Integrated thermal management system for an electric excavator and electric excavator

Abstract

The embodiment of the application provides an integrated thermal management system of an electric excavator and the electric excavator, and relates to the technical field of electric excavators. The integrated thermal management system comprises a cab air conditioning system, a motor electric control cooling system and a battery thermal management system. The cab air conditioning system is connected with the battery thermal management system. The cab air conditioning system comprises a condenser, the motor electric control cooling system comprises an integrated cooling structure, the integrated cooling structure comprises a water radiator, an oil radiator and a ringless electronic fan integrated on the water radiator and the oil radiator respectively, and the integrated cooling structure is arranged beside the condenser. The system is used to improve the thermal management efficiency and effect, improve the overall performance and reliability of the electric excavator and the like.

Description

Technical Field

[0001] This application relates to the field of electric excavator technology, and more particularly to an integrated thermal management system for an electric excavator and an electric excavator. Background Technology

[0002] With increasing global emphasis on sustainable development and environmental protection, electric excavators, as an environmentally friendly type of construction machinery, are gradually gaining an important position in the market. The thermal management system is a crucial component of electric excavators, determining whether they can operate comfortably and normally.

[0003] In existing technologies, the thermal management system of electric excavators typically consists of multiple independent subsystems, each operating independently without effective integration and coordination, resulting in low overall system efficiency. To improve the overall performance and reliability of electric excavators and meet the requirements of modern construction machinery for high efficiency, environmental protection, and intelligence, integrated management of the electric excavator's thermal management system is necessary. Utility Model Content

[0004] To address the aforementioned technical problems, embodiments of this application provide an integrated thermal management system for an electric excavator and an electric excavator.

[0005] In a first aspect, embodiments of this application provide an integrated thermal management system for an electric excavator, the integrated thermal management system including a cab air conditioning system, a motor electronic control cooling system, and a battery thermal management system;

[0006] The cab air conditioning system is connected to the battery thermal management system.

[0007] The cab air conditioning system includes a condenser, and the motor electronic control cooling system includes an integrated cooling structure. The integrated cooling structure includes a water radiator, an oil radiator, and a ringless electronic fan integrated on the water radiator and the oil radiator respectively. The integrated cooling structure is located next to the condenser.

[0008] In one possible implementation, the cab air conditioning system further includes: an electric compressor, an evaporator, and a first electronic expansion valve;

[0009] The input end of the electric compressor is connected to the evaporator, the output end of the electric compressor is connected to the input end of the condenser, and the output end of the condenser is connected to the first electronic expansion valve.

[0010] In one possible implementation, the cab air conditioning system further includes: a blower and an air heater;

[0011] Both the blower and the air heater are located on the side of the evaporator.

[0012] In one possible implementation, the input end of the electric compressor is equipped with an intake air temperature sensor and a low-pressure sensor, the output end of the electric compressor is equipped with a high-pressure sensor and an exhaust air temperature sensor, and the return air inlet of the evaporator is equipped with a return air temperature sensor.

[0013] In one possible implementation, the motor electronic control cooling system further includes: an all-in-one controller, a motor, a first electronic water pump, a first expansion tank, a hydraulic main pump, and an oil tank;

[0014] The water radiator is connected in series with the multi-function controller, the motor, and the first electronic water pump in sequence. The first electronic water pump is also connected to the first expansion tank.

[0015] The oil radiator is connected in series with the multi-function controller, the motor, the hydraulic main pump, the working device of the electric excavator, and the oil tank.

[0016] In one possible implementation, a first liquid level sensor is provided on the first expansion tank; an inlet water temperature sensor is provided at the input end of the water radiator, and an outlet water temperature sensor is provided at the output end of the water radiator.

[0017] The oil tank is equipped with a second liquid level sensor; the input end of the oil radiator is equipped with an oil inlet temperature sensor, and the output end of the oil radiator is equipped with an oil outlet temperature sensor.

[0018] In one possible implementation, the first electronic water pump has a pre-charge function, and the power cord of the first electronic water pump uses a 2mm power cord.

