Cycle process device, thermal management system and vehicle

Abstract

A cyclic process device (10), in particular a heat pump, for a vehicle, in particular an electric vehicle or a hybrid vehicle, comprising: at least a first heat exchanger (11a) and a second heat exchanger (11b) for transferring thermal energy, a compressor unit (12) for compressing a fluid, an expansion valve (13) for adjusting the pressure of a fluid, a housing (14) for receiving at least the compressor unit (12), wherein the first heat exchanger (11a) and / or the second heat exchanger (11b) are arranged in an axial direction (L') of the housing (14) on the compressor unit (12).

Description

[0001] The present invention relates to a cyclic process device, a thermal management system with such a cyclic process device and a vehicle.

[0002] Cyclic process devices, particularly heat pumps, are known. Heat pumps, for example, consist of a compressor, which can be driven mechanically or electrically, that draws in a gaseous fluid to compress it and then feeds it via a pipe or hose to a heat exchanger, such as a condenser. In the condenser, thermal energy is extracted from the fluid. This cools the fluid, preferably until it falls below a boiling point, allowing the fluid to undergo a phase change and at least partially transition into a liquid state. The liquid fluid is then expanded by passing it through an expansion valve. The fluid is then fed to another heat exchanger, an evaporator. The evaporator transfers thermal energy back to the fluid, causing it to return to a gaseous state.

[0003] It is known to assemble such devices or systems from standardized components or individual components. Furthermore, the individual components are connected by lines, particularly hoses or pipes. The heat exchangers, in particular, are connected to the compressor via additional lines. This leads to heat losses in the lines. Furthermore, leaks can occur, which can result in higher refrigerant consumption. The systems also require a large amount of installation space, as the individual and standard components can only be adapted to a limited extent in terms of shape and size. Consequently, the power density is low and the weight is high. In addition, numerous interfaces are required, which represent potential sources of error or unavoidable leakage, meaning these systems require regular maintenance and can release fluid into the environment.

[0004] It has thus become clear that there is a need to provide an improved, and in particular more compact, circular process device.

[0005] The object of the present invention is to provide a cycle process device. It is further an object of the present invention to provide a thermal management system, a vehicle, and a method.

[0006] Within the scope of the invention, the problem is solved with regard to the cycle process device by independent claim 1, the thermal management system by independent claim 9 and the vehicle by independent claim 10.

[0007] One aspect of the present invention relates to a cyclic process device, in particular a heat pump, for a vehicle, in particular an electric vehicle or a hybrid vehicle, comprising: at least a first heat exchanger and a second heat exchanger for transferring thermal energy, a compressor unit for compressing a fluid, an expansion valve for adjusting the pressure of a fluid, a housing for receiving at least the compressor unit, wherein the first heat exchanger and / or the second heat exchanger are arranged in an axial direction of the housing on the compressor unit.

[0008] In contrast to the known state of the art, this method enables a high degree of integration. The cycle device has a more compact, and in particular space-saving, design and allows for more efficient operation. In other words, a very compact refrigeration circuit with a small charge and high power density can be achieved. Furthermore, the more compact design reduces or eliminates leakage and corrosion of fluid lines, as the distances between the individual components of the heat exchanger, and thus the fluid lines, can be very short.

[0009] The cycle device is preferably a heat pump for a vehicle, in particular an electric vehicle or a hybrid vehicle. The cycle device comprises at least the first heat exchanger and the second heat exchanger. The heat exchangers can also be referred to as heat transfer units. In one embodiment, the two heat exchangers can be designed as plate heat exchangers. The two heat exchangers are designed to transfer thermal energy from a refrigerant circuit to a coolant circuit.

[0010] The compressor unit is specifically designed to compress a fluid. The compressor unit preferably includes a drive unit. The drive unit can, for example, be an electric motor. The drive unit can be arranged in the housing with the compressor unit. The compressor unit and the drive unit are preferably formed as a single unit. Alternatively, the drive unit can be arranged outside the housing and mechanically coupled to the compressor unit. The compressor unit can include a scroll compressor, a rotary piston compressor, or a turbo compressor. Other suitable compressor types are also possible. The selected compressor can preferably be integrated as a single unit with the housing to provide a one-piece thermodynamic device.

