulation pump 25, and upstream of the circulation pump 25 are: an automatic air vent valve 26, an expansion tank 27, an injection port 28, a return water temperature sensor 5, a return water pressure sensor 29, and an impurity filter 30. The circulation pump 25 is located in the return water main line 203, and the outlet water main line 204 is equipped with an outlet water outlet 31, an outlet water temperature sensor 6, and an outlet water pressure sensor 32.
[0137] The impurity filter 30 filters the coolant entering the liquid cooling circuit 2, preventing impurities in the coolant from damaging the circulating pump 25 and affecting the heat exchanger 3. The return water pressure sensor 29 and the outlet water pressure sensor 32 collect the return and outlet water pressure values of the coolant and feed these pressure values back to the controller for processing to execute relevant logic control. When the outlet or return water pressure is abnormal, the system will associate it with related faults to troubleshoot related problems in the return and outlet water pressures. For example, if the outlet water pressure is too high, the pump will stop operating; if the return water pressure is too low, an alarm will be issued. The drain port 31 and the fill port 28 are used to drain the coolant from the liquid cooling circuit 2 and to add coolant to it. The automatic air vent 26 is used to remove air from the liquid cooling circuit 2 when adding coolant, and can also remove gas flashed by the coolant during operation. The expansion tank 27 buffers the volume change of the coolant due to thermal expansion and contraction. One-way valve 16 prevents liquid refrigerant in the exhaust pipe from flowing back to compressor 11 during startup, thus avoiding damage to the compressor. Suction temperature sensor 14 and exhaust temperature sensor 17 monitor the operational stability of the refrigeration system and provide feedback signals to the controller. High-pressure safety switch 20 monitors the high-pressure condition of the refrigeration system to prevent compressor damage due to malfunction. High-pressure sensor 19 and low-pressure sensor 13 monitor the high and low pressure conditions of the refrigeration system to maintain stable operation. Gas-liquid separator 12 separates the refrigerant returning from the evaporator into a gas-liquid state, preventing liquid refrigerant from entering compressor 11 and causing damage. Dryer filter 22 filters impurities in the refrigeration system to prevent them from affecting the function of electronic expansion valve 24. Sight glass 23 observes the water content in the refrigeration system to prevent ice blockage due to excessive water content. Condenser fan provides cooling air to the condenser in the refrigeration system and, in certain modes, cools the dryer 4.
[0138] When the external environment is under normal cooling demand conditions, the thermal management system 1000 operates in normal cooling mode. Under these conditions, the ambient temperature is relatively high. To ensure the stable operation of the thermal protection device 100 of the thermal management system 1000, heat dissipation is required for the controller module 200. In normal cooling mode, the second control valve 8 is closed, and the coolant in the liquid cooling circuit 2 comes from the battery cabinet, resulting in a lower temperature. After passing through the impurity filter 30 and the circulation pump 25, the coolant returns to the liquid cooling circuit 2 at a still low temperature after cooling the battery cabinet. Therefore, the electrical module 200 is cooled by the coolant, causing a slight increase in coolant temperature. The coolant leaving the electrical module 200 is cooled by the heat exchanger 3 and then flows to the battery cabinet for further cooling via the heater 9 (without heating). After the coolant heats up in the battery cabinet, it re-enters the liquid cooling circuit 2 of the thermal protection device 100, completing one cycle. The heat exchanger 3 cools the coolant by absorbing heat through the evaporation of refrigerant in the cooling circuit 1. In refrigeration circuit 1, low-temperature, low-pressure refrigerant gas enters compressor 11 through suction pipe from gas-liquid separator 12. The refrigerant is compressed into high-temperature, high-pressure refrigerant gas, which then enters condenser and is cooled into high-temperature refrigerant liquid. After passing through dryer filter 22 and sight glass 23, it is throttled by electronic expansion valve 24 into low-temperature, low-pressure refrigerant liquid, which cools the coolant in heat exchanger 3. The low-temperature, low-pressure refrigerant gas evaporated in heat exchanger 3 re-enters gas-liquid separator 12 and then returns to compressor 11, completing a refrigeration cycle in normal refrigeration mode. At this time, refrigeration fan 402 needs to operate.
[0139] When the external environment is under normal heating demand conditions, the thermal management system 1000 operates in normal heating mode, with the second control valve 8 in the closed state. In this mode, the refrigeration circuit 1 stops operating. Under these conditions, the ambient temperature is relatively low, which in turn affects the temperature of the controller module 200, making it relatively low as well. Excessive low temperature can affect the safe and stable operation of the controller, therefore, a suitable temperature environment needs to be provided for the electrical module 200. Coolant enters through the liquid cooling circuit 2. After passing through the impurity filter 30 and the circulation pump 25, the coolant returns to the liquid cooling circuit 2 at a relatively high temperature after being heated by the battery cabinet. Therefore, the temperature of the electrical module 200 is maintained within a suitable range under the action of the coolant. After passing through the electrical module 200, the coolant passes through the heat exchanger 3 and reaches the heater 9. After being heated to the required temperature by the heater 9, the coolant travels through the liquid cooling circuit 2 to the battery cabinet for heat exchange. The coolant cooled by the battery cabinet returns to the liquid cooling circuit 2, thus completing the circulation of the liquid cooling circuit 2 in normal heating mode.