[0019] In one possible implementation, the battery thermal management system includes: a power battery, a second electronic expansion valve, a plate heat exchanger, a second electronic water pump, and a second expansion tank;

[0020] The plate heat exchanger is connected in parallel to both ends of the evaporator via a second electronic expansion valve. The plate heat exchanger is also connected to the power battery. The power battery is connected to the second electronic water pump, and the second electronic water pump is also connected to the second expansion tank.

[0021] In one possible implementation, the battery thermal management system further includes a water heater; wherein the water heater is connected to the power battery; and a battery water temperature sensor is provided at the water inlet of the power battery.

[0022] Secondly, embodiments of this application provide an electric excavator, the electric excavator including the first aspect and / or various possible integrated thermal management systems of the first aspect.

[0023] The integrated thermal management system and electric excavator provided in this application embodiment effectively combine the cab air conditioning system, motor electronic control cooling system, and battery thermal management system. By utilizing an integrated cooling structure and optimized layout design, it not only simplifies the system structure and improves the integration of thermal management, but also enhances the thermal management efficiency and heat dissipation effect of the electric excavator, which helps to reduce equipment maintenance costs and improve the reliability and service life of the equipment. Attached Figure Description

[0024] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0025] Figure 1 This is a schematic diagram of the structure of an integrated thermal management system for an electric excavator provided in an embodiment of this application.

[0026] Explanation of reference numerals in the attached figures:

[0027] 100 - Integrated Thermal Management System; 1 - Condenser; 2 - Water Radiator; 3 - Oil Radiator; 4 - Circulatorless Electric Fan; 5 - Electric Compressor; 6 - Evaporator; 7 - First Electronic Expansion Valve; 8 - Blower; 9 - Air Heater; 10 - Inlet Air Temperature Sensor; 11 - Low Pressure Sensor; 12 - High Pressure Sensor; 13 - Exhaust Air Temperature Sensor; 14 - Return Air Temperature Sensor; 15 - Multi-function Controller; 16 - Motor; 17 - First Electronic Water Pump; 18 19-First expansion tank; 20-Hydraulic main pump; 21-Oil tank; 22-First liquid level sensor; 23-Inlet water temperature sensor; 24-Outlet water temperature sensor; 25-Second liquid level sensor; 26-Inlet oil temperature sensor; 27-Power battery; 28-Second electronic expansion valve; 29-Plate heat exchanger; 30-Second electronic water pump; 31-Second expansion tank; 32-Water heater; 33-Battery water temperature sensor; 34-Working device.

[0028] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0029] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0030] Currently, large electric excavators suffer from pain points such as high energy consumption, low range, and limited space. These problems greatly reduce the user experience for customers. Therefore, it is necessary to integrate the thermal management system of electric excavators to optimize control strategies.

[0031] In one example, the air conditioning cooling system and the battery cooling system share a single radiator. Additionally, the waste heat from the battery pack can be used to provide some heat to the air conditioning system, thus saving overall vehicle energy consumption. However, this integrated thermal management system suffers from low integration, complex structure, low heat dissipation efficiency, and difficult maintenance.

[0032] To address the aforementioned technical problems, this application provides an integrated thermal management system for an electric excavator. This system integrates a cab air conditioning system, a motor control cooling system, and a battery thermal management system. Furthermore, it incorporates an integrated cooling structure within the motor control cooling system. This integrated cooling structure includes a water radiator, an oil radiator, and a ringless electronic fan integrated into both the water radiator and the oil radiator. This integrated cooling structure is located beside the condenser of the cab air conditioning system. Based on this, not only can the heat dissipation effect be improved, saving overall vehicle energy consumption, but it also provides protection against fan reversal.

[0033] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0034] Figure 1 This is a schematic diagram of the integrated thermal management system for an electric excavator, provided as an embodiment of this application. Figure 1As shown in the embodiment of this application, the integrated thermal management system 100 for an electric excavator includes: a cab air conditioning system, a motor electronic control cooling system, and a battery thermal management system. The cab air conditioning system is connected to the battery thermal management system. The cab air conditioning system includes a condenser 1, and the motor electronic control cooling system includes an integrated cooling structure. The integrated cooling structure includes a water radiator 2, an oil radiator 3, and a ringless electric fan 4 integrated on the water radiator 2 and the oil radiator 3, respectively. The integrated cooling structure is located beside the condenser 1.

