A thermal management control system for electric commercial trucks

Abstract

This utility model discloses a thermal management control system for electric commercial trucks, relating to the field of vehicle thermal management technology. It includes a motor cooling circuit comprising a first water pump, a cooling jacket, and a radiator connected sequentially through pipes to form a circulation loop. The radiator and condenser are used for heat exchange with the external environment. The battery coolant circuit includes a second water pump, a battery pack cooling plate, and a second water tank connected sequentially through pipes to form a circulation loop. This utility model uses multiple different sensors to detect the temperature and pressure in the main pipeline and feeds this data back to the controller in real time, enabling the controller to control the first water pump in real time. This achieves the technical effect of real-time detection and regulation of the battery pack and motor temperatures, solving the technical problems of existing thermal management systems lacking temperature and pipeline pressure monitoring, and being unable to accurately regulate the main pipeline liquid temperature in real time, resulting in low thermal management efficiency.

Description

Technical Field

[0001] This utility model relates to the field of vehicle thermal management technology, and in particular to a thermal management control system for electric commercial trucks. Background Technology

[0002] Electric new energy light trucks consist of a three-electric system primarily composed of batteries, motors, and electronic controls, including multiple high-voltage systems such as air conditioning, multi-functional control systems, and PTC (Power Transmission Control). These systems are characterized by complexity, high operating voltage (around 320VDC), and high current (continuous current reaching 200A). The entire vehicle system generates a significant amount of heat during operation. If heat dissipation is inadequate or untimely, it can cause severe overheating of the high-voltage components, reducing overall vehicle efficiency or even damaging them. Current technologies for light truck thermal management lack automatic water replenishment and water level alarms, the water temperature is not under closed-loop control, and pressure monitoring at the coolant pump output is absent. To effectively address the technical issues of low thermal management efficiency, the company's technology center plans to organize the research and development of a "thermal management control system for electric commercial trucks."

[0003] In practical use, it was found that although the above embodiments can start various water pumps at any time when the temperature is high based on the sensor detection, thereby cooling different components such as motors, the lack of synergy means that the cooling fans cannot be controlled to speed up and improve heat exchange efficiency, and the circulation speed of the water pumps cannot be adjusted accordingly. This results in the inability to cool down quickly at high temperatures and the easy waste of energy at low temperatures. Summary of the Invention

[0004] The purpose of this invention is to provide a thermal management control system for electric commercial trucks, in order to solve the technical problems mentioned in the background art, such as the lack of temperature and pipeline pressure monitoring in existing thermal management systems, and the inability to accurately control the temperature of the main pipeline fluid in real time, resulting in low thermal management efficiency.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a thermal management control system for electric commercial trucks, comprising: The motor cooling circuit includes a first water pump, a cooling jacket, and a radiator connected in sequence through pipes to form a circulation loop. The radiator is used for heat exchange with the external environment. A refrigerant circuit, comprising an electric compressor, a condenser, a first expansion valve, and a second expansion valve connected in sequence via pipelines to form a circulation loop; the condenser is used for heat exchange with the external environment. A battery coolant circuit, comprising a second water pump, a battery pack cold plate, and a second water tank connected in sequence via pipelines to form a circulation loop; The refrigerant circuit and the battery coolant circuit are thermally coupled through a plate heat exchanger. The plate heat exchanger has a refrigerant side and a coolant side. The refrigerant side is connected in series in the pipeline between the first expansion valve and the second expansion valve, and the coolant side is connected in series in the pipeline between the second water pump and the battery pack cold plate.

[0006] Preferably, the motor cooling circuit further includes an electric heater and a first water tank disposed in the circuit.

[0007] Preferably, the second water tank is connected to the pipeline between the coolant side outlet of the plate heat exchanger and the inlet of the second water pump.

[0008] Preferably, the plate heat exchanger has a high-temperature liquid outlet and a low-temperature liquid inlet on the coolant side; the high-temperature liquid outlet is connected to the inlet of the second water pump via a pipeline, and the low-temperature liquid inlet is connected to the outlet of the battery pack cold plate via a pipeline.

