Thermal Management System

Abstract

To provide a thermal management system capable of predicting the occurrence of a system failure and delaying the occurrence of the failure.SOLUTION: A thermal management system includes a heat medium circuit that circulates a heat medium that has exchanged heat with a refrigerant circuit to a temperature control target, and a control device 9 that controls the temperature of the temperature control target by controlling the heat medium circuit. The control device 9 includes a failure prediction unit 63 that predicts the occurrence of a failure in the system on the basis of information regarding the lifespan of devices configuring the system, and a life extension control unit 64 that executes predetermined life extension control to delay the occurrence of the failure on the basis of the system failure prediction by the failure prediction unit 63.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a thermal management system that controls temperature by circulating a heat medium that has exchanged heat with a heat source through a heat medium circuit to a temperature control target. [Background technology]

[0002] Conventionally, for example, batteries (cells) and traction motors (hereinafter referred to as temperature control targets) mounted on electric vehicles (electric cars, hybrid cars, etc.) generate heat. For this reason, thermal management systems have been developed that control the temperature by circulating a heat medium (water, etc.) around the temperature control target, or that use a heat pump circuit (refrigerant circuit) for air-conditioning the passenger compartment of an electric vehicle, heating / cooling the heat medium with a refrigerant (fluorocarbon refrigerant) that radiates heat in a radiator and a refrigerant that absorbs heat in a heat absorber, and circulating this heat medium around the temperature control target in the heat medium circuit (see, for example, Patent Document 1).

[0003] Here, the flow path of the heat medium in the heat medium circuit is switched by a flow path switching device composed of valves driven by solenoids or motors, etc., but these flow path switching devices are also mechanical parts and have a durability lifespan. Conventionally, measures have been taken to predict the failure and lifespan of these parts, prompt part replacement, and even notify the dealer (see, for example, Patent Document 2 and Patent Document 3).

[0004] Also, electric vehicles have been developed that extend the life of their driving functions by fully opening the battery door to cool the battery when the vehicle's air conditioning system breaks down (see, for example, Patent Document 4). Furthermore, solenoid valve control devices that determine the lifespan based on the number of times the solenoid valve operates, and vehicle air conditioning systems that operate the compressor at an appropriate ON / OFF frequency have also been developed (see, for example, Patent Documents 5 and 6). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-80123 [Patent Document 2] Japanese Patent Application Publication No. 2018-13842 [Patent Document 3] Japanese Patent Application Publication No. 2018-149825 [Patent Document 4] Japanese Patent Application Publication No. 8-40088 [Patent Document 5] Japanese Patent Application Laid-Open No. 2014-169771 [Patent Document 6] Japanese Patent Application Laid-Open No. 2016-141296 Summary of the Invention [Problem to be solved by the invention]

[0006] For example, if the temperature control target is a battery mounted on an electric vehicle, it cannot operate efficiently at either a low or high temperature, and the optimum temperature range is approximately +10°C to +30°C. Therefore, it is necessary to heat the battery to warm it up, especially in cold weather such as winter. Furthermore, because the battery is a component with a large heat capacity, it is conceivable to improve system efficiency by using waste heat from other components to heat the battery, storing the heat in the battery, and using that heat when needed. However, if the flow path switching device of the heat medium circuit fails and the state in which the battery is heated (operating mode) continues, the battery temperature will continue to rise, and in the worst case scenario, there is a risk of fire.

[0007] However, conventional systems do not have the concept of predicting failures in the heat transfer medium circuit for controlling the temperature of a temperature control target such as a battery, and delaying the occurrence of such failures (extending life), and improvements were desired.

[0008] The present invention has been made to solve the above-mentioned conventional technical problems, and provides a thermal management system that can predict the occurrence of a system failure and delay the occurrence of the failure. [Means for solving the problem]

[0009] In order to solve the above problems, the thermal management system of the present invention includes a heat medium circuit that circulates a heat medium that has exchanged heat with a heat source to a temperature control target, and a control device that controls the heat medium circuit to control the temperature of the temperature control target, and the control device: The system switches between a required operation mode, which is essential for the functions required of the system, and an additional operation mode other than the required operation mode, and A failure prediction unit that predicts the occurrence of a system failure based on information about the lifespan of the devices that make up the system, and a system failure prediction unit that predicts the occurrence of a system failure based on information about the lifespan of the devices that make up the system. Prediction of failure occurrence A life extension control unit that executes predetermined life extension control to delay the occurrence of the failure based on the The life extension control unit prohibits or limits the execution of the additional operation mode in the life extension control. It is characterized by:

[0010] The thermal management system of the invention of claim 2 is characterized in that in the above invention, the control device includes a notification control unit that notifies the outside when life extension control is executed.