[0035] For example, the cab air conditioning system is used to regulate the temperature inside the cab to provide a comfortable working environment for the driver. The motor and electronic control cooling system is used to cool the motor and electronic control components of the electric excavator to ensure they operate within their optimal temperature range and prevent performance degradation or damage caused by overheating. The battery thermal management system is used to manage the battery temperature, ensuring that the battery operates within a safe and efficient temperature range. In this embodiment, the cab air conditioning system is connected to the battery thermal management system, sharing some thermal management resources or pathways. When the power battery of the battery thermal management system needs heat dissipation, the cab air conditioning system can provide the heat dissipation capacity. Through this resource sharing, the overall thermal management efficiency can be improved.

[0036] The integrated cooling structure in the motor and electronic control cooling system is used to cool the motor and electronic control system of the electric excavator. The water radiator 2 removes heat using cooling water, while the oil radiator 3 removes heat using hydraulic oil. The ringless electronic fan 4, also known as a "commutatorless electronic fan," typically refers to a fan driven by a brushless DC motor or permanent magnet synchronous motor. Its core characteristic is the absence of a mechanical commutator (such as carbon brushes and commutation rings), with commutation and speed regulation achieved through an electronic controller. In this application, the ringless electronic fan 4 also eliminates the outermost frame, reducing the impact of the frame on reverse rotation and achieving reverse rotation protection for the fan. The ringless electronic fan 4 is used to accelerate cooling speed, achieving better cooling effect. The integrated cooling structure is located beside the condenser 1 of the cab air conditioning system. When the integrated cooling structure and condenser 1 work simultaneously, better heat dissipation can be achieved, contributing to improved overall heat dissipation capacity.

[0037] In the integrated thermal management system of the electric excavator provided in this application embodiment, the integrated thermal management system effectively combines the cab air conditioning system, the motor electronic control cooling system, and the battery thermal management system. By utilizing an integrated cooling structure and optimized layout design, it not only simplifies the system structure and improves the integration of thermal management, but also enhances the thermal management efficiency and heat dissipation effect of the electric excavator, which helps to reduce equipment maintenance costs and improve the reliability and service life of the equipment.

[0038] Alternatively, in one possible embodiment, such as Figure 1As shown, the cab air conditioning system may further include: an electric compressor 5, an evaporator 6, and a first electronic expansion valve 7; wherein, the input end of the electric compressor 5 is connected to the evaporator 6 via a pipeline, the output end of the electric compressor 5 is connected to the input end of the condenser 1 via a pipeline, and the output end of the condenser 1 is connected to the first electronic expansion valve 7 via a pipeline.

[0039] For example, the electric compressor 5 is electrically driven and used to compress the refrigerant gas, thereby increasing its temperature and pressure. The evaporator 6, also known as the evaporator chamber, is the part of the air conditioning system responsible for absorbing heat. The refrigerant evaporates in the evaporator 6, thereby absorbing heat from the surrounding air and lowering the air temperature. The first electronic expansion valve 7 is used to control the flow rate of refrigerant to the driver's cab. By adjusting the valve opening, the refrigerant flow rate can be precisely controlled to optimize the cooling effect and system efficiency. The condenser 1 is used to cool and condense the high-temperature, high-pressure refrigerant gas output from the electric compressor 5 into a liquid.

[0040] Based on the structural relationship of the evaporator 6, electric compressor 5, condenser 1, and first electronic expansion valve 7 connected in series, the following can be achieved: In the evaporator 6, the refrigerant absorbs heat and evaporates into gas, and the refrigerant is drawn into the electric compressor 5 under low pressure and low temperature conditions; then, the electric compressor 5 compresses the low-pressure gas into high-pressure and high-temperature gas and delivers it to the condenser 1; in the condenser 1, the refrigerant releases heat and condenses into liquid, and the condensed high-pressure liquid refrigerant will enter the evaporator 6 to evaporate again and absorb heat.