[0011] The thermodynamic device further comprises at least one expansion valve for adjusting or regulating the fluid pressure. It is possible for the thermodynamic device to include two expansion valves. The at least one expansion valve can be designed as a directly controllable, in particular electrically controllable, valve. The term "regulation" can be understood as the control or regulation of a variable to be set, for example, a pressure. "Control" is understood as a process in which a controlled variable is influenced by another variable. Thus, control is understood as a process in which an input variable influences an output variable in a device or system in a specific way.

[0012] The housing is preferably made of aluminum. Alternatively, other metals or suitable plastics may be used. The housing may be manufactured by deep drawing, roll forming, die casting, or other manufacturing processes. The housing is preferably hermetically sealed, in particular fluid-tight. This means that nothing can enter or escape from the inside. In particular, the housing may be welded and / or brazed. The housing may have a cylindrical, circular, oval, square, or rectangular geometry or shape.

[0013] The housing is preferably designed such that the cycle device can be handled as a single unit. In other words, the cycle device can, for example, be designed as a heat pump and installed as a single unit in a vehicle.

[0014] The housing contains at least the compressor unit. Additional components may also be located within the housing. This means that the compressor unit is at least partially enclosed by the housing. In other words, an outer wall of the compressor unit can form an outer wall of the housing. The compressor unit can be formed integrally with the housing, at least partially. Alternatively or additionally, the compressor unit can be positively connected, frictionally connected, and / or materially connected to the housing. In one embodiment, the compressor unit is integrally formed with the housing, at least partially.

[0015] It is possible for the housing to have a substantially cylindrical geometry. In particular, the housing may have a cylindrical geometry at least in sections. This means that the housing has a central longitudinal axis, at least in sections, that passes through the center point of a cross-section of a cylindrical body. It is also conceivable that further shapes or elements are arranged on or project from the cylindrical geometry. Alternatively or additionally, the housing may have a polygonal geometry in sections. Preferably, the two heat exchangers and / or the compressor unit are adapted to the geometry of the housing or have a substantially corresponding geometry, at least in sections.

[0016] Within the scope of the present invention, the term "essentially" can be understood to mean a deviation of between + / -15%, in particular between + / -10%, and in particular between + / -5%.

[0017] The first and / or second heat exchanger are arranged axially along the housing of the compressor unit. The axial direction can be understood as the longitudinal direction of the housing. This axial direction can run parallel to the central longitudinal axis of the housing. Alternatively, the axial direction can be parallel to a longitudinal axis of the compressor unit's drive unit. In other words, the heat exchangers are preferably arranged axially along an end face of the housing and connected to the compressor. One or more heat exchangers can be arranged on each end face. These can be connected in series or in parallel. Furthermore, the heat exchangers can have different sizes, shapes, or geometries. For example, the first heat exchanger can be larger than the second heat exchanger. This allows the two heat exchangers to have different cooling capacities.The heat exchangers can take on any shape, for example round, oval, square, or rectangular. Depending on the designed operating point, at least one heat exchanger per side can be used.

[0018] In one embodiment, the first and second heat exchangers are directly adjacent to the compressor unit. The terms "directly" and "immediately" mean that, at least in sections, no further element, component, or part is arranged between the compressor unit and the heat exchangers. It is possible that a gap, a free space, a fluid line, or a housing wall is arranged between the compressor unit and the heat exchangers. It is also possible that the compressor unit and the heat exchangers are in contact, at least in sections. It is conceivable that a housing wall is arranged between the heat exchangers and the compressor unit, and that the compressor unit and the heat exchangers are connected to each other by this housing wall.This means that the first and second heat exchangers are arranged directly on the compressor unit, so that no other components are located between the first and second heat exchangers and the compressor unit. Furthermore, the first and second heat exchangers can be in contact with the compressor unit. Preferably, the first and second heat exchangers are arranged on the compressor unit in such a way that no additional fluid line is required between the first and second heat exchangers and the compressor unit. For example, the first and second heat exchangers can be arranged on the housing that forms part of the compressor unit or to which the compressor unit is connected. The first and second heat exchangers can, for example, be welded to the housing.

