An air conditioning thermal management control system for an electric reach truck

Abstract

The utility model discloses a kind of electric telescopic handler air conditioner thermal management control systems, belong to engineering machinery technical field.The system includes control assembly, air conditioning system assembly, power battery pack thermal management assembly and cooler with double independent passage.Control assembly contains whole vehicle VCU, BMS and thermal management controller.When BMS detects that battery temperature is too high, through VCU instruction thermal management controller starts compressor and water pump, refrigerant cools battery circulating fluid in cooler, realizes battery cooling;When battery temperature is too low, then start WPTC heater for coolant heating, simultaneously can be through VCU coordination motor controller limit torque to guarantee safety.The utility model realizes the high integration and intelligent cooperation of air conditioner refrigeration and battery thermal management, effectively maintains the best working temperature of battery, improves system energy efficiency, safety and whole machine reliability, with Compact structure, low in cost, long in service life Advantage.

Description

Technical Field

[0001] This utility model relates to an air conditioning thermal management control system for an electric telescopic boom forklift truck, belonging to the field of thermal management technology for construction machinery. Background Technology

[0002] With the increasing sophistication of new energy technologies and stricter environmental requirements, the electrification of engineering machinery has become a trend. Lithium-ion batteries, due to their superior performance in terms of specific energy, lifespan, and cost, have become the most commonly used energy storage element. However, their performance is significantly affected by temperature. Too low a temperature can lead to lithium plating during charging and a reduction in capacity (or power); too high a temperature will significantly accelerate the internal degradation process of the lithium-ion battery and may also trigger safety issues such as thermal runaway. Therefore, the temperature of power lithium-ion batteries during service should be strictly controlled. The optimal operating temperature range for lithium-ion batteries is typically 15–35℃, with a suitable range of 10–40℃. Currently, the cooling methods for power batteries in the engineering industry mainly employ air cooling and liquid cooling. Liquid cooling achieves the cooling effect of the power battery through heat exchange between the refrigerant and the coolant. Compared to air cooling, liquid cooling is more efficient, thereby improving the service life of the power battery.

[0003] In electric construction machinery, especially in equipment such as telescopic boom forklifts that are space-constrained, operate under complex conditions, and require high energy efficiency, there is an urgent need for a highly integrated, intelligent, collaborative, efficient, and reliable thermal management and control system. Summary of the Invention

[0004] Purpose of the invention: To address the shortcomings of existing technologies, this utility model provides an air conditioning thermal management control system for electric telescopic boom forklifts, thereby solving the problems mentioned in the background section.

[0005] Technical solution: An air conditioning thermal management control system for an electric telescopic boom forklift includes a control assembly, an air conditioning system assembly, a power battery pack thermal management assembly, and a cooler; the control assembly is connected to the air conditioning system assembly and the power battery pack thermal management assembly via communication wiring harnesses. The cooler includes two non-communicating channels that are respectively connected to the air conditioning system assembly and the power battery pack thermal management assembly. The power battery pack thermal management assembly includes a water pump, a WPTC heater, and a water collector connected in sequence by pipes, and a cooler connected in series between the WPTC heater and the heat exchange pipes in the power battery pack.

[0006] This invention integrates the control assembly, air conditioning system assembly, and power battery thermal management assembly, and sets up two coolers with independent channels connected to the two sets of system piping respectively. Simultaneously, the coolers are connected in series between the water pump, WPTC heater, and water collector in the battery circuit. This solves the problems of component redundancy, large space occupation, and inability to coordinate energy utilization caused by the independent operation of air conditioning and battery thermal management systems in traditional electric construction machinery. This solution achieves deep integration of air conditioning cooling and battery thermal management at the physical and signal levels, laying the foundation for intelligent collaborative control of the system and achieving the technical effects of reducing costs, minimizing space occupation, and improving overall energy efficiency.