[0009] Preferably, the cooling jacket is thermally coupled to the motor for cooling the motor; the battery pack cold plate is thermally coupled to the battery pack for cooling or heating the battery pack.

[0010] Preferably, the refrigerant circuit further includes an evaporator connected in series in the pipeline between the second expansion valve and the electric compressor.

[0011] Preferably, both the first water tank and the second water tank are equipped with a liquid level sensor and a water replenishment device.

[0012] Preferably, the cooling jacket has a wave-shaped flow channel inside, and coolant inlet and coolant outlet are respectively provided on both sides of the cooling jacket. The cooling jacket is fitted onto the motor through a connector.

[0013] Preferably, a pressure sensor is provided at the outlet of both the first and second water pumps, a flow sensor is provided at the inlet of both the first and second water pumps, a first temperature sensor is provided at the inlet of both the cooling jacket and the plate heat exchanger, and a second temperature sensor is provided at the outlet of both the cooling jacket and the plate heat exchanger.

[0014] Preferably, the system further includes sensors for detecting temperature, pressure or flow of key components, and a controller that receives sensor signals and controls the operation of the electric compressor, the first water pump, the second water pump, the electric heater, the first expansion valve and the second expansion valve according to preset logic.

[0015] The beneficial effects of this utility model are: 1. By coordinating and cooperating with the controller, the first temperature sensor, the second temperature sensor, the flow sensor, the cooling fan, the water replenishment device, and the liquid level sensor, and combining them with the liquid level alarm mechanism, the temperature, flow rate, and pressure of the main water circuit are precisely controlled, providing timely and effective heat dissipation for the motor, battery pack, and passenger compartment, thus significantly improving the overall vehicle thermal management efficiency. Through the cooperation of the controller and various sensors, real-time thermal intervention management can be performed based on the heat status of the truck during operation, thereby saving energy consumption of electric trucks, increasing the effectiveness of vehicle thermal management, and extending the driving range of electric trucks after a single charge. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the system of this utility model.

[0017] Figure 2 This is a schematic diagram of the battery coolant circuit of this utility model.

[0018] Figure 3 This is a schematic diagram of the motor cooling circuit of this utility model.

[0019] Figure 4 This is a schematic diagram of the cooling jacket and connecting parts in this utility model.

[0020] Figure 5 This is a schematic diagram of the connecting component in this utility model.

[0021] Figure 6 This is a schematic diagram of the cooling jacket in this utility model.

[0022] Figure 7 This is a schematic diagram of the cross-sectional plane structure of the cooling jacket in this utility model.

[0023] The attached figures are labeled as follows: 1. Motor cooling circuit; 2. First water pump; 3. Motor; 4. Cooling jacket; 401. Flow channel; 402. Coolant inlet; 403. Coolant outlet; 404. Connector; 6. First water tank; 7. Radiator; 9. Evaporator; 10. External environment; 11. First expansion valve; 12. Refrigerant circuit; 13. Condenser; 14. Second expansion valve; 15. Electric compressor; 16. Second water pump; 17. Second water tank; 18. Battery pack; 19. Battery coolant circuit; 20. Battery pack cold plate; 21. Plate heat exchanger; 23. Pressure sensor; 24. Liquid level sensor; 25. Water replenishment device; 26. First temperature sensor; 27. Second temperature sensor; 28. Flow sensor. Detailed Implementation

[0024] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0025] Example 1 Electric new energy light trucks consist of a three-electric system: battery, motor, and electronic control system. This includes multiple high-voltage systems such as air conditioning, a multi-functional control system, and a PTC (Power Transmission Control) system. The system is characterized by its complexity, high operating voltage (around 320VDC), and high current (continuous current reaching 200A). This results in the entire vehicle system generating a significant amount of heat during operation. If heat dissipation is inadequate or untimely, it can cause severe overheating of the high-voltage components, reducing overall vehicle efficiency or even damaging them. Current technologies for light truck thermal management lack automatic water replenishment and water level alarms, the water temperature is not under closed-loop control, and pressure monitoring at the coolant pump output is absent. To effectively address the technical issues of low thermal management efficiency, the company's technology center plans to organize the research and development of a "thermal management control system for electric commercial trucks."