[0140] When the external environment is in a mixed-mode operation, the thermal management system 1000 operates in mixed mode. In this mixed-mode cooling, the second control valve 8 is open, and the first control valve 7 downstream of the heat exchanger 3 is also open, with the specific opening degree electrically adjusted based on the temperature detected by the outlet water temperature sensor 6. Under these conditions, the ambient temperature is not as high as in normal cooling mode, but similar to the need for cooling in the battery cabinet, the electrical module 200 of the thermal protection device 100 still requires a certain amount of cooling to achieve optimal operating conditions. Similarly, in this mode, the coolant enters through the liquid cooling circuit 2, passes through the impurity filter 30 and the circulation pump 25, and the electrical module 200 is cooled to a certain extent by the coolant. After leaving the electrical module 200, the coolant flows in two parts. One part is cooled by the heat exchanger 3, then passes through the first control valve 7 and the heater 9 (without heating), resulting in a cooled coolant; the other part of the coolant enters the dry cooler 4 through the second control valve 8, where it exchanges heat with the external environment and is cooled. The coolant passing through heat exchanger 3 and the coolant that has exchanged heat with the external environment through dry cooler 4 merge before leaving liquid cooling circuit 2 and are then transported together to the battery cabinet to cool it down. In mixed mode, refrigeration circuit 1 also needs to operate, cooling the coolant in heat exchanger 3. In this mode, refrigeration fan 402 not only cools the high-temperature, high-pressure refrigerant gas in the condenser of refrigeration circuit 1, but also dissipates heat from the coolant in dry cooler 4.
[0141] When the external environment is in energy-saving mode, the thermal management system 1000 operates in energy-saving mode. In energy-saving mode, the battery cabinet is cooled. At this time, the second control valve 8 is open, and the first control valve 7 after the heat exchanger 3 is also open. The specific opening degree is electrically adjusted according to the temperature detected by the outlet water temperature sensor 6. Under this condition, the ambient temperature is lower than in mixed mode, but like the locomotive battery cabinet, the controllers of the power battery and thermal protection device 100 need to be cooled to achieve a better operating temperature. In this mode, the refrigeration circuit 1 stops operating. Similarly, in this mode, the coolant enters through the liquid cooling circuit 2, passes through the impurity filter 30 and the circulation pump 25, and the electrical module 200 is cooled to a certain extent by the coolant. At this time, the coolant flows in two parts. Part of the coolant enters the dry cooler 4 through the second control valve 8. In the dry cooler 4, the coolant exchanges heat with the external environment due to the action of the refrigeration fan 402, resulting in cooled coolant. Another part of the coolant passes through the heat exchanger 3 (without cooling), the first control valve 7, and the heater 9 (without heating), merging with the coolant cooled by the dry cooler 4, and is then sent to the battery cabinet to cool the batteries. In this mode, the opening degree of the first control valve 7 and the second control valve 8 is determined by the temperature detected by the outlet water temperature sensor 6. Furthermore, although the refrigeration circuit 1 is not operating, the refrigeration fan 402 needs to operate because the coolant in the dry cooler 4 needs to be cooled.
[0142] In some cases, the refrigeration fan 402 is an axial flow fan. The heater 9 is a pipe heater (or pipe-type electric heater). The first control valve 7 and the second control valve 8 are electrically operated two-way valves. The heat exchanger 3 is a plate heat exchanger. The first heat exchange structure 10 and the second heat exchange structure 401 are finned heat exchangers.
[0143] This application also provides an electrical energy device, including the aforementioned thermal management system 1000.
[0144] The electrical equipment includes the aforementioned thermal management system 1000 and should possess all the beneficial technical effects of the aforementioned thermal management system 1000, which will not be elaborated here.
[0145] In this embodiment, the electrical equipment can be a device integrating a power battery, such as a battery cabinet, specifically the power battery cabinet of a new energy vehicle. By integrating the aforementioned thermal management system 1000, it meets the thermal management requirements of its internal battery or other energy storage components while using coolant to directly regulate the temperature of the electrical module 200. This design enables the electrical equipment to achieve precise temperature control of the internal battery and controller through the thermal management system 1000, thereby ensuring that the battery and controller operate within a suitable temperature range, extending their lifespan, and improving equipment performance and safety.
[0146] This application also provides a vehicle that includes the aforementioned electrical power equipment.