[0041] Through the design of the cab air conditioning system described above, the cab air conditioning system can efficiently circulate refrigerant and achieve temperature regulation inside the cab.

[0042] Alternatively, in one possible embodiment, such as Figure 1 As shown, the cab air conditioning system also includes a blower 8 and an air heater 9; both the blower 8 and the air heater 9 are located on the side of the evaporator 6.

[0043] For example, the primary function of the blower 8 is to drive airflow, ensuring rapid air circulation and temperature regulation within the cab by forcing air through the evaporator 6 and air heater 9. The air heater 9 is used to heat the air when needed to increase the temperature within the cab, which is particularly important for operation in cold environments, providing additional comfort. Positioning the blower 8 and air heater 9 beside the evaporator 6 helps optimize and utilize space, and also facilitates the implementation of cooling / heating functions.

[0044] This embodiment, by adding a blower 8 and an air heater 9, enables the cab air conditioning system to provide flexible temperature control under different environmental conditions, allowing it to both cool and heat, significantly enhancing the functionality and adaptability of the cab air conditioning system and providing a comfortable working environment under various conditions.

[0045] Alternatively, in one possible embodiment, such as Figure 1 As shown, the input end of the electric compressor 5 is equipped with an intake air temperature sensor 10 and a low-pressure sensor 11, and the output end of the electric compressor 5 is equipped with a high-pressure sensor 12 and an exhaust air temperature sensor 13; the return air inlet of the evaporator 6 is equipped with a return air temperature sensor 14.

[0046] For example, the intake air temperature sensor 10 is used to measure the temperature of the refrigerant gas entering the electric compressor 5; the low pressure sensor 11 is used to measure the pressure of the refrigerant entering the low-pressure side of the electric compressor 5; the high pressure sensor 12 is used to measure the pressure of the high-pressure refrigerant output by the electric compressor 5; the exhaust air temperature sensor 13 is used to measure the temperature of the refrigerant gas discharged by the electric compressor 5; and the return air temperature sensor 14 is used to measure the temperature of the return air in the evaporator 6.

[0047] Optionally, the intake air temperature sensor 10 and the low-pressure sensor 11 can be separate sensors or integrated temperature and pressure (PT) sensors; similarly, the high-pressure sensor 12 and the exhaust air temperature sensor 13 can also be separate sensors or integrated temperature and pressure (PT) sensors, and the embodiments of this application are not limited thereto.

[0048] By integrating multiple sensors into the cab air conditioning system, key parameters of the air conditioning system can be monitored in real time, which helps to achieve accurate monitoring and intelligent control of the air conditioning system.

[0049] Alternatively, in one possible embodiment, such as Figure 1 As shown, the motor control cooling system also includes: a multi-function controller 15, a motor 16, a first electronic water pump 17, a first expansion tank 18, a hydraulic main pump 19, and an oil tank 20; wherein, the water radiator 2 is connected in series with the multi-function controller 15, the motor 16, and the first electronic water pump 17 via pipelines, and the first electronic water pump 17 is also connected to the first expansion tank 18 via pipelines; the oil radiator 3 is connected in series with the multi-function controller 15, the motor 16, the hydraulic main pump 19, the working device 34 of the electric excavator, and the oil tank 20 via pipelines.

[0050] For example, the all-in-one controller 15 is used to manage and control the motor 16 in the electric motor cooling system, such as managing the working status of the motor 16. The motor 16 is the core drive device of the electric excavator, and the heat it generates needs to be effectively managed to ensure its normal operation. The first electronic water pump 17 is responsible for circulating coolant (water) in the water cooling circuit to remove the heat generated by the motor 16 and the all-in-one controller 15. The first expansion tank 18 is used to accommodate the volume change of coolant in the water cooling circuit due to temperature changes, preventing the system pressure from becoming too high. The hydraulic main pump 19 is responsible for circulating coolant (oil) in the oil cooling circuit. The oil radiator 3 can not only cool the all-in-one controller 15 and the motor 16, but also cool the working device 34 of the electric excavator. The oil tank 20 is used to hold the coolant (oil) in the oil cooling circuit. The working device 34 may include the boom, stick, and bucket of the electric excavator, etc., which is not limited in this embodiment.