[0026] To resolve the above technical issues, please refer to Figures 1 to 7As shown, the technical solution adopted includes a motor cooling circuit 1, which includes a first water pump 2, a cooling jacket 4, and a radiator 7 connected in sequence through pipes to form a circulation loop. The radiator 7 is used for heat exchange with the external environment 10. A refrigerant circuit 12 includes an electric compressor 15, a condenser 13, a first expansion valve 11, and a second expansion valve 14 connected in sequence through pipes to form a circulation loop. The condenser 13 is used for heat exchange with the external environment 10. A battery coolant circuit 19 includes a second water pump 16, a battery pack cold plate 20, and a second water tank 17 connected in sequence through pipes to form a circulation loop. The refrigerant circuit... The 12 is thermally coupled to the battery coolant circuit 19 via a plate heat exchanger 21. The plate heat exchanger 21 has a refrigerant side and a coolant side. The refrigerant side is connected in series in the pipeline between the first expansion valve 11 and the second expansion valve 14, and the coolant side is connected in series in the pipeline between the second water pump 16 and the battery pack cold plate 20. The motor cooling circuit 1 also includes an electric heater and a first water tank 6 disposed in its circuit. The second water tank 17 is connected in the pipeline between the coolant side outlet of the plate heat exchanger 21 and the inlet of the second water pump 16. The coolant side of the plate heat exchanger 21 has a high-temperature liquid outlet and a low-temperature liquid inlet; the high-temperature liquid outlet is connected to the battery pack cold plate 20 via a pipeline. The inlet of the second water pump 16 is connected to the outlet of the battery pack cold plate 20 via a pipeline. The cooling jacket 4 is thermally coupled to the motor 3 for cooling the motor 3. The battery pack cold plate 20 is thermally coupled to the battery pack 18 for cooling or heating the battery pack 18. The refrigerant circuit 12 also includes an evaporator 9, which is connected in series in the pipeline between the second expansion valve 14 and the electric compressor 15. The first water tank 6 and the second water tank 17 are both equipped with a liquid level sensor 24 and a water replenishment device 25. A wavy flow channel 401 is formed inside the cooling jacket 4. Coolant inlet 402 and coolant outlet 403 are respectively provided on both sides of the cooling jacket 4. The cooling jacket 4 is fitted onto the motor 3 via a connector 404. Pressure sensors 23 are provided at the outlets of the first water pump 2 and the second water pump 16. Flow sensors 28 are provided at the inlets of the first water pump 2 and the second water pump 16. First temperature sensors 26 are provided at the inlets of the cooling jacket 4 and the plate heat exchanger 21. Second temperature sensors 27 are provided at the outlets of the cooling jacket 4 and the plate heat exchanger 21. The system also includes sensors for detecting the temperature, pressure, or flow of key components, and a controller that receives sensor signals and controls the operation of the electric compressor 15, the first water pump 2, the second water pump 16, the electric heater, and the first expansion valve 11 and the second expansion valve 14 according to preset logic.

[0027] The motor cooling circuit 1 includes a circulating loop formed by connecting a first water pump 2, a cooling jacket 4, a radiator 7, an electric heater, and a first water tank 6 in sequence through pipelines. The radiator 7 is used for heat exchange with the external environment 10. The cooling jacket 4 is thermally coupled to the motor 3 and can cool the motor 3. The electric heater can heat the coolant when the motor 3 temperature is low. The electric heater is not shown in the figure. The first water tank 6 is used to store coolant and maintain the amount of coolant in the circuit. It is equipped with a liquid level sensor 24 and a water replenishment device 25.