[0007] The air conditioning system assembly includes a condenser, a liquid receiver, an evaporator, and a compressor connected in sequence by pipes, with the compressor and condenser connected by a return pipe. The cooler is connected to the storage tank and the evaporator via a three-way pipe, and the liquid from the storage tank is distributed to the evaporator and the cooler via the three-way pipe.

[0008] By sequentially connecting the condenser, receiver-dryer, evaporator, and compressor, and using a three-way pipe to divert the liquid from the receiver-dryer to the evaporator and cooler, the specific problem of how to simultaneously provide cooling for both the cab and the battery in an integrated architecture is solved. This solution enables a single refrigeration system to serve two purposes, clarifies the connection method of the cooler in the air conditioning circuit, and achieves the technical effects of improving system practicality, ensuring structural feasibility, and enhancing refrigeration efficiency.

[0009] It also includes an electronic expansion valve connected to the control assembly via a CAN bus, the electronic expansion valve being located on the pipeline between the cooler and the tee pipe.

[0010] By adding an electronic expansion valve connected to the control assembly and placing it on the pipeline between the cooler and the tee pipe, the problem of accurately controlling the flow rate and state of the refrigerant when it is diverted to the cooler was solved. This solution enables active and precise throttling regulation of the refrigerant flowing into the cooler, achieving the technical effects of improving the heat exchange efficiency of the battery cooling process, enhancing system control accuracy, and improving operational reliability.

[0011] The power battery pack thermal management assembly also includes an auxiliary water tank, and the water collector is provided with at least two water outlets, which are respectively connected to the water pump and the auxiliary water tank.

[0012] By adding an auxiliary water tank to the battery thermal management assembly and connecting it to a water outlet via a water collector, the problems of volume expansion and contraction and gas accumulation caused by coolant temperature changes in the liquid cooling system are solved. This solution provides the system with a pressure buffer and coolant compensation container, achieving the technical effects of maintaining stable system pressure, ensuring continuous coolant circulation, and facilitating system venting and maintenance.

[0013] The control assembly includes a vehicle VCU, a BMS battery management system for collecting temperature signals from the power battery pack, and a thermal management controller; the BMS battery management system is connected to the temperature sensor signals at the inlet and outlet of the power battery pack and is connected to the vehicle VCU via a CAN bus. The electronic expansion valve, compressor, and WPTC heater are connected to the thermal management controller via a CAN bus.

[0014] Specifically, the control assembly, comprising the vehicle's VCU, BMS (Battery Management System), and thermal management controller, is disclosed, and their connections and controlled objects are clarified. This solution addresses the control logic challenge of how multiple components in an integrated system can achieve coordinated signal acquisition, decision-making, and execution. The solution constructs a closed-loop control chain of "BMS sensing—VCU decision-making—thermal management controller execution," achieving the technical effects of intelligent battery temperature regulation, extended battery life, and ensuring system safety and stable operation.

[0015] It also includes a motor controller that is connected to the vehicle's VCU via a CAN bus signal. The motor controller is connected to the travel motor and the hydraulic pump motor via control lines.

[0016] By introducing a motor controller connected to the vehicle's VCU and controlling the drive motor and hydraulic pump motor, the problem of insufficient rapid heat source control through thermal management alone when battery temperatures are extremely abnormal is solved. This solution achieves cross-domain synergy between thermal management and the powertrain, enabling the limitation of motor torque to reduce thermal load when battery temperatures are severely exceeded, thus buying time for thermal management and significantly improving the overall vehicle operational safety.

[0017] The auxiliary water tank is equipped with a steam hose for venting steam.

[0018] By installing steam hoses on the auxiliary water tank, the problem of steam generated in the liquid cooling system during heating and other operating conditions that could not be discharged in a timely manner was solved. This solution achieves effective steam drainage through a simple exhaust structure, thus maintaining system pressure safety, preventing vapor lock, ensuring coolant circulation efficiency, and ensuring long-term stable system operation.

