A new energy automobile direct-cooling battery pack detection system

Abstract

The utility model discloses a new energy automobile direct cooling type battery package detection system belongs to battery heat management technical field. The system includes compressor, air -cooled condenser, supercooling heat exchange plate, mass flowmeter and direct cooling heat exchange plate etc. component. Its innovation point lies in having adopted liquid accumulator dual -purpose design: in the air -cooled condenser after positive setting liquid accumulator no.

Description

Technical Field

[0001] This utility model relates to the field of thermal management technology for power batteries of new energy vehicles, specifically to a direct-cooling battery pack testing system for new energy vehicles, and more particularly to a dual-purpose liquid reservoir design, which simplifies the system structure and reduces costs. Background Technology

[0002] With global warming, air pollution, and soaring energy costs, new energy vehicles have become a crucial development direction in the automotive industry due to their advantages such as low emissions, good economic performance, and independence from petroleum resources. As the core component of new energy vehicles, the thermal management technology of the power battery is of paramount importance. Direct cooling technology, due to its high cooling efficiency and superior system-level efficiency, is gradually replacing natural cooling, air cooling, and liquid cooling technologies, becoming the mainstream solution in the thermal management industry.

[0003] However, direct cooling technology faces uncertainties in its application: existing direct-cooling battery pack testing systems typically require a liquid receiver after the condenser to store the refrigerant and a gas-liquid separator before the flow meter to separate the liquid and gaseous components in the refrigerant, ensuring the accuracy of the flow meter measurement. This results in a complex system structure, increased equipment costs, and the development of direct cooling solutions relies heavily on experiments, with feasibility only verifiable at the prototype stage, increasing design risks. Utility Model Content

[0004] The purpose of this invention is to provide a direct-cooling battery pack testing system for new energy vehicles, which simplifies the equipment structure and reduces equipment costs through a dual-purpose liquid reservoir design.

[0005] Therefore, this utility model proposes a testing system for a direct-cooled battery pack of a new energy vehicle, including a compressor, an oil separator, an air-cooled condenser, a subcooled plate heat exchanger, a dryer filter, a sight glass, a mass flow meter, a direct-cooling main solenoid valve, a direct-cooling stepping electronic expansion valve, a check valve, a ball valve one, a direct-cooling plate heat exchanger, a ball valve two, a direct-cooling return gas solenoid valve, an evaporator pressure regulating expansion valve, a return gas solenoid valve one, an evaporator heat exchange plate, and a gas-liquid separator. The system also includes a liquid storage tank 1 and a liquid storage tank 2; the outlet of the air-cooled condenser is connected in sequence to the liquid storage tank 1, the subcooled plate heat exchanger and the liquid storage tank 2 via pipelines; the outlet of the liquid storage tank 2 is connected in sequence to the dryer filter, the sight glass and the mass flow meter via pipelines. The first liquid reservoir is installed upright, with its inlet located at the top and its outlet pipe extending to the bottom of the container; the second liquid reservoir is installed upside down, with its inlet located at the bottom and its outlet located at the top.

[0006] Preferably, the compressor's exhaust port is connected to the inlet of the oil separator via a pipeline, and the oil separator's outlet is connected to the inlet of the air-cooled condenser via a pipeline.

[0007] Preferably, the outlet of the mass flow meter is connected in sequence through a pipeline to the direct-cooling main solenoid valve, the direct-cooling stepping electronic expansion valve, the check valve, and the ball valve, and then connected to the inlet of the direct-cooling plate heat exchanger.

[0008] Preferably, the outlet of the direct-cooling plate heat exchanger is connected in sequence to the ball valve, the direct-cooling return gas solenoid valve, and the evaporation pressure regulating expansion valve via a pipeline, and then merges with the outlet of the return gas solenoid valve, and is then connected to the inlet of the gas-liquid separator. The outlet of the gas-liquid separator is connected to the suction port of the compressor.

[0009] Preferably, a first sensor assembly is provided on the pipeline between the compressor's exhaust port and the oil separator to detect exhaust pressure and exhaust temperature.

[0010] Preferably, a second sensor assembly is provided on the pipeline between the subcooled plate heat exchanger and the liquid receiver 2 for detecting condensation pressure and subcooling temperature.

[0011] Preferably, a third sensor assembly is provided on the pipeline between the ball valve and the inlet of the direct-cooling plate heat exchanger to detect the inlet pressure and inlet temperature.

[0012] Preferably, a fourth sensor assembly is provided on the pipeline between the second ball valve and the outlet of the direct-cooling plate heat exchanger to detect the outlet pressure and outlet temperature.