[0028] When the temperature of motor 3 is high, the first water pump 2 drives the coolant to circulate in the circuit. The coolant flows into the cooling jacket 4 through the coolant inlet 402, absorbs the heat of motor 3 through the wave-shaped flow channel 401, and then flows into the first water pump 2 from the coolant outlet 403 for continuous delivery. It flows to the radiator 7 and exchanges heat with the external environment 10. The cooled coolant flows back to the first water pump 2, completing the cooling cycle. When the coolant passes through the cooling jacket 4, the temperature of the coolant entering and exiting the cooling jacket 4 and the temperature difference between the two ends of the coolant are detected by the first temperature sensor 26 and the second temperature sensor 27. When the temperature is suitable and the temperature difference is small, the heat dissipation of motor 3 is completed. The first water pump 2 can be temporarily shut down by the controller. When the first temperature sensor 26 and the second temperature sensor 27 detect the temperature rise, the first water pump 2 is restarted to circulate the coolant to dissipate heat from motor 3. A first cooling fan is provided on one side of the radiator 7 to accelerate the heat exchange efficiency with the external environment 10.

[0029] When the motor 3 is at a low temperature, the electric heater works to heat the coolant. The heated coolant flows through the cooling jacket 4 to raise the temperature of the motor 3, and then circulates back to the first water pump 2. This prevents the motor 3 from consuming too much electricity when it is in a low-temperature working state, which would reduce the truck's mileage and affect work efficiency.

[0030] The refrigerant circuit 12 includes a loop formed by connecting an electric compressor 15, a condenser 13, a first expansion valve 11, a second expansion valve 14 and an evaporator 9 in sequence through pipelines. The condenser 13 is used for heat exchange with the external environment 10. The refrigerant side of the plate heat exchanger 21 is connected in series in the pipeline between the first expansion valve 11 and the second expansion valve 14. A second cooling fan is provided on one side of the condenser 13 to accelerate the heat exchange efficiency with the external environment 10.

[0031] During operation, the electric compressor 15 compresses the refrigerant into a high-temperature, high-pressure gas, which is then sent to the condenser 13 to exchange heat with the external environment 10. After the refrigerant dissipates heat, it condenses into a high-pressure liquid. The high-pressure liquid is throttled and depressurized by the first expansion valve 11 and enters the refrigerant side of the plate heat exchanger 21, where it exchanges heat with the coolant in the battery coolant circuit 19, absorbing or releasing heat. Afterward, the refrigerant flows through the second expansion valve 14 for further throttling and enters the evaporator 9 to absorb heat and evaporate into gas. Finally, it flows back to the electric compressor 15 to complete the cycle. During the above process, the temperature inside the cockpit is regulated.

[0032] The battery coolant circuit 19 is connected in sequence to the second water pump 16, the battery pack cold plate 20 and the second water tank 17 through pipelines to form a circulation loop. The coolant side of the plate heat exchanger 21 is connected in series in the pipeline between the second water pump 16 and the battery pack cold plate 20. The coolant side of the plate heat exchanger 21 has a high-temperature liquid outlet and a low-temperature liquid inlet. The high-temperature liquid outlet is connected to the inlet of the second water pump 16 through a pipeline, and the low-temperature liquid inlet is connected to the outlet of the battery pack cold plate 20 through a pipeline. The battery pack cold plate 20 is thermally coupled to the battery pack 18.

[0033] During operation, when the first temperature sensor 26 and the second temperature sensor 27 corresponding to the plate heat exchanger 21 detect that the temperature of the plate heat exchanger 21 is too high and cooling is required, the first temperature sensor 26 and the second temperature sensor 27 send a signal feedback to the controller. The controller controls the second water pump 16 to drive the coolant circulation. The coolant flows through the coolant side of the plate heat exchanger 21 to absorb cold energy. After cooling down, the coolant flows into the battery pack cold plate 20 to absorb the heat of the battery pack 18. The cooled coolant flows from the outlet of the battery pack cold plate 20 into the second water tank 17, and then flows back to the low-temperature liquid inlet of the plate heat exchanger 21 to complete the cooling cycle. When the battery pack 18 needs to be heated, the coolant absorbs heat in the plate heat exchanger 21, and after the temperature rises, it heats the battery pack 18 through the battery pack cold plate 20. The cooled coolant after releasing heat circulates back to the plate heat exchanger 21.