[0019] In one embodiment, the first heat exchanger is configured as an evaporator for vaporizing a fluid, and the second heat exchanger is configured as a condenser for liquefying a fluid. For example, the heat exchangers can each be thermally coupled to a cooling circuit of a vehicle's thermal management system. In particular, a high-temperature circuit can be thermally coupled to the condenser, and a low-temperature circuit to the evaporator.

[0020] In one embodiment, the first heat exchanger, the second heat exchanger, the compressor unit, and / or the expansion valve are at least partially arranged within the housing and / or integrally integrated with the housing. Preferably, all components of the cycle device intended to be subjected to fluid or refrigerant flow are arranged within the housing. This allows the cycle device to be designed as a holistic system, making it manageable as a single unit. For example, the first and second heat exchangers can be arranged directly on and connected to the compressor unit within the housing.

[0021] In one embodiment, the first and / or the second heat exchanger is screwed, welded, and / or clamped to the housing. For example, a screw connection with multiple screws can be used to connect the heat exchangers to the housing. This allows for a fixed and detachable connection between the heat exchangers and the housing. Alternatively or additionally, the heat exchangers can be screwed directly to the housing. Welding the heat exchangers to the housing enables a material-bonded and hermetically sealed connection. Furthermore, a tight connection between the heat exchangers can be achieved by clamping. This can be accomplished, for example, by elements with corresponding geometries that exert a clamping force on each other when assembled.

[0022] In one embodiment, the first and second heat exchangers are arranged in a fluid inlet region and / or a fluid outlet region of the compressor unit. A housing wall can be arranged between the heat exchangers and the compressor unit. The compressor unit can be formed integrally with the housing or the housing wall. The fluid inlet region is understood to be the region located upstream of the compressor unit in a low-pressure area in the direction of fluid flow. The fluid outlet region is understood to be the region located downstream of the compressor unit in a high-pressure area in the direction of fluid flow. The fluid inlet region is, for example, located between an evaporator and the compressor unit, and the fluid outlet region is, for example, located between the compressor unit and a condenser.

[0023] In one embodiment, the first and second heat exchangers are arranged at the same axial end of the housing. In other words, the two heat exchangers are located on the same axial end face of the housing. The two heat exchangers can be arranged, for example, side by side transversely or longitudinally. This allows for a compact design in the thermodynamic device.

[0024] In one embodiment, the compressor unit is arranged axially within the cycle device between the first and second heat exchangers. In other words, the cycle device has a sandwich structure. This means that the compressor unit is bounded axially in both directions by a heat exchanger. For example, in a compressor unit where the fluid inlet and outlet are axially opposite each other, the first and second heat exchangers can be arranged accordingly on the housing and the compressor unit, respectively. For instance, the first heat exchanger can be located at the fluid inlet of the compressor unit, and the second heat exchanger at the fluid outlet, and connected to them.

[0025] In one embodiment, the cycle device comprises a third heat exchanger arranged axially on the compressor unit. The third heat exchanger can, for example, be arranged axially on an end face of the housing or compressor unit together with the first or second heat exchanger. The third heat exchanger can be configured as a condenser or an evaporator.

[0026] In one embodiment, the cycle device includes a further expansion valve configured to set a medium pressure in a medium-pressure line, with the third heat exchanger being located in this medium-pressure line. This additional expansion valve is necessary to implement additional functions such as vapor injection or precooling. It allows for targeted separation of the mass flow and the implementation of further functions such as vapor injection or the use of the third heat exchanger as an evaporator or precooler. The two expansion valves are preferably arranged at an angle between 150° and 210°, preferably in a lower region of the cycle device when installed, and preferably at an angle of 180°. Preferably, the two expansion valves are arranged symmetrically, particularly at the same height within the housing of the cycle device.