[0013] Preferably, the mass flow meter is installed at the front end of the direct-cooling plate heat exchanger to detect the refrigerant flow rate entering the direct-cooling plate heat exchanger.

[0014] Preferably, the direct-cooling stepping electronic expansion valve is located at the front end of the direct-cooling plate heat exchanger to adjust the subcooling at the inlet of the direct-cooling plate heat exchanger, and the evaporation pressure regulating expansion valve is located at the rear end of the direct-cooling plate heat exchanger to control the outlet pressure and superheat of the direct-cooling plate heat exchanger.

[0015] The beneficial effects of the direct-cooling battery pack testing system for new energy vehicles provided by this utility model are: 1) The dual-purpose liquid receiver design allows it to be used as a liquid receiver after the condenser and as a gas-liquid separator before the flow meter, reducing the need for a dedicated gas-liquid separator and simplifying the system structure; 2) It reduces equipment manufacturing and maintenance costs; 3) It improves system stability and flow meter measurement accuracy, thereby enhancing the certainty of direct cooling solution development.

[0016] In addition to the purposes, features, and advantages described above, this application has other purposes, features, and advantages. A further detailed description of this application will be provided below with reference to the figures. Attached Figure Description

[0017] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings: Figure 1 This is the general schematic diagram of the new energy vehicle direct-cooled battery pack testing system of this utility model; Figure 2 This is a schematic diagram of the upright installation of the liquid reservoir in this utility model (used as a liquid reservoir); Figure 3 This is a schematic diagram of the inverted liquid storage device in this utility model (used as a gas-liquid separator); Explanation of reference numerals in the attached diagram: 1. Compressor; 2. Oil separator; 3. Direct cooling liquid supply solenoid valve one; 4. Air-cooled condenser; 5. Direct cooling liquid supply solenoid valve two; 6. Liquid receiver one; 7. Subcooled plate heat exchanger; 8. Direct cooling liquid supply solenoid valve three; 9. Liquid receiver two; 10. Dryer filter; 11. Sight glass; 12. Mass flow meter; 13. Direct cooling main solenoid valve; 14. Direct cooling stepping electronic expansion valve; 15. Check valve; 16. Ball valve one; 17. Direct cooling plate heat exchanger; 18. Ball valve two; 19. Direct cooling return gas solenoid valve; 20. Evaporator pressure regulating expansion valve; 21. Return gas solenoid valve one; 22. Evaporator heat exchange plate; 23. Return gas solenoid valve two; 24. Gas-liquid separator; 25. Sensor assembly. Detailed Implementation

[0018] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0019] like Figure 1 As shown, the new energy vehicle direct-cooled battery pack testing system of this utility model includes a direct-cooling main circuit and auxiliary components. The main direct cooling circuit flow is as follows: Compressor 1 → Oil separator 2 → Direct cooling liquid supply solenoid valve 1 3 → Air-cooled condenser 4 → Direct cooling liquid supply solenoid valve 2 5 → Liquid receiver 1 6 → Subcooled plate heat exchanger 7 → Direct cooling liquid supply solenoid valve 3 8 → Liquid receiver 2 9 → Dryer filter 10 → Sight glass 11 → Mass flow meter 12 → Direct cooling main solenoid valve 13 → Direct cooling stepping electronic expansion valve 14 → Check valve 15 → Ball valve 1 16 → Direct cooling plate heat exchanger 17 (workpiece under test) → Ball valve 2 18 → Direct cooling return gas solenoid valve 19 → Evaporation pressure regulating expansion valve 20 → Return gas solenoid valve 1 21 → Evaporation heat exchange plate 22 → Gas-liquid separator 24 → Compressor 1. In addition, a return gas solenoid valve 23 is also installed between the evaporation pressure regulating expansion valve 20 and the gas-liquid separator 24, and is connected in parallel with the circuit containing the return gas solenoid valve 1 21 and the evaporation heat exchange plate 22.

[0020] like Figure 2As shown, the key operating points of the dual-purpose liquid receiver direct cooling system are as follows: The air-cooled condenser 4 performs primary condensation to stabilize the system pressure; the liquid receiver 6 is installed upright, with liquid refrigerant entering from side A and exiting from side B, with side B extending into the container to store the liquid refrigerant and provide sufficient liquid refrigerant for the direct cooling system. The subcooled plate heat exchanger 7 performs secondary condensation to reach the preset subcooling degree.

[0021] like Figure 2 As shown, the liquid receiver 2 9 is inverted, with the liquid refrigerant entering from side B and exiting from side A. Side B extends into the container to filter the gaseous refrigerant in the pipeline, reducing fluctuations in the liquid refrigerant entering the mass flow meter 12 and increasing the accuracy of the refrigeration flow meter.