[0011] The thermal management system of the invention of claim 3 is characterized in that in the invention of claim 1, the temperature control target includes any one of the passenger compartment of the electric vehicle, the battery mounted on the electric vehicle, the traction motor of the electric vehicle, the inverter that drives the traction motor, and the power control unit of the electric vehicle, or a combination of these, or all of these.

[0012] The thermal management system of the invention of claim 4 is the invention of claim 1. The heat medium circuit is equipped with a flow path switching device that switches the flow path of the heat medium, and the failure prediction unit predicts the occurrence of a failure in the flow path switching device, and the life extension control unit delays the occurrence of a failure in the flow path switching device by reducing the operating frequency of the flow path switching device during life extension control.

[0013] The thermal management system of the invention of claim 5 comprises: The system includes a heat medium circuit that circulates a heat medium that has exchanged heat with a heat source to a temperature control target, and a control device that controls the heat medium circuit to control the temperature of the temperature control target. The heat medium circuit includes a flow path switching device that switches the flow path of the heat medium. The control device includes a failure prediction unit that predicts the occurrence of a system failure based on information related to the lifespan of equipment that constitutes the system, and a life extension control unit that executes predetermined life extension control to delay the occurrence of the failure based on the prediction of the occurrence of a system failure by the failure prediction unit. The failure prediction unit predicts the occurrence of a failure of the flow path switching device, and the life extension control unit delays the occurrence of a failure of the flow path switching device by reducing the operating frequency of the flow path switching device in the life extension control.

[0014] The thermal management system of the present invention according to claim 6 is characterized in that in the above invention, the failure prediction unit predicts a failure of the flow path switching device based on the number of operations of the flow path switching device.

[0015] The thermal management system of the invention of claim 7 is characterized in that in the invention of claim 5, the flow path switching device switches the flow path of the heat medium depending on the rotational position, and the failure prediction unit predicts failure of the flow path switching device based on the integrated value of the rotation angle of the flow path switching device.

[0016] The thermal management system of the invention of claim 8 is characterized in that in the invention of claim 5, the temperature control target is a battery mounted on an electric vehicle, the control device has an operating mode in which the flow path of the heat medium is switched by a flow path switching device to heat the battery, and the life extension control unit prohibits or restricts execution of the operating mode in which the battery is heated.

[0017] The thermal management system of the invention of claim 9 is characterized in that in the above invention, the life extension control unit limits the execution of an operation mode that heats the battery by lowering a threshold for completing the operation mode.

[0018] The thermal management system of the invention of claim 10 is characterized in that in each of the above inventions, the heat source is composed of a refrigerant circuit having a compressor that compresses a refrigerant, a radiator that radiates heat from the high-temperature refrigerant discharged from the compressor, a pressure reducing device that depressurizes the refrigerant that has radiated heat in the radiator, and a heat absorber that absorbs heat from the refrigerant that has been depressurized in the pressure reducing device, and the heat medium circuit has a heating section that heats the heat medium and a cooling section that cools the heat medium, and the heating section exchanges heat with the radiator and the cooling section exchanges heat with the heat absorber.

[0019] The thermal management system of the invention of claim 11 is characterized in that in the above invention, the failure prediction unit predicts failure of the compressor based on the operation of the compressor, and the life extension control unit delays the occurrence of failure of the compressor by reducing the frequency of starting / stopping the compressor in the life extension control. [Effects of the Invention]

[0020] According to the invention of claim 1, in a thermal management system comprising a heat medium circuit that circulates a heat medium that has exchanged heat with a heat source to a temperature control target, and a control device that controls the temperature of the temperature control target by controlling this heat medium circuit, the control device is equipped with a failure prediction unit that predicts the occurrence of a system failure based on information regarding the lifespan of the equipment that constitutes the system, and a life extension control unit that executes predetermined life extension control to delay the occurrence of the failure based on the system failure predicted by the failure prediction unit.Therefore, the failure prediction unit predicts whether or not a failure will occur in the system based on information regarding the lifespan of the equipment that constitutes the system, and if there is a high possibility of a failure occurring, the life extension control unit executes life extension control to delay the occurrence of the failure.

[0021] This reduces or avoids the risk of an accident occurring in the temperature control target due to a failure in the equipment that constitutes the system, making it possible to control the temperature of the temperature control target more safely and for a longer period of time.

