A distributed three-in-one thermal management system

Abstract

The utility model discloses a kind of distributed three-in-one thermal management systems, relate to engineering machinery field.A kind of distributed three-in-one thermal management system, comprising: whole vehicle controller, as core control unit;Battery system, including battery pack and temperature sensor;Motor electric control system, including motor, electric control and temperature sensor;Air conditioning system, including compressor, condenser, evaporative tank and control module;The utility model integrates battery system, motor electric control system and air conditioning system's thermal management resource, utilizes VCU as core control unit, realizes the efficient management and control to three major systems, with reduce cost, improve performance, simplify software workload and facilitate cleaning maintenance and the like advantages, applicable to electric loader and other engineering machinery, by separating independent arrangement of main machine and common heat dissipation unit, it is conducive to miniaturization after each sub-module, installed in the position facilitating cleaning maintenance, solve the problem that each heat dissipation submodule is dirty and blocked.

Description

Technical Field

[0001] This utility model belongs to the field of engineering machinery technology, specifically, it relates to a distributed three-in-one thermal management system. Background Technology

[0002] With the continuous development of electrification in construction machinery, technological innovation has become an inevitable trend. In order to enhance product competitiveness, the industry is gradually inclined to integrate multiple systems of the whole vehicle into one. This integration can effectively reduce manufacturers' costs, improve performance, and change the previous model of independent management of a single system.

[0003] However, most construction machinery still adopts the traditional design, with each battery management system (BMS), power system, and air conditioning system (AC) having its own independent thermal management system. This practice leads to serious waste of resources. Since each system is independently configured with cooling units, condenser fans, and other hardware, it not only increases production costs but also causes space occupation and energy loss. In view of this, this utility model is proposed. Utility Model Content

[0004] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art and provide a distributed three-in-one thermal management system that can overcome or at least partially solve the above problems.

[0005] To solve the above-mentioned technical problems, the basic concept of the technical solution adopted by this utility model is as follows: a distributed three-in-one thermal management system, including: a vehicle controller as the core control unit; a battery system including a battery pack and temperature sensors; a motor and electronic control system including a motor, electronic control, and temperature sensors; an air conditioning system including a compressor, condenser, evaporator, and control module; and a common heat dissipation unit including a condenser radiator fan, which provides heat dissipation support for the battery system cooling unit, the motor and electronic control system radiator, and the air conditioning system condenser; the vehicle controller is communicatively connected to the battery management module in the battery system, the sensors in the power system, and the DC controller in the air conditioning system, respectively, for receiving temperature signals and controlling the operation of the common heat dissipation unit.

[0006] Furthermore, the shared heat dissipation unit includes four sets of condenser radiator fans, wherein fan 1 and fan 2 are connected in parallel for heat dissipation of the condenser of the air conditioning system, and fan 3 and fan 4 are connected in parallel for shared heat dissipation of the radiator of the battery system cooling unit motor and electronic control system.

[0007] Furthermore, it also includes: a battery-side water pump and a motor-side water pump, respectively used to drive the coolant circulation of the battery system and the motor control system; an electronic expansion valve, used to regulate the refrigerant flow rate of the air conditioning system; and a high-pressure sensor and a low-pressure sensor, used to monitor the refrigerant pressure of the air conditioning system.

[0008] Furthermore, the battery system integrates a temperature acquisition module, which is directly connected to the battery inlet and outlet water temperature sensors, the motor control temperature sensor, the evaporator temperature sensor, the ambient temperature sensor, and the outlet air temperature sensor.

[0009] Furthermore, the battery system, motor control system, air conditioning system, and shared heat dissipation unit are arranged independently and installed in designated areas of the electric loader.

[0010] Furthermore, the vehicle controller is connected to the actuator via a LIN bus or CAN bus, and includes a drive circuit for controlling the speed of the brushless blower, relays, and fan.

[0011] After adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art: the present invention reduces the investment in hardware equipment and effectively reduces costs by sharing a heat dissipation device.

[0012] After resource integration, the heat dissipation management of each system becomes more efficient and coordinated, which helps to improve the overall performance of the electric loader.

[0013] The VCU replaces the TMS controller as the core controller, and the sensors and actuators inside the unit are directly controlled by the VCU, reducing the workload of software development and debugging.