[0027] It is particularly advantageous if the third heat exchanger is arranged in the medium-pressure line and the second heat exchanger is arranged in a high-pressure line. For example, the third heat exchanger can be configured as an evaporator, especially a precooler, for evaporating a fluid or as a condenser for liquefying a fluid. The cycle device can, for example, include two condensers, such as a dual condenser, each coupled to separate high-temperature circuits. Alternatively, the third heat exchanger can be arranged as an evaporator or precooler in the medium-pressure line, and the first heat exchanger in a low-pressure line. The medium-pressure and low-pressure lines can be connected in parallel. This allows the mass flow of the fluid to be divided.

[0028] In one embodiment, the third heat exchanger is arranged or connected in series or parallel with the first or second heat exchanger. For example, the second and third heat exchangers can be configured as condensers, with the second heat exchanger connected in series with the third. Alternatively, the second heat exchanger can be connected in parallel with the third. The second and third heat exchangers can be arranged on the same axial end face of the compressor unit.

[0029] In one embodiment, the first and third heat exchangers are arranged at the fluid inlet of the compressor unit, and the second heat exchanger is arranged at the fluid outlet of the compressor unit. For example, the first and third heat exchangers are configured as evaporators. The third heat exchanger is designed as a precooler located in the medium-pressure line, which is connected in parallel to the low-pressure line.

[0030] In one embodiment, the third heat exchanger and the first heat exchanger are arranged axially at the same axial end of the housing. This makes it possible to position the two heat exchangers, designed as evaporators, in the fluid inlet area of ​​the compressor unit. This allows both evaporators to be more easily coupled to a low-temperature circuit.

[0031] In one embodiment, the housing comprises at least one fluid line, or the housing forms at least one fluid line, wherein the fluid line is configured to fluidically connect the two heat exchangers, the compressor unit, and / or the expansion valve. In other words, at least one fluid line is integrally formed with the housing. This means that the fluid line is formed by the housing. This means that preferably no separate fluid line is arranged within the housing. The at least one fluid line makes it possible to reduce or largely eliminate the use of external fluid lines, in particular pipes or hoses. The at least one fluid line can be designed for a fluid, for example, a refrigerant and / or a coolant. The fluid can be a gas and / or a liquid.Alternatively or additionally, the housing can have at least one connection for at least one fluid line.

[0032] Another aspect of the present invention relates to a thermal management system with a cycle process device according to one of the preceding embodiments.

[0033] Another aspect of the present invention relates to a vehicle with a thermal management system according to the preceding embodiment and / or a cycle process device according to one of the preceding embodiments.

[0034] Individual features and embodiments of the present invention can be combined with other features in other embodiments to form new embodiments. Advantages and further developments mentioned for the features or embodiments also apply analogously to the new embodiments. Further developments and advantages mentioned in connection with the apparatus also apply analogously to the method and vice versa.

[0035] The following is an exemplary description of the revelation with reference to the attached figures, which show: Fig. 1a: a perspective view of an embodiment of a circular process device according to the invention; Fig. 1b: a sectional view of the circular process device according to Fig. 1a; Fig. 1c: another sectional view of the circular process device according to Fig. 1a; Fig. 2a: a perspective view of an embodiment of a circular process device according to the invention; Fig. 2b: a sectional view of the circular process device according to Fig. 2a Fig. 2c: another sectional view of the circular process device according to Fig. 2a; Fig. 3a: a perspective view of an embodiment of a circular process device according to the invention; Fig. 3b: a sectional view of the circular process device according to Fig. 3a; and Fig. 3c: another sectional view of the circular process device according to Fig. 3a.

[0036] Fig. Figure 1a shows a thermodynamic device 10 designed as a heat pump. The heat pump comprises a housing 14. The housing 14 is essentially cylindrical. A compressor unit 12 is arranged in the housing 14. The compressor unit comprises a compressor 12a and an electric motor 12b. The compressor 12a is connected to the electric motor 12b via a power transmission mechanism. In other words, the electric motor 12b drives the compressor 12a. For this purpose, the electric motor 12b is connected to the compressor 12a via a shaft.