[0022] In addition, the control device switches between an essential operating mode that is essential for the functions required of the system and an additional operating mode other than this essential operating mode, and the life extension control unit prohibits or restricts the execution of the additional operating mode during life extension control.This makes it possible to reduce the number of operating mode switches while ensuring the execution of the essential operating mode that is essential for the system, extend the lifespan of the equipment that makes up the system, and delay the occurrence of failures in the system.

[0023] Furthermore, by configuring the control device to include a notification control unit that notifies the outside when life extension control is executed, as in the invention of claim 2, it is possible to predict the occurrence of a failure in an equipment that makes up the system, and notify the outside that life extension control is being performed to delay the occurrence of the failure, thereby encouraging early response regarding equipment maintenance, replacement, etc., and also to avoid the inconvenience of continuing operation with reduced efficiency if the efficiency of the system is reduced due to life extension control.

[0024] In this case, the temperature control targets may include the passenger compartment of the electric vehicle, the battery mounted on the electric vehicle, the traction motor of the electric vehicle, the inverter that drives the traction motor, the power control unit of the electric vehicle, etc., as in the invention of claim 3.

[0025] More specifically, Claim 4 andAs in the invention of claim 5, the failure prediction unit predicts the occurrence of a failure in the flow path switching device that switches the flow path of the heat medium in the heat medium circuit, and the life extension control unit delays the occurrence of a failure in the flow path switching device by reducing the operating frequency of the flow path switching device in the life extension control.

[0026] Furthermore, as in the invention of claim 6, the failure prediction unit predicts a failure of the flow path switching device based on the number of times the flow path switching device operates.

[0027] On the other hand, if the flow path switching device switches the flow path of the heat medium depending on the rotational position, as in the invention of claim 7, the failure prediction unit predicts a failure of the flow path switching device based on the integrated value of the rotation angle of the flow path switching device.

[0028] In particular, in the case where the temperature control target is a battery mounted on an electric vehicle as in the invention of claim 8, and the control device has an operating mode in which the flow path of the heat medium is switched using a flow path switching device to heat the battery, the life extension control unit can prohibit or limit the execution of the operating mode in which the battery is heated, thereby making it possible to avoid accidents in which the battery temperature continues to rise and lead to fire.

[0029] In this case, specifically, the life extension control unit limits the execution of the operation mode for heating the battery by lowering the threshold for completing the operation mode, as in the invention of claim 9.

[0030] Furthermore, as in the invention of claim 9, when the heat source is configured from a refrigerant circuit having a compressor that compresses a refrigerant, a radiator that radiates heat from the high-temperature refrigerant discharged from the compressor, a pressure reducing device that depressurizes the refrigerant that has radiated heat in the radiator, and a heat absorber that absorbs heat from the refrigerant that has been depressurized in the pressure reducing device, the heat medium circuit is configured to have a heating section that heats the heat medium and a cooling section that cools the heat medium, and the heating section exchanges heat with the radiator, and the cooling section exchanges heat with the heat absorber.

[0031] Furthermore, in the case of the above invention, as in the invention of claim 10, if the failure prediction unit predicts a failure of the compressor based on the operation of the compressor, and the life extension control unit delays the occurrence of a failure of the compressor by reducing the frequency of starting / stopping the compressor in the life extension control, the occurrence of a failure of the compressor that constitutes the refrigerant circuit that serves as the heat source will also be delayed, making it possible to continue temperature control of the temperature control target for a longer period of time and more safely. [Brief explanation of the drawings]

[0032] [Figure 1] 1 is a block diagram illustrating the configuration of an embodiment of a thermal management system according to the present invention. [Figure 2] FIG. 2 is a functional block diagram relating to failure prediction and life extension control of the control device of FIG. [Figure 3] 1 is a diagram showing a heat medium circuit and a refrigerant circuit of an embodiment of a heat management system according to the present invention; [Figure 4] FIG. 4 is another diagram of a heat medium circuit and a refrigerant circuit of the heat management system of FIG. 3 (first operation mode). [Figure 5] FIG. 4 is yet another heat medium circuit and refrigerant circuit diagram of the heat management system of FIG. 3 (second operation mode). [Figure 6] FIG. 4 is yet another heat medium circuit and refrigerant circuit diagram of the heat management system of FIG. 3 (third operation mode). [Figure 7] FIG. 10 is a diagram showing yet another heat medium circuit and refrigerant circuit of the heat management system of FIG. 3 (fourth operation mode). [Figure 8] FIG. 10 is a diagram showing yet another heat medium circuit and refrigerant circuit of the heat management system of FIG. 3 (fifth operation mode). [Figure 9] 2 is a flowchart illustrating the operation of one embodiment of failure prediction and life extension control by the control device of FIG. 1 (Embodiment 1); [Figure 10] 10 is a flowchart illustrating the operation of another embodiment regarding failure prediction and life extension control by the control device of FIG. 1 (Embodiment 2). DETAILED DESCRIPTION OF THE INVENTION