[0051] This embodiment provides an efficient, reliable, and flexible motor control cooling system by integrating multiple components and control strategies. It is suitable for the complex working environment of electric excavators. Through water cooling circuits and oil cooling circuits, it can effectively manage the heat generated by different components and improve the overall cooling efficiency.

[0052] Alternatively, in one possible embodiment, such as Figure 1 As shown, a first liquid level sensor 21 is installed on the first expansion tank 18; an inlet water temperature sensor 22 is installed at the input end of the water radiator 2, and an outlet water temperature sensor 23 is installed at the output end of the water radiator 2; a second liquid level sensor 24 is installed on the oil tank 20; an inlet oil temperature sensor 25 is installed at the input end of the oil radiator 3, and an outlet oil temperature sensor 26 is installed at the output end of the oil radiator 3.

[0053] For example, the first level sensor 21 monitors the coolant level in the first expansion tank 18. By monitoring the level, insufficient coolant or leakage can be detected, ensuring the normal operation of the water cooling circuit. The inlet temperature sensor 22 measures the coolant temperature entering the water radiator 2, and the outlet temperature sensor 23 measures the coolant temperature leaving the water radiator 2. The corresponding controller (such as a vehicle controller, EAC controller, or other controller used for thermal management) can evaluate the heat dissipation efficiency of the water radiator 2 by comparing the inlet and outlet temperatures. The second level sensor 24 monitors the coolant level in the oil tank 20, helping to detect the coolant status in the oil cooling circuit. The inlet oil temperature sensor 25 measures the coolant temperature entering the oil radiator 3, providing information about the thermal load of the motor 16 and related components. The outlet oil temperature sensor 26 measures the coolant temperature leaving the oil radiator 3, used to evaluate the heat dissipation efficiency of the oil radiator 3.

[0054] The aforementioned sensors provide real-time monitoring of key parameters of the motor's electronic control cooling system, which can be used to determine the system's operating status and efficiency. They help detect potential faults such as coolant leakage, radiator efficiency reduction, or system overheating, enabling precise monitoring and intelligent control of the cooling system and improving the overall performance, reliability, and maintenance efficiency of the system.

[0055] Alternatively, in one possible embodiment, such as Figure 1 As shown, the first electronic water pump 17 has a pre-charge function, and the power cord of the first electronic water pump 17 uses a 2mm power cord.

[0056] For example, the pre-charge function refers to charging the internal capacitor through a pre-charge circuit before the high-voltage circuit starts, thereby reducing the instantaneous high voltage and current surge generated when the high-voltage relay closes, thus protecting high-voltage components such as the electronic water pump from damage. For instance, the pre-charge relay can be integrated into the electronic water pump. When the pump is first turned on, the pump's own controller sends a command and opens the pre-charge circuit, thereby reducing the instantaneous current when the pump starts and preventing damage from overcurrent. After the current stabilizes, the pump's power supply circuit resumes normal power supply.

[0057] A 2mm power cord refers to a wire diameter (i.e., the cross-sectional diameter of the wire conductor) of 2 millimeters. This specification of power cord can provide sufficient current carrying capacity to meet the power requirements of the pump. To ensure a more stable voltage when the electronic water pump of this application is turned on and to improve the reliability of the power supply to the water pump circuit, the wire diameter of the electronic water pump is increased to 2mm, corresponding to a cross-sectional area of ​​approximately 3.3320 square millimeters.

[0058] In this embodiment, the performance and reliability of the electric water pump are significantly improved by introducing a pre-charge function and using a 2mm power cord. These designs not only protect the pump's lifespan but also optimize the startup efficiency and overall safety of the cooling system.