[0037] On the axially L'-oriented end faces of the housing 14, a first heat exchanger 11a, a second heat exchanger 11b, and a third heat exchanger 11c are arranged. The first and third heat exchangers are each designed as evaporators. The first and third heat exchangers are located on an end face of the housing 14 closest to the electric motor. The second heat exchanger 11b is designed as a condenser. The second heat exchanger is located on an end face opposite the one containing the first and third heat exchangers. In other words, the second heat exchanger is located on an end face of the housing 14 closest to the compressor.

[0038] An expansion valve 13 is arranged in the housing 14. Furthermore, another expansion valve 13' is arranged in the housing 14. Both expansion valves are located in the area of ​​the electric motor 12b. More precisely, when installed, the two expansion valves 13 and 13' are located below the electric motor 12b. Expansion valve 13 is arranged in a low-pressure line, and the other expansion valve 13' is arranged in a medium-pressure line. A low pressure is set in the low-pressure line. This low-pressure level is set by expansion valve 13. A medium pressure is set in the medium-pressure line. This medium-pressure level is set by the other expansion valve 13'.

[0039] A power electronics unit 16 is arranged on an outer surface of the housing 14. The power electronics unit 16 is connected to the compressor unit 12 via the housing 14 for signal and / or energy transmission. Alternatively, the power electronics unit can be located inside the housing 14.

[0040] Fig. 1b and Fig. Figure 1c shows the sectional views at different positions of the heat pump. Fig. Figure 1B shows a sectional view through the area of ​​the condenser or the second heat exchanger 11b. The second heat exchanger 11b is essentially rectangular in design or has an essentially rectangular geometry. The housing 14 has an essentially circular geometry in cross-section.

[0041] Figure 1 shows a sectional view through the area of ​​the expansion valves 13, 13'. The expansion valves 13, 13' are arranged in a lower region of the housing 14. The expansion valves 13, 13' are arranged within an angular range between 150° and 210°. In this range, the expansion valves 13, 13' are positioned at the bottom of the assembled circular process device 10.

[0042] Fig. Figure 2a shows an essentially identical embodiment of the heat pump according to Fig. 1a. In contrast to the previous embodiment, the heat pump has two condensers or two secondary heat exchangers 11b, each arranged on the same end face of the housing 14. This arrangement can be referred to as a double condenser. The two secondary heat exchangers 11b can be connected in series or in parallel. The two secondary heat exchangers can be thermally coupled to the same or to different high-temperature circuits.

[0043] In Fig. 2b is a sectional view through the arrangement of the two second heat exchangers 11b from Fig. 2a shown. The two second heat exchangers are arranged side by side and have essentially the same rectangular geometry. Fig. Figure 2c shows a section through the expansion valve 13,13'. The arrangement of the expansion valve 13,13' in Fig. 2c corresponds to the one in Fig. Arrangement shown in 1c.

[0044] Fig. Figure 3a shows another embodiment of a possible heat pump. In the case of the Fig. In the embodiment shown in Figure 3a, the first heat exchanger 11a (or evaporator), the second heat exchanger 11b (or condenser), and the third heat exchanger 11c (or precooler) are arranged on the same end face of the housing 14. The remaining features are the same as in the previous embodiments. The heat exchangers are arranged on the end face of the housing 14 that is closest to the compressor 12a. Fig. Figure 3b shows a sectional view through the evaporator and the condenser. The evaporator and the condenser are arranged side by side. The third heat exchanger 11C is arranged axially L' on a surface or side of the first heat exchanger and / or the second heat exchanger facing away from the housing 14.

[0045] Other embodiments of the present invention are possible and can be understood and carried out by persons skilled in the art when applying the claimed subject matter by studying the figures, the disclosure, and the appended claims. In particular, the respective parts / functions of each embodiment described above can also be combined with one another. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are mentioned in interdependent claims does not mean that a combination of these measures cannot be advantageous. Any reference numerals in the claims should not be interpreted as limiting the scope of the claims. Reference sign L' Longitudinal direction 10 Circular process device 11a first heat exchanger 11b second heat exchanger 11c third heat exchanger 12 compressor unit 12a Compressor 12b Electric motor 13 Expansion valve 14 cases 15 wave 16 Power Electronics

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