[0033] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. [Example]

[0034] (1) Configuration of Thermal Management System 1 1 and 2 show functional blocks of an embodiment of a thermal management system 1 of the present invention, and Fig. 3 shows the configuration of a heat medium circuit 2 and a refrigerant circuit 3 of the thermal management system 1. The thermal management system 1 of the embodiment air-conditions the passenger compartment of an electric vehicle (EV) such as an electric vehicle or a hybrid vehicle, and also regulates the temperature of a battery (BATT) 4 mounted on the electric vehicle EV, a traction motor (MOT) 6 for the electric vehicle EV, an inverter (INV) 7 that drives the traction motor 6, and a power control unit (PCU) 8 for the electric vehicle EV, and is configured to include the heat medium circuit 2, the refrigerant circuit 3, and a control device 9.

[0035] Therefore, the vehicle interior of the electric vehicle EV, the battery 4, the traction motor 6, the inverter 7, and the power control unit 8 are examples of temperature control targets in the present invention. Also, the refrigerant circuit 3 is an example of a heat source in the present invention, but in this application, the battery 4 is conceptually intended to include a fuel cell.

[0036] (1-1) Configuration of Heat Transfer Medium Circuit 2 First, the heat medium circuit 2 of the heat management system 1 of the embodiment will be described with reference to Fig. 3. The heat medium circuit 2 is composed of pumps 11 to 14, a heating section 16 (heat exchanger), a cooling section 17 (heat exchanger), two indoor heat exchangers 18 and 19, an outdoor heat exchanger (radiator) 22, two integrated valves 23 and 24 as flow path switching devices, and a four-way valve 26, and these are connected to a battery 4, a driving motor 6, an inverter 7, a power control unit 8, and an electric heater (ECH) 33 as an auxiliary heating device by heat medium piping 34 as shown in Fig. 3.

[0037] In this case, a jacket structure is configured around the battery 4, the traction motor 6, the inverter 7, and the power control unit 8, and a heat medium (water in this embodiment) flows through this jacket, allowing the battery 4, the traction motor 6, the inverter 7, and the power control unit 8 to exchange heat with the heat medium. The exterior heat exchanger 22 is disposed outside the passenger compartment of the electric vehicle EV, and is configured to receive outside air from an exterior blower 36. The exterior heat exchanger 22 is further provided with a grill shutter 37 that opens and closes to control the inflow of outside air into the exterior heat exchanger 22.

[0038] Furthermore, the interior heat exchangers 18 and 19 are disposed in an air flow passage 39 of an HVAC unit 38 that supplies air for air conditioning to the interior of the electric vehicle EV. Inside air and outside air are ventilated through this air flow passage 39 by an interior blower 41, and the inside air and outside air are switched between by an intake switching damper 42. Furthermore, reference numeral 43 denotes an air mix damper that adjusts the ventilation ratio to the interior heat exchanger 19, which is disposed on the downwind side of the interior heat exchanger 18 in the air flow passage 39.

[0039] The four-way valve 26 has four ports A, B, C, and D, and an internal valve element is driven by a motor or a solenoid to switch between switching modes 1 and 2. In this case, in switching mode 1, the heat medium flowing in from port A flows to port D, and the heat medium flowing in from port B flows to port C. In switching mode 2, the heat medium flowing in from port A flows to port C, and the heat medium flowing in from port B flows to port D.

[0040] The integrated valve 23 (flow path switching device) has eight ports: B, C, D, E, F, I, J, and L. An internal valve element is rotated by a motor (servo motor). Depending on the rotational position of the valve element, switching can be performed in multiple switching modes. In this embodiment, switching modes 2, 5, and 6 are used. In this case, in switching mode 2, port C and port B are communicated, port L and port D are communicated, port E and port F are communicated, and port J and port I are communicated (FIG. 7). In switching mode 5, port C and port B are communicated, port E and port D are communicated, port J and port F are communicated, and port L and port I are communicated (FIGS. 4 to 6). In switching mode 6, port J and port B are communicated, port C and port D are communicated, port E and port F are communicated, and port L and port I are communicated (FIG. 8).