[0034] When the liquid level sensor 24 detects that the liquid level in the first water tank 6 and the second water tank 17 has dropped to a certain value, the liquid level sensor 24 sends a signal to the controller, so that the controller controls the water replenishment device 25 to add the corresponding liquid to the first water tank 6 and the second water tank 17. The water replenishment device 25 adopts existing technology and will not be described in detail here. At the same time, the flow sensor 28 is set to detect the flow rate of the coolant in the main pipeline in real time, and then the controller controls the first water pump 2 and the second water pump 16 to adjust the driving speed of the coolant, thereby improving the heat dissipation efficiency.

[0035] By coordinating and cooperating with the controller, the first temperature sensor 26, the second temperature sensor 27, the flow sensor 28, the cooling fan, the water replenishment device 25, and the liquid level sensor 24, and combined with the liquid level alarm mechanism, the temperature, flow rate, and pressure of the main water circuit are precisely controlled, providing timely and effective heat dissipation for the motor 3, the battery pack 18, and the passenger compartment, thus significantly improving the overall vehicle thermal management efficiency.

[0036] Example 2 In actual use, it was found that although the above embodiments can start various water pumps at any time when the temperature is high based on the sensor detection, so as to cool down different components such as motor 3, in actual use, due to the lack of synergy, it is not possible to control the cooling fan to speed up and improve the exchange efficiency, and the circulation speed of the water pump cannot be adjusted accordingly. As a result, it cannot cool down quickly at high temperatures, and it is easy to waste energy at low temperatures.

[0037] To solve the above technical problems, based on the above embodiments, please refer to... Figures 1 to 7 As shown, the technical solution includes a first water tank 6, both the first water tank 6 and the second water tank 17 are equipped with a liquid level sensor 24 and a water replenishment device 25. A wave-shaped flow channel 401 is formed inside the cooling jacket 4. Coolant inlets 402 and coolant outlets 403 are respectively provided on both sides of the cooling jacket 4. The cooling jacket 4 is fitted onto the motor 3 via a connector 404. Pressure sensors 23 are provided at the outlets of the first water pump 2 and the second water pump 16. Flow sensors 28 are provided at the inlets of the first water pump 2 and the second water pump 16. A first temperature sensor 26 is provided at the inlet of both the cooling jacket 4 and the plate heat exchanger 21. Each heat exchanger 21 is equipped with a second temperature sensor 27 at its outlet. The system also includes sensors for detecting the temperature, pressure, or flow rate of key components, as well as a controller that receives sensor signals and controls the operation of the electric compressor 15, the first water pump 2, the second water pump 16, the electric heater, the first expansion valve 11, and the second expansion valve 14 according to preset logic.

[0038] During use, when the second temperature sensor 27 at the outlet of the cooling jacket 4 detects that the temperature of the motor 3 is too high, the controller increases the speed of the first water pump 2 to increase the flow rate and ensures efficient heat dissipation of the radiator 7. When the second temperature sensor 27 at the outlet of the plate heat exchanger 21 detects that the temperature of the battery pack 18 is too high, the controller starts the electric compressor 15, adjusts the opening of the first expansion valve 11 and the second expansion valve 14, and controls the second water pump 16 to run, cooling the battery pack 18 through the plate heat exchanger 21 and the battery pack cold plate 20. When the liquid level sensor 24 of the first water tank 6 or the second water tank 17 detects that the liquid level is too low, the controller triggers the water replenishment device 25 of the corresponding water tank to replenish water.

[0039] When the temperature is not high but heat dissipation is required, the temperature is detected by the first temperature sensor 26 and the second temperature sensor 27. Based on the detected temperature, a signal is sent to the controller. The controller sends a command to the first water pump 2 and the second water pump 16 based on the feedback of the temperature detected by the first temperature sensor 26 and the second temperature sensor 27, adjusting the power sent by the first water pump 2 and the second water pump 16 to reduce the energy loss and extend the vehicle's driving distance to a certain extent.