[0014] The main unit and the shared heat dissipation unit are arranged separately and independently, which allows for the miniaturization of each sub-module and installation in a location that is easy to clean and maintain, thus solving the problem of each heat dissipation sub-module being prone to getting dirty and clogged.

[0015] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings. Attached Figure Description

[0016] In the attached diagram:

[0017] Figure 1 This is a system module connection diagram of this utility model;

[0018] Figure 2 This is a schematic diagram of the system principle of this utility model;

[0019] Figure 3 This utility model Figure 2 A schematic diagram of part A in the middle;

[0020] Figure 4 This utility model Figure 2 A schematic diagram of Part B;

[0021] Figure 5 This utility model Figure 2 A schematic diagram of section C;

[0022] Figure 6 This is a schematic diagram of the system structure of this utility model. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate this utility model, but are not intended to limit the scope of this utility model.

[0024] Example: Refer to Figures 1-6 As shown, a distributed three-in-one thermal management system includes: a vehicle controller as the core control unit; a battery system including a battery pack and temperature sensors; a motor and electronic control system including a motor, electronic control, and temperature sensors; an air conditioning system including a compressor, condenser, evaporator, and control module; and a shared heat dissipation unit including a condenser radiator fan, which provides heat dissipation support for the battery system cooling unit, the motor and electronic control system radiator, and the air conditioning system condenser. The vehicle controller is communicatively connected to the battery management module in the battery system, the sensors in the power system, and the DC controller in the air conditioning system, respectively, for receiving temperature signals and controlling the operation of the shared heat dissipation unit.

[0025] The shared heat dissipation unit includes four sets of condenser radiator fans, wherein fan 1 and fan 2 are connected in parallel for heat dissipation of the condenser of the air conditioning system, and fan 3 and fan 4 are connected in parallel for shared heat dissipation of the radiator of the battery system cooling unit motor and electronic control system.

[0026] It also includes: a battery-side water pump and a motor-side water pump, used to drive the coolant circulation of the battery system and the motor control system, respectively; an electronic expansion valve, used to regulate the refrigerant flow of the air conditioning system; and a high-pressure sensor and a low-pressure sensor, used to monitor the refrigerant pressure of the air conditioning system.

[0027] The battery system integrates a temperature acquisition module, which is directly connected to the battery inlet and outlet water temperature sensors, motor control temperature sensors, evaporator temperature sensors, ambient temperature sensors, and outlet air temperature sensors.

[0028] The battery system, motor and electronic control system, air conditioning system and common heat dissipation unit are arranged independently and installed in designated areas of the electric loader.

[0029] The vehicle controller is connected to the actuator via a LIN bus or CAN bus, and includes a drive circuit for controlling the speed of the brushless blower, relays, and fan.

[0030] Taking a certain model of electric loader as an example, the specific implementation of this distributed three-in-one thermal management system is as follows:

[0031] Hardware architecture: The vehicle control unit (VCU) is installed in the electrical control box under the cab. It communicates with the BMS in the battery system, the motor controller in the motor control system, and the DCU in the air conditioning system via the CAN bus to collect the temperature of the battery pack (25kWh lithium iron phosphate battery), the temperature of the motor (peak power 180kW) control system, and the operating parameters of the air conditioning system in real time.

[0032] Four 3000rpm brushless fans (fans 1-4) are integrated at the rear of the frame. Fans 1 and 2 correspond to the air conditioning system condenser (heat exchange area 8㎡), and fans 3 and 4 correspond to the battery system cooling plate (heat exchange area 5㎡) and the motor and electronic control system radiator (heat exchange area 6㎡). The fans use PWM speed control.

[0033] The battery side is equipped with a 24V DC water pump (flow rate 15L / min), and the motor side is equipped with a water pump of the same specification. The air conditioning system uses R134a refrigerant, and the opening of the electronic expansion valve is dynamically adjusted by the vehicle control unit (VCU) according to the evaporator temperature (-5℃~10℃).

[0034] Battery heat dissipation control: When the BMS detects that the battery pack temperature is ≥45℃, the VCU starts fans 3 and 4 at low speed (1500rpm). When the temperature is ≥50℃, the fans run at full speed, and the battery-side water pump is turned on at the same time.