[0147] The vehicle includes the aforementioned electrical equipment and should possess all the beneficial technical effects of the aforementioned electrical equipment, which will not be elaborated here.
[0148] In this embodiment, the vehicle can be a new energy rail vehicle (or new energy locomotive), such as an electric train, subway, or light rail. This design enables the new energy rail vehicle to utilize the thermal management system 1000 for efficient thermal management of the onboard power battery or other energy storage devices, while simultaneously regulating the temperature of the electrical module 200. This ensures that the battery and controller maintain optimal operating temperatures under various operating conditions, thereby improving the vehicle's operating efficiency, reliability, and safety. Furthermore, by optimizing thermal management, the lifespan of the battery and controller can be extended, reducing vehicle maintenance costs.
[0149] It should be noted that many of the components mentioned in this application are general standard parts or components known to those skilled in the art, and their structure and principle can be learned by those skilled in the art through technical manuals or through conventional experimental methods.
[0150] It should be noted that in this specification, relational terms such as first and second are used only to distinguish one entity from several other entities, and do not necessarily require or imply any such actual relationship or order between these entities.
[0151] The thermal management system, electrical equipment, and vehicle provided in this application have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are merely for the purpose of helping to understand the method and core ideas of this application. It should be noted that those skilled in the art can make various improvements and modifications to this application without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this application.
Claims
1. A thermal management system, characterized in that, include: The heat exchanger is equipped with refrigerant channels and coolant channels for heat exchange. A refrigeration circuit is connected to the refrigerant flow channel, and refrigerant can circulate between the refrigeration circuit and the refrigerant flow channel; A liquid cooling circuit is connected to the coolant flow channel, and coolant can circulate between the liquid cooling circuit and the coolant flow channel; An electrical module is located on the coolant path formed by the connection between the liquid cooling circuit and the coolant flow channel, so that the coolant flows through the electrical module.
2. The thermal management system according to claim 1, characterized in that, The coolant flow channel is provided with an inlet end, and the electrical module is located in the direction from the liquid cooling circuit to the inlet end of the coolant flow channel.
3. The thermal management system according to claim 2, characterized in that, The liquid cooling circuit includes: The liquid cooling branch is connected to the cooling liquid flow channel of the heat exchanger; A dry cooling branch is provided in parallel with the liquid cooling branch. The first parallel node of the liquid cooling branch and the dry cooling branch is located upstream of the liquid inlet end of the coolant flow channel. The dry cooling branch is connected to a dry cooler. The electrical module is located upstream of the first parallel node of the liquid-cooled branch and the dry-cooled branch.
4. The thermal management system according to claim 3, characterized in that, The liquid cooling circuit includes a return water main line and an outlet water main line. The return water main line is connected to the first parallel node of the liquid cooling branch line and the dry cooling branch line. The outlet water main line is connected to the second parallel node of the liquid cooling branch line and the dry cooling branch line. The main return water line is equipped with a return water temperature sensor, the main outlet water line is equipped with an outlet water temperature sensor, the liquid cooling branch line is equipped with a first control valve, and the dry cooling branch line is equipped with a second control valve. When the thermal management system is in normal mode, the refrigeration circuit is working, the liquid cooling circuit is working, the first control valve is open, and the second control valve is closed. When the thermal management system is in energy-saving mode, the refrigeration circuit stops working, the liquid cooling circuit works, the first control valve opens, the second control valve opens, and the opening degree of the first control valve and the second control valve is adjusted and controlled according to the temperature detected by the return water temperature sensor and the outlet water temperature sensor. When the thermal management system is in hybrid mode, the refrigeration circuit is working, the liquid cooling circuit is working, the first control valve is open, and the second control valve is open. The opening degree of the first control valve and the second control valve is adjusted and controlled according to the temperature detected by the return water temperature sensor and the outlet water temperature sensor.
5. The thermal management system according to claim 3, characterized in that, The coolant flow channel is provided with an outlet end; the liquid cooling branch is connected to one or more heaters, and the heaters are located in the direction from the liquid cooling branch to the outlet end of the coolant flow channel.
6. The thermal management system according to claim 5, characterized in that, The multiple heaters are connected in parallel.
7. The thermal management system according to claim 3, characterized in that, The refrigeration circuit is connected to one or more first heat exchange structures, and the dry cooler includes one or more second heat exchange structures and a refrigeration fan. The first heat exchange structure and the second heat exchange structure share the refrigeration fan.
8. The thermal management system according to claim 7, characterized in that, The plurality of first heat exchange structures are arranged in parallel, and the plurality of second heat exchange structures are arranged in parallel.
9. An electrical energy device, characterized in that, Includes the thermal management system as described in any one of claims 1 to 8.
10. A vehicle, characterized in that, Includes the electrical power equipment as described in claim 9.