[0040] By cooperating with the aforementioned controller and various sensors, real-time thermal intervention management can be performed based on the thermal status of the truck during operation. This can save energy consumption of electric trucks, increase the effectiveness of vehicle thermal management, and extend the driving range of trucks after a single electric charge.

[0041] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A thermal management control system for electric commercial trucks, characterized in that, include: The motor cooling circuit (1) includes a first water pump (2), a cooling jacket (4) and a radiator (7) connected in sequence through pipelines to form a circulation loop. The radiator (7) is used to exchange heat with the external environment (10). The refrigerant circuit (12) includes an electric compressor (15), a condenser (13), a first expansion valve (11), and a second expansion valve (14) connected in sequence through pipelines to form a circulation loop. The condenser (13) is used to exchange heat with the external environment (10). The battery coolant circuit (19) includes a second water pump (16), a battery pack cold plate (20), and a second water tank (17) connected in sequence through pipelines to form a circulation loop. The refrigerant circuit (12) and the battery coolant circuit (19) are thermally coupled through a plate heat exchanger (21). The plate heat exchanger (21) has a refrigerant side and a coolant side. Its refrigerant side is connected in series in the pipeline between the first expansion valve (11) and the second expansion valve (14), and its coolant side is connected in series in the pipeline between the second water pump (16) and the battery pack cold plate (20).

2. The thermal management control system for an electric commercial truck according to claim 1, characterized in that, The motor cooling circuit (1) also includes an electric heater and a first water tank (6) disposed in the circuit.

3. The thermal management control system for an electric commercial truck according to claim 2, characterized in that, The second water tank (17) is connected to the pipeline between the coolant side outlet of the plate heat exchanger (21) and the inlet of the second water pump (16).

4. The thermal management control system for an electric commercial truck according to claim 3, characterized in that, The plate heat exchanger (21) has a high-temperature liquid outlet and a low-temperature liquid inlet on the cooling liquid side; the high-temperature liquid outlet is connected to the inlet of the second water pump (16) through a pipeline, and the low-temperature liquid inlet is connected to the outlet of the battery pack cold plate (20) through a pipeline.

5. The thermal management control system for an electric commercial truck according to claim 4, characterized in that, The cooling jacket (4) is thermally coupled to the motor (3) for cooling the motor (3); the battery pack cold plate (20) is thermally coupled to the battery pack (18) for cooling or heating the battery pack (18).

6. The thermal management control system for an electric commercial truck according to claim 5, characterized in that, The refrigerant circuit (12) also includes an evaporator (9), which is connected in series in the pipeline between the second expansion valve (14) and the electric compressor (15).

7. The thermal management control system for an electric commercial truck according to claim 6, characterized in that, The first water tank (6) and the second water tank (17) are each equipped with a liquid level sensor (24) and a water replenishment device (25).

8. The thermal management control system for an electric commercial truck according to claim 7, characterized in that, The cooling sleeve (4) has a wave-shaped flow groove (401) inside. Cooling liquid inlet (402) and cooling liquid outlet (403) are respectively provided on both sides of the cooling sleeve (4). The cooling sleeve (4) is sleeved on the motor (3) through the connector (404).

9. A thermal management control system for an electric commercial truck according to claim 8, characterized in that, Pressure sensors (23) are provided at the outlets of the first water pump (2) and the second water pump (16), flow sensors (28) are provided at the inlets of the first water pump (2) and the second water pump (16), first temperature sensors (26) are provided at the inlets of the cooling jacket (4) and the plate heat exchanger (21), and second temperature sensors (27) are provided at the outlets of the cooling jacket (4) and the plate heat exchanger (21).

10. A thermal management control system for an electric commercial truck according to claim 9, characterized in that, The system also includes sensors for detecting temperature, pressure or flow of key components, and a controller that receives sensor signals and controls the operation of the electric compressor (15), the first water pump (2), the second water pump (16), the electric heater, the first expansion valve (11), and the second expansion valve (14) according to preset logic.

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