[0022] The direct-cooling stepping electronic expansion valve 14 regulates the subcooling at the inlet of the direct-cooling plate heat exchanger 17. The evaporation pressure regulating expansion valve 20 controls the outlet pressure and superheat of the direct-cooling plate heat exchanger 17.

[0023] A sensor assembly 25 (pressure sensor and temperature sensor) is installed between the compressor 1 and the oil separator 2; the pressure sensor detects the discharge pressure of the compressor 1 and provides high pressure protection for the compressor 1, and the temperature sensor detects the discharge temperature of the compressor 1 and provides thermal overload protection for the compressor.

[0024] A sensor assembly (pressure sensor and temperature sensor) is also installed between the subcooled plate heat exchanger 7 and the direct-cooling liquid supply solenoid valve 8 to detect the secondary condensing pressure and subcooling temperature. The detected condensing pressure and subcooling temperature serve as the control inputs for the ambient high-temperature system on the subcooled plate heat exchanger side. The condensing pressure is a constant value and does not change with the subcooling temperature. The condensing pressure and condensing temperature have a corresponding relationship.

[0025] Mass flow meter 12 detects the amount of refrigerant entering the direct-cooling plate heat exchanger 17. In direct-cooling operation, when the battery pack's heating power is constant, heat exchange between the refrigerant and the direct-cooling plate heat exchanger 17 is achieved manually by setting the superheat and subcooling levels. In direct-cooling operation, when the battery pack's heating power is not constant, priority is given to ensuring superheat and subcooling, and the mass flow rate is automatically controlled based on the battery's heat output to achieve heat exchange between the refrigerant and the direct-cooling plate.

[0026] The ball valve 16 and the direct-cooling plate heat exchanger 17 are connected by pressure and temperature sensors. The temperature sensor detects the subcooling during direct-cooling operation, and this temperature reading serves as the control input for the direct-cooling stepping electronic expansion valve 14 and the direct-cooling main solenoid valve 13. The pressure sensor detects the input to the condensing pressure regulating electronic expansion valve during direct-heating operation, controlling the pressure inside the direct-cooling plate.

[0027] The pressure and temperature between ball valve 18 and the direct-cooling plate heat exchanger 17 are monitored. The temperature sensor detects the superheat under direct-cooling conditions, and this temperature reading serves as the control input for the stepping electronic expansion valve before the plate. The pressure sensor detects the input for the evaporation pressure regulating electronic expansion valve under direct-cooling conditions, controlling the pressure inside the direct-cooling plate.

[0028] Pressure and temperature sensors at the inlet of evaporator heat exchanger plate 22. These sensors detect the inlet pressure and temperature of evaporator heat exchanger plate 22, and the detected inlet pressure serves as a reference value for the evaporative heating system.

[0029] The function of oil separator 2 is to separate the lubricating oil from the high-pressure steam discharged from compressor 1 to ensure the safe and efficient operation of the unit. After separation, the lubricating oil flows back to compressor 1 for re-lubrication, and the cycle continues to improve the service life of the compressor.

[0030] The gas-liquid separator 24 separates the gas and liquid, preventing incomplete refrigerant evaporation from causing liquid slugging and damaging the compressor 1. The dryer filter 10 protects the refrigeration system from contamination by external liquid and solid pollutants. The sight glass 11 allows observation of the refrigerant status in the liquid lines of the refrigeration unit. The one-way valve 15 ensures that the refrigerant flows in only one direction, preventing reverse flow.

[0031] In existing direct-cooled battery pack testing systems for new energy vehicles, a liquid receiver is typically installed after the condenser to store refrigerant for system stability. Simultaneously, to separate the liquid and gaseous components in the refrigerant and improve the accuracy of the flow meter, a gas-liquid separator is required before the flow meter. Therefore, our system adds two liquid receivers: one placed after the condenser and used as a liquid receiver, and the other placed before the flow meter and inverted to function as a gas-liquid separator. This simplifies the equipment structure, reduces equipment costs, and simultaneously ensures the efficient and stable operation of the direct-cooling system.

[0032] This application discloses a direct-cooling battery pack testing system for new energy vehicles. It utilizes refrigerant phase change heat transfer to absorb the heat generated by the battery module or individual cells during operation, transferring the heat from the battery module or individual cells to the heat dissipation system. Through the direct cooling system, the heat inside the battery can be quickly transferred to the outside and effectively removed by the cooling system, maintaining the battery temperature within a reasonable range and improving battery performance and cycle life.