[0059] Alternatively, in one possible embodiment, such as Figure 1 As shown, the battery thermal management system includes: a power battery 27, a second electronic expansion valve 28, a plate heat exchanger 29, a second electronic water pump 30, and a second expansion tank 31; wherein, the plate heat exchanger 29 is connected in parallel to both ends of the evaporator 6 via the second electronic expansion valve 28 through a pipeline, the plate heat exchanger 29 is also connected to the power battery 27 through a pipeline, the power battery 27 is connected to the second electronic water pump 30 through a pipeline, and the second electronic water pump 30 is also connected to the second expansion tank 31 through a pipeline.

[0060] For example, the power battery 27 is the core energy source of the electric excavator. The battery's performance and lifespan are closely related to its operating temperature, thus requiring effective thermal management. The second electronic expansion valve 28 controls the flow rate of refrigerant to the power battery 27. By adjusting the opening of the expansion valve, the amount of refrigerant flowing to the power battery 27 can be precisely controlled. The plate heat exchanger 29 is a highly efficient heat exchange device used for heat exchange between the refrigerant and the battery coolant, enabling rapid and effective regulation of the battery temperature. The second electronic water pump 30 is responsible for circulating coolant (water) in the battery cooling circuit to remove the heat generated by the battery. The second expansion tank 31 is used to accommodate changes in coolant volume caused by temperature variations in the battery cooling circuit, preventing excessive system pressure.

[0061] This application provides an efficient and reliable battery thermal management system suitable for the working needs of electric excavators by integrating a plate heat exchanger 29, an electronic expansion valve, and an electronic water pump.

[0062] Alternatively, in one possible embodiment, such as Figure 1 As shown, the battery thermal management system may further include: a water heater 32; wherein the water heater 32 is connected to the power battery 27 via a pipeline; and a battery water temperature sensor 33 is provided at the water inlet of the power battery 27.

[0063] Understandably, a liquid cooling plate can be integrated on the power battery 27, with coolant pipes on the plate for circulating coolant. A water heater 32 is connected to these coolant pipes on the liquid cooling plate of the power battery 27 via a pipe. The coolant heated by the water heater 32 flows through these pipes to heat the power battery 27. Similarly, a battery water temperature sensor 33 is installed at the inlet of the coolant pipes on the liquid cooling plate of the power battery 27 to measure the temperature of the coolant at the inlet.

[0064] For example, the water heater 32 is used to heat the coolant when the ambient temperature is low, so as to ensure that the power battery 27 can be maintained within the optimal operating temperature range under low temperature conditions. The battery water temperature sensor 33 is installed at the water inlet of the power battery 27 to monitor the temperature of the coolant entering the battery in real time.

[0065] The water heater 32 and the battery water temperature sensor 33 enable comprehensive temperature monitoring and management of the power battery 27, ensuring its efficient and reliable operation under various environmental conditions. This design improves battery performance and lifespan while enhancing the system's flexibility and adaptability.

[0066] Next, combined Figure 1 The working process of the integrated thermal management system of an electric excavator is described.

[0067] Understandably, the integrated thermal management system of an electric excavator requires control via a controller to achieve cooling / heating functions. Optionally, the controller controlling the integrated thermal management system of the electric excavator may include an EAC controller (cabin air conditioning system controller) and a BMS controller (battery management system controller). The EAC controller and BMS controller are electrically connected to the vehicle controller. The user can send a cab cooling or heating request to the EAC controller through the vehicle controller, and the BMS controller can send a cooling request to the EAC controller via CAN communication. After receiving the request, the EAC controller controls the corresponding components of the cab air conditioning system via LIN communication to achieve cooling or heating control.