[0035] Motor and electronic control system heat dissipation: When the motor and electronic control temperature is ≥80℃, the VCU will prioritize the use of fans 3 and 4 that are not occupied by the battery system. When the temperature is ≥95℃, the dual fans will be activated for coordinated heat dissipation.

[0036] Air conditioning cooling control: When the DCU receives a cooling command and the evaporator temperature is ≥12℃, the VCU starts the compressor and controls the speed of fans 1 and 2 to adjust according to the high pressure (1.5MPa~2.5MPa). When the pressure is ≥2.2MPa, the fans run at full speed.

[0037] Working principle: The VCU, as the core control unit, receives real-time battery pack status commands from the BMS, temperature information from the motor control unit, and air conditioning system commands from the DCU. When the BMS issues a command that the battery pack needs cooling, the VCU controls the battery system cooling unit and the corresponding shared fan to start working to dissipate heat from the battery pack. When the temperature of the motor control unit exceeds the set threshold, the VCU controls the shared fan and cooling device corresponding to the motor control system to start, dissipating heat from the motor control system. When the DCU issues a command that the air conditioning system needs cooling, the VCU controls the condenser fan and other components of the air conditioning system to operate, achieving the cooling function. Since the battery system cooling unit shares the same condenser fan with the air conditioning system and the condenser fan of the motor control system, it avoids the waste of resources caused by each system having its own independent cooling device. At the same time, the VCU directly controls the sensors and actuators inside the unit, simplifying the software workload.

[0038] The shared cooling unit is installed in the rear grille area of ​​the chassis, and the main unit (VCU, water pump, electronic expansion valve, etc.) is integrated in the maintenance compartment behind the cab. The spacing between each module is ≥300mm, which makes it easy for operators to clean from both sides of the loader and solves the problem of dirt and blockage caused by the compact space of traditional integrated modules.

[0039] This distributed three-in-one thermal management system integrates the thermal management resources of the battery system, motor control system, and air conditioning system, and uses the VCU as the core control unit to achieve efficient control of the three systems. It has the advantages of reducing costs, improving performance, simplifying software workload, and facilitating cleaning and maintenance, and is suitable for construction machinery such as electric loaders.

[0040] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model.

Claims

1. A distributed three-in-one thermal management system, characterized in that, include: The vehicle controller serves as the core control unit. Battery system, including battery pack and temperature sensor; Motor control system, including motor, control unit and temperature sensor; An air conditioning system, comprising a compressor, condenser, evaporator, and control module; A shared heat dissipation unit, including a condenser radiator fan, provides heat dissipation support for the battery system cooling unit, the motor and electronic control system radiator, and the air conditioning system condenser. The vehicle controller is communicatively connected to the battery management module in the battery system, the sensors in the power system, and the DC controller in the air conditioning system, respectively, and is used to receive temperature signals and control the operation of the shared heat dissipation unit.

2. The distributed three-in-one thermal management system according to claim 1, characterized in that, The shared heat dissipation unit includes four sets of condenser radiator fans, wherein fan 1 and fan 2 are connected in parallel for heat dissipation of the condenser of the air conditioning system, and fan 3 and fan 4 are connected in parallel for shared heat dissipation of the radiator of the battery system cooling unit motor and electronic control system.

3. The distributed three-in-one thermal management system according to claim 1, characterized in that, Also includes: The battery-side water pump and the motor-side water pump are used to drive the coolant circulation of the battery system and the motor control system, respectively. An electronic expansion valve is used to regulate the refrigerant flow rate of the air conditioning system; High-pressure and low-pressure sensors are used to monitor the refrigerant pressure of the air conditioning system.

4. The distributed three-in-one thermal management system according to claim 1, characterized in that, The battery system integrates a temperature acquisition module, which is directly connected to the battery inlet and outlet water temperature sensors, motor control temperature sensors, evaporator temperature sensors, ambient temperature sensors, and outlet air temperature sensors.

5. A distributed three-in-one thermal management system according to claim 3, characterized in that, The vehicle controller, battery-side water pump, motor-side water pump, electronic expansion valve, and shared cooling unit are arranged independently and installed in designated areas of the electric loader.

6. A distributed three-in-one thermal management system according to any one of claims 1-5, characterized in that, The vehicle controller is connected to the actuator via a LIN bus or CAN bus, and includes a drive circuit for controlling the speed of the brushless blower, relays, and fan.

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