[0019] Beneficial Effects: The core effect of the air conditioning thermal management control system for electric telescopic boom forklifts proposed in this invention lies in its highly integrated, intelligent, and collaborative thermal management architecture, which simultaneously achieves efficient, precise, and safe control of the cab air conditioning and power battery temperatures. Specifically, the system physically couples the air conditioning cooling circuit and the battery liquid cooling circuit through a dual-channel cooler, allowing the air conditioning cooling capacity to be directly used for battery cooling, avoiding the redundancy of independent dual systems and reducing cost and space occupation. Through a control strategy centered on the vehicle's VCU and coordinated with the BMS battery management system and thermal management controller, the system can automatically switch between cooling (starting the compressor and electronic expansion valve) or heating (starting the WPTC heater) modes in real time based on the battery temperature, ensuring that the battery always operates within the optimal temperature range, thereby significantly extending battery life and preventing thermal runaway. Furthermore, by integrating a motor controller, the system can actively limit motor torque when the battery temperature is extremely abnormal, reducing the heat load from the source, forming a safety redundancy of "thermal management-power control" linkage. Ultimately, this solution improves the overall energy efficiency and reliability of the machine while ensuring the safe, efficient, and stable operation of the electric telescopic boom forklift under various working conditions. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0021] Figure 1 This is a structural framework diagram of the present invention. Detailed Implementation

[0022] 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 of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] In the description of this utility model, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0024] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0025] like Figure 1 As shown, an air conditioning thermal management control system for an electric telescopic boom forklift includes a control assembly, an air conditioning system assembly, a power battery pack thermal management assembly, and a cooler 1; the control assembly is connected to the air conditioning system assembly and the power battery pack thermal management assembly via communication harnesses. The cooler 1 includes two non-interconnected channels, which are respectively connected to the air conditioning system assembly and the power battery pack thermal management assembly. The power battery pack thermal management assembly includes a water pump 2, a WPTC heater 3 and a water collector 4 connected in sequence by pipes, and a cooler 1 connected in series between the WPTC heater 3 and the heat exchange pipe in the power battery pack.

[0026] This invention integrates the control assembly, air conditioning system assembly, and power battery thermal management assembly, and sets up a cooler 1 with two independent channels connected to two separate system piping systems. The cooler 1 is connected in series between the water pump 2, WPTC heater 3, and water collector 4 in the battery circuit. This solves the problems of component redundancy, large space occupation, and inability to coordinate energy utilization caused by the independent operation of air conditioning and battery thermal management systems in traditional electric construction machinery. This solution achieves deep integration of air conditioning cooling and battery thermal management at the physical and signal levels, laying the foundation for intelligent collaborative control of the system and achieving the technical effects of reducing costs, minimizing space occupation, and improving overall energy efficiency.

[0027] The air conditioning system assembly includes a condenser 5, a liquid receiver 6, an evaporator 7, and a compressor 8 connected in sequence by pipes. The compressor 8 is connected to the condenser 5 through a return pipe. The cooler 1 is connected to the storage tank 6 and the evaporator 7 via a three-way pipe. The liquid in the storage tank 6 is diverted to the evaporator 7 and the cooler 1 via the three-way pipe.

[0028] By sequentially connecting the condenser 5, liquid receiver 6, evaporator 7, and compressor 8, and using a three-way pipe to divert the liquid receiver 6 to the evaporator 7 and cooler 1, the specific implementation problem of how the air conditioning system in the integrated architecture can simultaneously provide cooling for both the cab and the battery is solved. This solution enables a single refrigeration system to serve two purposes, clarifies the connection method of cooler 1 in the air conditioning circuit, and achieves the technical effects of improving system practicality, ensuring structural feasibility, and enhancing refrigeration efficiency.

[0029] It also includes an electronic expansion valve 9 connected to the control assembly via a CAN bus, the electronic expansion valve 9 being disposed on the pipeline between the cooler 1 and the three-way pipe.