[0068] When the cab / power battery requires cooling: The refrigerant (such as R134A refrigerant) is compressed by the electric compressor 5, transforming from a low-temperature, low-pressure gas into a high-temperature, high-pressure gas. The high-pressure sensor 12 and exhaust temperature sensor 13 monitor the refrigerant pressure and temperature in real time. As the refrigerant passes through the condenser 1, the annular electric fan 4 simultaneously cools the water radiator 2, oil radiator 3, and the refrigerant, converting the high-temperature, high-pressure gas into a medium-temperature, high-pressure liquid in the condenser 1. The flow rate of the refrigerant can be controlled by the opening of the first electronic expansion valve 7 and the second electronic expansion valve 28, expanding the medium-temperature, high-pressure liquid into a low-temperature, low-pressure mist mixture. When the refrigerant in the cab branch passes through the evaporator 6, the blower 8 blows hot air from the cab onto the evaporator 6, causing the refrigerant to vaporize and absorb heat, carrying away the heat from the cab and transforming it into a low-temperature, low-pressure gas that returns to the electric compressor 5. The gas then blows cool air onto the driver through the duct. The return air temperature sensor 14 monitors the temperature of the return air vent of the evaporator 6 in real time. When the refrigerant in the battery branch passes through the plate heat exchanger 29, the second electronic water pump 30 carries the heat from the power battery 27 to the plate heat exchanger 29. The refrigerant vaporizes and absorbs heat, carrying away the battery heat and converting into a low-temperature, low-pressure gas that returns to the electric compressor 5. The second expansion tank 31 acts as a water replenishment tank, and the battery water temperature sensor 33 monitors the battery inlet water temperature in real time. By switching the first electronic expansion valve 7 and the second electronic expansion valve 28 on and off, cooling can be achieved for the ride-on vehicle and / or the power battery 27, respectively.

[0069] The rotation speed of the ringless electric fan 4 can be set according to the high pressure of the refrigerant, and the rotation speed of the electric compressor 5 can be set according to the outlet air temperature of the evaporator 6, the target cooling temperature, etc. This application embodiment does not impose any restrictions.

[0070] When the cab needs heating: turn on the relay in the air heater 9 (APTC), and the blower 8 will blow the cold air from the cab into the evaporator 6 for heating, and then blow the hot air onto the driver through the air duct.

[0071] Optionally, the APTC heating setting can be set via the evaporator outlet temperature 6 and the instrument setting temperature, with a total of 5 settings. The actual APTC setting is adjusted by real-time detection of the return air temperature to ensure thermal comfort in the cab.

[0072] When the power battery 27 needs heating: the water heater 32 (WPTC) is turned on, and the heated antifreeze flows into the power battery 27 through the second electronic water pump 30 to heat it. The second expansion tank 31 acts as a water replenishment function, and the battery water temperature sensor 33 detects the battery water inlet temperature in real time.

[0073] Optionally, the WPTC heating level can be set to multiple levels, and the start and stop status of the WPTC can be automatically controlled according to the water temperature. For example, when the BMS controller requests heating, it controls the WPTC to start heating immediately, stops heating when the water temperature reaches 55°C, and starts heating again when the temperature drops to 50°C.

[0074] Control of the motor and electronic cooling system: When the vehicle is under high pressure, the first electronic water pump 17 will carry the heat from the multi-function controller 15 and the motor 16 to the water radiator 2, and the hydraulic main pump 19 will also carry the heat from the multi-function controller 15 and the motor 16 to the oil radiator 3. If the working device 34 of the electric excavator is also in operation or needs to dissipate heat, the hydraulic main pump 19 will also carry the heat from the working device 34 to the oil radiator 3, so that the heat can be carried out to the outside of the vehicle by the ringless electronic fan 4; the inlet water temperature sensor 22 and the outlet water temperature sensor 23 detect the inlet and outlet water temperatures of the water radiator 2 in real time, the first expansion tank 18 plays a role in replenishing water, and the first liquid level sensor 21 detects whether the first expansion tank 18 is low on liquid; the inlet oil temperature sensor 25 and the outlet oil temperature sensor 26 detect the inlet and outlet oil temperatures of the oil radiator 3 in real time, the oil tank 20 plays a role in replenishing oil, and the second liquid level sensor 24 detects whether the oil tank 20 is low on liquid.