[0041] The integrated valve 24 (flow path switching device) has eight ports: B, C, D, F, G, H, I, and J. An internal valve element is rotated by a motor (servo motor). Depending on the rotational position of the valve element, switching can be performed in multiple switching modes. In this embodiment, switching modes 1, 3, 4 to 6 are used. In this case, in switching mode 1, port F is connected to port B, port C is connected to port D, port H is connected to port G, and port I is connected to port J (FIG. 7). In switching mode 3, port C is connected to port B, port I is connected to port D, port F is connected to port J, and port H is connected to port G (FIG. 5). In switching mode 4, port C is connected to port B, port I is connected to port D, port F is connected to port G, and port H is connected to port J (FIG. 4). In addition, in switching mode 5, port I and port B are connected, port C and port D are connected, port F and port G are connected, and port H and port J are connected (Fig. 6). Furthermore, in switching mode 6, port I and port B are connected, port C and port D are connected, port F and port J are connected, and port H and port G are connected (Fig. 8).

[0042] (1-2) Configuration of refrigerant circuit 3 3 is a heat pump circuit in which a compressor 44 that compresses a refrigerant (R1234yf refrigerant in this embodiment), a radiator 46 that radiates heat from the refrigerant (high-temperature refrigerant) discharged from the compressor 44, an expansion valve 47 as a pressure reducing device that reduces the pressure of the refrigerant that has radiated heat in the radiator 46, a heat absorber 48 that evaporates and absorbs heat from the refrigerant that has been decompressed by the expansion valve 47, and an accumulator 49 are sequentially connected in a ring shape by refrigerant piping 52. The radiator 46 of the refrigerant circuit 3 and the heating section 16 of the heat medium circuit 2 are disposed in a heat exchange relationship, and the heat absorber 48 and the cooling section 17 are disposed in a heat exchange relationship.

[0043] (1-3) Configuration of the control device 9 Next, the configuration of the control device 9 will be described with reference to Figures 1 and 2. The control device 9 is configured with a microcomputer equipped with a processor, memory, and input / output interface, and as shown in Figure 1, has as its functions an operation mode determination unit 51, a control target value calculation unit 52, an operation mode switching control unit 53, and a control target value control unit 54. This control device 9 receives detection data from sensors (representatively shown by reference numeral 56 in Figure 1) that detect the temperature of the air inside the passenger compartment of the electric vehicle EV, the temperature of the air blown into the passenger compartment, and the like, as well as the temperature and pressure of various parts of the refrigerant circuit 3, the amount of solar radiation into the passenger compartment, and the like.

[0044] In addition, the control device 9 is connected to the aforementioned integrated valves 23, 24, four-way valve 26, pumps 11 to 14, grill shutter 37 (representatively shown by reference numeral 57 in FIG. 1), as well as the aforementioned compressor 44, expansion valve 47, outdoor blower 36, indoor blower 39, suction switching damper 41, air mix damper 43, and electric heater (ECH) 33 (representatively shown by reference numeral 58 in FIG. 1), and these are controlled by the control device 9.

[0045] Furthermore, the control device 9 is configured to transmit and receive data (temperature data, etc.) to and from a battery management system 61 that controls the charging and discharging of the battery 4 and the aforementioned power control unit (PCU) 8 via a CAN 59 of the electric vehicle EV. The control device 9 also obtains necessary data (vehicle speed, etc.) from other ECUs (not shown) of the electric vehicle EV via the CAN 59. A router 60 that transmits and receives data wirelessly to and from the outside via an internet line is connected to the CAN 59, and the control device 9 is configured to transmit and receive data to and from the outside via the CAN 59 and the router 60.

[0046] An operation mode determination unit 51 of the control device 9 determines the air conditioning of the vehicle cabin, such as cooling or heating, and each operation mode (described later) of the heat medium circuit 2 and the refrigerant circuit 3, based on the detection data of the above-mentioned sensor 56, etc. Furthermore, a control target value calculation unit 52 calculates a control target value for the operation mode determined by the operation mode determination unit 51. Furthermore, an operation mode switching control unit 53 controls the integrating valves 23 and 24, the four-way valve 26, and the pumps 11 to 14 of the heat medium circuit 2, based on the operation mode determined by the operation mode determination unit 51. Furthermore, a control target value control unit 54 controls the compressor 44, the expansion valve 47, the blowers 36 and 41, the electric heater (ECH) 33, the dampers 42 and 43, and the grille shutter 37 of the refrigerant circuit 3, based on the control target value calculated by the control target value calculation unit 52.