[0030] By adding an electronic expansion valve 9 connected to the control assembly and placing it on the pipeline between the cooler 1 and the three-way pipe, the problem of accurately controlling the flow rate and state of the refrigerant when it is diverted to the cooler 1 is solved. This solution enables active and precise throttling regulation of the refrigerant flowing into the cooler 1, achieving the technical effects of improving the heat exchange efficiency of the battery cooling process, enhancing the system control accuracy and operational reliability.

[0031] The power battery pack thermal management assembly also includes an auxiliary water tank 10, and the water collector 4 is provided with at least two water outlets, which are respectively connected to the water pump 2 and the auxiliary water tank 10.

[0032] By adding an auxiliary water tank 10 to the battery thermal management assembly and connecting it to the water collector 4 via an outlet, the problem of volume expansion and contraction and gas accumulation caused by coolant temperature changes in the liquid cooling system is solved. This solution provides the system with a pressure buffer and coolant compensation container, achieving the technical effects of maintaining stable system pressure, ensuring continuous coolant circulation, and facilitating system venting and maintenance.

[0033] The control assembly includes a vehicle VCU 11, a BMS battery management system 12 for collecting temperature signals from the power battery pack, and a thermal management controller 13; the BMS battery management system 12 is connected to the temperature sensor signals at the inlet and outlet of the power battery pack and is connected to the vehicle VCU 11 via a CAN bus. The electronic expansion valve 9, compressor 8, and WPTC heater 3 are respectively connected to the thermal management controller 13 via a CAN bus.

[0034] Specifically, the control assembly, comprising the vehicle VCU 11, the BMS battery management system 12, and the thermal management controller 13, is disclosed, and their connection relationships and controlled objects are clarified. This solution addresses the control logic problem of how multiple components in an integrated system can achieve coordinated signal acquisition, decision-making, and execution. The solution constructs a closed-loop control link of "BMS battery management system 12 sensing—VCU decision-making—thermal management controller 13 execution," achieving the technical effects of intelligent battery temperature regulation, extended battery life, and ensuring system safety and stable operation.

[0035] It also includes a motor controller 14 that is connected to the vehicle VCU11 via a CAN bus signal. The motor controller 14 is connected to the travel motor 15 and the hydraulic pump motor 16 via control lines.

[0036] By introducing a motor controller 14 connected to the vehicle's VCU11 and controlling the travel motor 15 and hydraulic pump motor 16, the problem of insufficient heat source control through thermal management alone when battery temperature is extremely abnormal is solved. This solution achieves cross-domain synergy between thermal management and the power system, enabling the reduction of thermal load by limiting motor torque when battery temperature is severely exceeded, thus buying time for thermal management and significantly improving the overall vehicle's operational safety.

[0037] The auxiliary water tank 10 is equipped with a steam hose 17 for venting steam.

[0038] A steam hose 17 is installed on the auxiliary water tank 10, which solves the problem of steam generated by the liquid cooling system not being able to be discharged in time under heating and other operating conditions. This solution achieves effective steam drainage through a simple exhaust structure, thus maintaining system pressure safety, preventing air lock, ensuring coolant circulation efficiency, and ensuring long-term stable system operation.

[0039] Working principle: When the power battery temperature is too high, the battery management system (BMS) 12 sends the cooling demand to the thermal management controller 13 via the vehicle VCU 11. The latter simultaneously starts the electric compressor 8, adjusts the opening of the electronic expansion valve 9, and drives the water pump 2 to operate. The low-temperature refrigerant in the air conditioning circuit absorbs the heat of the battery circulating coolant in the cooler 1, thereby achieving active cooling of the battery. At the same time, the vehicle VCU 11 can limit the motor torque through the motor controller 14 based on the battery temperature status, as a thermal safety redundancy control.