[0033] To achieve better thermal management, direct cooling systems are typically equipped with temperature sensors and controllers to monitor battery temperature and adjust parameters such as coolant flow rate and reversing valve status according to actual conditions, ensuring the battery operates within a safe temperature range. In summary, direct cooling solutions for the thermal management of power batteries in new energy vehicles are of great significance, with broad application prospects, and are expected to provide better guarantees for the reliability, performance, and safety of new energy vehicles. With continuous technological advancements and increasing market demand, direct cooling thermal management technology will become increasingly sophisticated and play an increasingly important role in the new energy vehicle field.

[0034] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A testing system for direct-cooled battery packs in new energy vehicles, characterized in that, It includes a compressor (1), an oil separator (2), an air-cooled condenser (4), a subcooled plate heat exchanger (7), a dryer filter (10), a sight glass (11), a mass flow meter (12), a direct-cooling main solenoid valve (13), a direct-cooling stepping electronic expansion valve (14), a check valve (15), a ball valve one (16), a direct-cooling plate heat exchanger (17), a ball valve two (18), a direct-cooling return gas solenoid valve (19), an evaporation pressure regulating expansion valve (20), a return gas solenoid valve one (21), an evaporation heat exchange plate (22), and a gas-liquid separator (24). The system also includes a first liquid reservoir (6) and a second liquid reservoir (9); the outlet of the air-cooled condenser (4) is connected in sequence to the first liquid reservoir (6), the subcooled plate heat exchanger (7) and the second liquid reservoir (9) via pipelines; the outlet of the second liquid reservoir (9) is connected in sequence to the dryer filter (10), the sight glass (11) and the mass flow meter (12) via pipelines. The first liquid reservoir (6) is installed upright, with its inlet located at the top and its outlet pipe extending to the bottom of the container; the second liquid reservoir (9) is installed upside down, with its inlet located at the bottom and its outlet located at the top.

2. The new energy vehicle direct-cooled battery pack testing system according to claim 1, characterized in that, The exhaust port of the compressor (1) is connected to the inlet of the oil separator (2) through a pipeline, and the outlet of the oil separator (2) is connected to the inlet of the air-cooled condenser (4) through a pipeline.

3. The new energy vehicle direct-cooled battery pack testing system according to claim 1, characterized in that, The outlet of the mass flow meter (12) is connected to the inlet of the direct-cooling plate heat exchanger (17) via a pipeline, which is then connected in sequence to the direct-cooling main solenoid valve (13), the direct-cooling stepping electronic expansion valve (14), the check valve (15), and the ball valve (16).

4. The new energy vehicle direct-cooled battery pack testing system according to claim 3, characterized in that, The outlet of the direct-cooling plate heat exchanger (17) is connected in sequence to the ball valve (18), the direct-cooling return gas solenoid valve (19) and the evaporation pressure regulating expansion valve (20) through a pipeline, and then merges with the outlet of the return gas solenoid valve (21), and is then connected to the inlet of the gas-liquid separator (24). The outlet of the gas-liquid separator (24) is connected to the suction port of the compressor (1).

5. The new energy vehicle direct-cooled battery pack testing system according to claim 1, characterized in that, A first sensor assembly (25) is provided on the pipeline between the exhaust port of the compressor (1) and the oil separator (2) for detecting exhaust pressure and exhaust temperature.

6. The new energy vehicle direct-cooled battery pack testing system according to claim 1, characterized in that, A second sensor assembly is installed on the pipeline between the subcooled plate heat exchanger (7) and the liquid reservoir (9) to detect the condensing pressure and subcooling temperature.

7. The new energy vehicle direct-cooled battery pack testing system according to claim 1, characterized in that, A third sensor assembly is installed on the pipeline between the ball valve (16) and the inlet of the direct-cooling plate heat exchanger (17) to detect the inlet pressure and inlet temperature.

8. The new energy vehicle direct-cooled battery pack testing system according to claim 1, characterized in that, A fourth sensor assembly is installed on the pipeline between the ball valve (18) and the outlet of the direct-cooling plate heat exchanger (17) to detect the outlet pressure and outlet temperature.

9. The new energy vehicle direct-cooled battery pack testing system according to claim 1, characterized in that, The mass flow meter (12) is installed at the front end of the direct-cooled plate heat exchanger (17) to detect the refrigerant flow rate entering the direct-cooled plate heat exchanger (17).

10. The new energy vehicle direct-cooled battery pack testing system according to claim 1, characterized in that, The direct-cooling stepping electronic expansion valve (14) is located at the front end of the direct-cooling plate heat exchanger (17) and is used to adjust the subcooling at the inlet of the direct-cooling plate heat exchanger (17). The evaporation pressure regulating expansion valve (20) is located at the rear end of the direct-cooling plate heat exchanger (17) and is used to control the outlet pressure and superheat of the direct-cooling plate heat exchanger (17).

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