[0047] 2 shows functional blocks relating to failure prediction and life extension control of the control device 9 of the embodiment. In Fig. 2, 63 is a failure prediction unit, 64 is a life extension control unit, and 66 is a notification control unit. The failure prediction and life extension control by these units will be described in detail later.

[0048] (2) Operation mode of the control device 9 Next, the operation modes of the control device 9 of the embodiment will be described with reference to FIGS. (2-1) First operation mode 4 shows the first operation mode by the control device 9. In this first operation mode, the compressor 44, the outdoor blower 36, the indoor blower 41, and the pumps 11 to 14 are operated, the four-way valve 26 is in switching mode 2, the integrating valve 23 is in switching mode 5, and the integrating valve 24 is in switching mode 4. In addition, the grill shutter 37 is opened, and the electric heater 33 is operated as needed.

[0049] As a result, the high-temperature refrigerant discharged from the compressor 44 of the refrigerant circuit 3 radiates heat in the radiator 46 to the heat medium flowing in the heating section 16, and in the heat absorber 48, the refrigerant decompressed in the expansion valve 47 evaporates and absorbs heat from the heat medium flowing in the cooling section 17. The refrigerant that has left the heat absorber 48 is separated into gas and liquid in the accumulator 49, and then is sucked into the compressor 44.

[0050] On the other hand, the heat medium discharged from the pump 12 of the heat medium circuit 2 reaches the heating section 16, where it is heated by the refrigerant (the refrigerant releases heat). The heat medium heated in the heating section 16 flows into port C of the integrated valve 23, flows out from port B, and reaches the indoor heat exchanger 19. The heat medium leaving this indoor heat exchanger 19 flows into port L of the integrated valve 23, flows out from port I, and reaches the indoor heat exchanger 18. The heat medium leaving this indoor heat exchanger 18 flows into port E of the integrated valve 23, flows out from port D, and flows into port A of the four-way valve 26. The heat medium that flows into port A of the four-way valve 26 leaves port C and repeats the circulation returning to the pump 12 (indicated by the arrows next to the heat medium piping 34 in FIG. 4).

[0051] On the other hand, the heat medium discharged from the pump 11 reaches the cooling unit 17, where the heat medium is cooled by the refrigerant (the refrigerant absorbs heat). The heat medium cooled in the cooling unit 17 flows into port J of the integrated valve 23, flows out from port F, and flows into port I of the integrated valve 24. The heat medium that flows into port I of the integrated valve 24 flows out from port D and reaches the outdoor heat exchanger 22, where it absorbs heat from the outside air. The heat medium that leaves the outdoor heat exchanger 22 flows into port H of the integrated valve 24, flows out from port J, and repeats the circulation returning to the pump 11 (indicated by the arrows next to the heat medium piping 34 in FIG. 4).

[0052] The heat medium discharged from the pump 14 flows sequentially into the power control unit 8, the inverter 7, and the drive motor 6. The heat medium is heated by waste heat from these components and then reaches the electric heater 33. When the electric heater 33 is activated, the heat medium is further heated by the electric heater 33, flows into port B of the four-way valve 26, flows out from port D, and flows into port C of the integrated valve 24. The heat medium that flows into port C of the integrated valve 24 flows out from port B, is sucked into the pump 13, and is discharged to the battery 4. After reaching the battery 4, the heat medium heats the battery 4 there, flows into port F of the integrated valve 24, flows out from port G, and repeats this circulation returning to the pump 14 (as indicated by the arrows next to the heat medium piping 34 in FIG. 4).

[0053] As a result, in the first operating mode, heat pumped up from the outside air by the outdoor heat exchanger 22 is transported to the indoor heat exchangers 19, 18 in the order of heat medium (cooling unit 17) → refrigerant (heat absorber 48) → refrigerant (radiator 46) → heat medium (heating unit 16). Because the air blown into the vehicle cabin flows through the indoor heat exchangers 18, 19, the air heated by the indoor heat exchangers 18, 19 is blown into the vehicle cabin, thereby heating the vehicle cabin (temperature-controlled target).

[0054] In addition, the battery 4 is heated by the heat medium heated by the power control unit 8, the inverter 7, the driving motor 6, and the electric heater 33 (if activated), thereby warming up the battery 4.