[0040] When the power battery temperature is too low, the battery management system (BMS) 12 forwards the heating demand to the thermal management controller 13 via the vehicle VCU 11. The controller starts the WPTC heater 3 and adjusts the speed of the water pump 2, so that the heated coolant flows in the battery circulation pipeline to provide direct heating for the battery. In this mode, the air conditioning cooling circuit does not work, and the cooler 1 only serves as a circulation channel. The vehicle VCU 11 can also instruct the motor controller 14 to limit the torque as needed to protect the battery performance and safety at low temperatures.

[0041] This system enables intelligent thermal management of the power battery during both vehicle operation and charging. In hot summer conditions, the battery temperature may still rise during charging due to internal resistance heat generation and the high-temperature environment. The BMS continuously monitors the temperature; if it exceeds a set threshold, it sends a cooling request to the thermal management controller via the vehicle's VCU. The system then activates the compressor and water pump, using the air conditioning refrigerant to cool the battery coolant, ensuring charging safety and efficiency. In low-temperature winter conditions, especially before charging or when starting the vehicle, if the BMS detects an excessively low battery temperature, it proactively requests heating. The thermal management controller activates the WPTC heater and runs the water pump to preheat the battery system, quickly bringing it to a suitable temperature range and ensuring charging acceptance and discharge performance at low temperatures. Through adaptive temperature control under all operating conditions, this system maintains the battery's optimal thermal state under various environments and usage scenarios.

[0042] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0043] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A thermal management control system for an electric telescopic boom forklift truck, characterized in that: It includes a control assembly, an air conditioning system assembly, a power battery pack thermal management assembly, and a cooler (1); the control assembly is connected to the air conditioning system assembly and the power battery pack thermal management assembly via communication harnesses. The cooler (1) includes two non-connected channels, which are respectively connected to the air conditioning system assembly and the power battery pack thermal management assembly; The power battery pack thermal management assembly includes a water pump (2), a WPTC heater (3) and a water collector (4) connected in sequence by pipes, and a cooler (1) connected in series between the WPTC heater (3) and the heat exchange pipe in the power battery pack.

2. The air conditioning thermal management control system for electric telescopic boom forklifts according to claim 1, characterized in that: The air conditioning system assembly includes a condenser (5), a liquid receiver (6), an evaporator (7), and a compressor (8) connected in sequence by pipes. The compressor (8) is connected to the condenser (5) by a return pipe. The cooler (1) is connected to the storage tank (6) and the evaporator (7) respectively through a three-way pipe. The storage tank (6) is diverted to the evaporator (7) and the cooler (1) through the three-way pipe.

3. The air conditioning thermal management control system for electric telescopic boom forklifts according to claim 2, characterized in that: It also includes an electronic expansion valve (9) connected to the control assembly via a CAN bus, the electronic expansion valve (9) being disposed on the pipeline between the cooler (1) and the tee pipe.

4. The air conditioning thermal management control system for electric telescopic boom forklifts according to claim 3, characterized in that: The power battery pack thermal management assembly also includes an auxiliary water tank (10), and the water collector (4) is provided with at least two water outlets, which are respectively connected to the water pump (2) and the auxiliary water tank (10).

5. The air conditioning thermal management control system for electric telescopic boom forklifts according to claim 4, characterized in that: The control assembly includes a vehicle VCU (11), a BMS battery management system (12) for collecting temperature signals from the power battery pack, and a thermal management controller (13); the BMS battery management system (12) is connected to the temperature sensor signals of the power battery pack inlet and outlet, and is connected to the vehicle VCU (11) via a CAN bus. The electronic expansion valve (9), compressor (8) and WPTC heater (3) are connected to the thermal management controller (13) via CAN bus.

6. The air conditioning thermal management control system for electric telescopic boom forklifts according to claim 5, characterized in that: It also includes a motor controller (14) connected to the vehicle VCU (11) via a CAN bus signal, wherein the motor controller (14) is connected to the walking motor (15) and the hydraulic pump motor (16) via control lines.

7. The air conditioning thermal management control system for electric telescopic boom forklifts according to claim 6, characterized in that: The auxiliary water tank (10) is equipped with a steam hose (17) for venting steam.

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