[0075] The integrated thermal management system for electric excavators provided in this application integrates the cab air conditioning system, motor and electronic control cooling system, and battery thermal management system to achieve efficient thermal management and resource sharing. The integrated cooling structure includes a water radiator, an oil radiator, and a brushless electric fan, compactly arranged beside the condenser, optimizing space utilization and enhancing heat dissipation performance. The brushless electric fan provides efficient forced convection, improving the system's cooling capacity, while the brushless design improves fan efficiency and lifespan. Through effective thermal management, the system ensures that the motor, electronic control system, working device, and battery operate within their optimal temperature range, improving overall reliability and lifespan, and reducing maintenance requirements. The connection between the cab air conditioning system and the battery thermal management system further improves the temperature regulation efficiency within the cab, providing a comfortable operating environment. The overall design not only adapts to various working conditions and climates but also reduces energy consumption and maintenance costs, comprehensively improving the performance and operational comfort of the electric excavator.

[0076] Furthermore, embodiments of this application also provide an electric excavator, which includes the integrated thermal management system of any of the above-mentioned electric excavators.

[0077] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the utility models disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this application are indicated by the following claims.

[0078] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. An integrated thermal management system for an electric excavator, characterized in that, The integrated thermal management system includes a cab air conditioning system, a motor electronic control cooling system, and a battery thermal management system. The cab air conditioning system is connected to the battery thermal management system. The cab air conditioning system includes a condenser, and the motor electronic control cooling system includes an integrated cooling structure. The integrated cooling structure includes a water radiator, an oil radiator, and a ringless electronic fan integrated on the water radiator and the oil radiator respectively. The integrated cooling structure is located next to the condenser.

2. The integrated thermal management system according to claim 1, characterized in that, The cab air conditioning system also includes: an electric compressor, an evaporator, and a first electronic expansion valve; The input end of the electric compressor is connected to the evaporator, the output end of the electric compressor is connected to the input end of the condenser, and the output end of the condenser is connected to the first electronic expansion valve.

3. The integrated thermal management system according to claim 2, characterized in that, The cab air conditioning system also includes: a blower and an air heater; Both the blower and the air heater are located on the side of the evaporator.

4. The integrated thermal management system according to claim 3, characterized in that, The electric compressor is equipped with an intake air temperature sensor and a low-pressure sensor at its input end, and a high-pressure sensor and an exhaust air temperature sensor at its output end; the evaporator is equipped with a return air temperature sensor at its return air inlet.

5. The integrated thermal management system according to claim 2, characterized in that, The motor electronic control cooling system also includes: an all-in-one controller, a motor, a first electronic water pump, a first expansion tank, a hydraulic main pump, and an oil tank; The water radiator is connected in series with the multi-function controller, the motor, and the first electronic water pump in sequence. The first electronic water pump is also connected to the first expansion tank. The oil radiator is connected in series with the multi-function controller, the motor, the hydraulic main pump, the working device of the electric excavator, and the oil tank.

6. The integrated thermal management system according to claim 5, characterized in that, The first expansion tank is equipped with a first liquid level sensor; the input end of the water radiator is equipped with an inlet water temperature sensor, and the output end of the water radiator is equipped with an outlet water temperature sensor. The oil tank is equipped with a second liquid level sensor; the input end of the oil radiator is equipped with an oil inlet temperature sensor, and the output end of the oil radiator is equipped with an oil outlet temperature sensor.

7. The integrated thermal management system according to claim 5, characterized in that, The first electronic water pump has a pre-charge function, and the power cord of the first electronic water pump uses a 2mm power cord.

8. The integrated thermal management system according to any one of claims 2-7, characterized in that, The battery thermal management system includes: a power battery, a second electronic expansion valve, a plate heat exchanger, a second electronic water pump, and a second expansion tank; The plate heat exchanger is connected in parallel to both ends of the evaporator via a second electronic expansion valve. The plate heat exchanger is also connected to the power battery. The power battery is connected to the second electronic water pump, and the second electronic water pump is also connected to the second expansion tank.

9. The integrated thermal management system according to claim 8, characterized in that, The battery thermal management system further includes a water heater; wherein the water heater is connected to the power battery; and a battery water temperature sensor is provided at the water inlet of the power battery.

10. An electric excavator, characterized in that, The electric excavator includes the integrated thermal management system as described in any one of claims 1-9.

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