[0055] That is, the battery 4 is warmed up (heated) using waste heat from the power control unit 8, inverter 7, and traction motor 6, which saves energy and reduces the energy consumption in the thermal management system 1, but it is not possible to cool the battery 4. Furthermore, since the functions required of the thermal management system 1 in the embodiment are the air conditioning of the interior of the electric vehicle EV and battery cooling, this first operating mode is not essential for the thermal management system 1, but is an additional operating mode in the present invention.

[0056] (2-2) Second operation mode Next, Fig. 5 shows a second operation mode by the control device 9. In this second operation mode, the compressor 44, the outdoor fan 36, the indoor fan 41, and the pumps 11 to 14 are operated, the four-way valve 26 is in switching mode 2, the integrated valve 23 is in switching mode 5, and the integrated valve 24 is in switching mode 3. In addition, the grill shutter 37 is opened, and the electric heater 33 is not operated.

[0057] As a result, the high-temperature refrigerant discharged from the compressor 44 of the refrigerant circuit 3 radiates heat in the radiator 46 to the heat medium flowing in the heating section 16, and in the heat absorber 48, the refrigerant decompressed in the expansion valve 47 evaporates and absorbs heat from the heat medium flowing in the cooling section 17. The refrigerant that has left the heat absorber 48 is separated into gas and liquid in the accumulator 49, and then is sucked into the compressor 44.

[0058] On the other hand, the heat medium discharged from the pump 12 of the heat medium circuit 2 reaches the heating section 16, where it is heated by the refrigerant (the refrigerant releases heat). The heat medium heated in the heating section 16 flows into port C of the integrated valve 23, flows out from port B, and reaches the indoor heat exchanger 19. The heat medium leaving this indoor heat exchanger 19 flows into port L of the integrated valve 23, flows out from port I, and reaches the indoor heat exchanger 18. The heat medium leaving this indoor heat exchanger 18 flows into port E of the integrated valve 23, flows out from port D, and flows into port A of the four-way valve 26. The heat medium that flows into port A of the four-way valve 26 leaves from port C and repeats the circulation returning to the pump 12 (indicated by the arrows next to the heat medium piping 34 in FIG. 5).

[0059] On the other hand, the heat medium discharged from the pump 11 reaches the cooling unit 17, where the heat medium is cooled by the refrigerant (the refrigerant absorbs heat). The heat medium cooled in the cooling unit 17 flows into port J of the combining valve 23, flows out from port F, and flows into port I of the combining valve 24. The heat medium that flows into port I of the combining valve 24 flows out from port D and reaches the outdoor heat exchanger 22, where it absorbs heat from the outdoor air. The heat medium that leaves the outdoor heat exchanger 22 flows into port H of the combining valve 24, flows out from port G, is sucked into the pump 14, and is discharged.

[0060] The heat medium discharged from the pump 14 flows sequentially into the power control unit 8, the inverter 7, and the driving motor 6. The heat medium is heated by waste heat from these components, then passes through the electric heater 33, flows into port B of the four-way valve 26, flows out from port D, and flows into port C of the integrated valve 24. The heat medium that flows into port C of the integrated valve 24 flows out from port B, is sucked into the pump 13, and is discharged to the battery 4. After reaching the battery 4, the heat medium heats the battery 4 there, then flows into port F of the integrated valve 24, flows out from port J, and repeats this circulation returning to the pump 11 (as indicated by the arrows next to the heat medium piping 34 in FIG. 5).

[0061] As a result, in the second operating mode, heat pumped up from the outside air by the exterior heat exchanger 22 and waste heat from the power control unit 8, inverter 7, and traction motor 6 are transported to the interior heat exchangers 19, 18 in the following order: heat medium (cooling unit 17) → refrigerant (heat absorber 48) → refrigerant (radiator 46) → heat medium (heating unit 16). Because the air blown into the vehicle cabin flows through the interior heat exchangers 18, 19, air heated by the interior heat exchangers 18, 19 is blown into the vehicle cabin, thereby heating the vehicle cabin (temperature-controlled target).

[0062] If the heating inside the vehicle cabin due to the heat from the outside air, the driving motor 6, etc. is insufficient, the electric heater 33 is operated to heat the heat medium flowing through the cooling unit 17. The heat from this electric heater 33 is transported in the following order: heat medium (cooling unit 17) → refrigerant (heat absorber 48) → refrigerant (radiator 46) → heat medium (heating unit 16), and heats the heat medium flowing through the interior heat exchangers 19 and 18. The battery 4 is also adjusted to a target temperature by the heat medium pumped up by the power control unit 8, inverter 7, and driving motor 6, and the heat from the electric heater 33.

[0063] The second operation mode is a basic mode for heating the vehicle interior, which is an essential function required for the heat management system 1 in this embodiment, and is an essential operation mode in the present invention.

[0064] (2-3) Third operation mode Next, Fig. 6 shows a third operation mode by the control device 9. In this third operation mode, the compressor 44, the indoor blower 41, and the pumps 11 to 14 are operated, the four-way valve 26 is in switching mode 2, the integrated valve 23 is in switching mode 5, and the integrated valve 24 is in switching mode 5. In addition, the outdoor blower 36 is stopped, the grill shutter 37 is closed, and the electric heater 33 is operated as needed.

[0065] As a result, the high-temperature refrigerant discharged from the compressor 44 of the refrigerant circuit 3 radiates heat in the radiator 46 to the heat medium flowing in the heating section 16, and in the heat absorber 48, the refrigerant decompressed in the expansion valve 47 evaporates and absorbs heat from the heat medium flowing in the cooling section 17. The refrigerant that has left the heat absorber 48 is separated into gas and liquid in the accumulator 49, and then is sucked into the compressor 44.

[0066] On the other hand, the heat medium discharged from the pump 12 of the heat medium circuit 2 reaches the heating section 16, where it is heated by the refrigerant (the refrigerant releases heat). The heat medium heated in the heating section 16 flows into port C of the integrated valve 23, flows out from port B, and reaches the indoor heat exchanger 19. The heat medium leaving this indoor heat exchanger 19 flows into port L of the integrated valve 23, flows out from port I, and reaches the indoor heat exchanger 18. The heat medium leaving this indoor heat exchanger 18 flows into port E of the integrated valve 23, flows out from port D, and flows into port A of the four-way valve 26. The heat medium that flows into port A of the four-way valve 26 leaves from port C and repeats the circulation returning to the pump 12 (indicated by the arrows next to the heat medium piping 34 in FIG. 6).

[0067] On the other hand, the heat medium discharged from the pump 11 reaches the cooling unit 17, where the heat medium is cooled by the refrigerant (the refrigerant absorbs heat). The heat medium cooled in the cooling unit 17 flows into port J of the integrated valve 23, flows out from port F, and flows into port I of the integrated valve 24. The heat medium that flows into port I of the integrated valve 24 flows out from port B, is sucked into the pump 13, and is discharged to the battery 4. The heat medium that reaches the battery 4 cools the battery 4 there, then flows into port F of the integrated valve 24, flows out from port G, is sucked into the pump 14, and is discharged.

[0068] The heat medium discharged from the pump 14 flows sequentially into the power control unit 8, the inverter 7, and the driving motor 6. The heat medium is heated by waste heat from these components and then reaches the electric heater 33. When the electric heater 33 is activated, the heat medium is further heated by the electric heater 33, and then flows into port B of the four-way valve 26, flows out from port D, and flows into port C of the integrated valve 24. The heat medium that flows into port C of the integrated valve 24 flows out from port D and reaches the outdoor heat exchanger 22, passes through it, flows into port H of the integrated valve 24, flows out from port J, and returns to the pump 11, repeating this cycle (indicated by the arrows next to the heat medium piping 34 in FIG. 6).

[0069] As a result, in the third operating mode, waste heat from the power control unit 8, inverter 7, and traction motor 6, and heat from the electric heater 33 (if activated) are transported to the interior heat exchangers 19, 18 in the following order: heat medium (cooling section 17) → refrigerant (heat absorber 48) → refrigerant (radiator 46) → heat medium (heating section 16). Because the air blown into the vehicle cabin flows through the interior heat exchangers 18, 19, the air heated by the interior heat exchangers 18, 19 is blown into the vehicle cabin, thereby heating the vehicle cabin (temperature-controlled target).

[0070] At this time, heat is not exchanged between the heat medium and the outside air in the outdoor heat exchanger 22, so frost does not form on the outdoor heat exchanger 22 even when the outside air temperature is low. On the other hand, the heat medium that flows through the battery 4 immediately after being cooled by the cooling unit 17 is lower in temperature than in the second operation mode described above. Therefore, when the temperature of the battery 4 drops below the optimum temperature range, the battery 4 cannot be heated without stopping the refrigerant circuit 3. Therefore, the third operation mode is not essential for the thermal management system 1, but is an additional operation mode in the present invention.

[0071] (2-4) Fourth operation mode Next, Fig. 7 shows a fourth operation mode by the control device 9. In this fourth operation mode, the compressor 44, the outdoor blower 36, the indoor blower 41, and the pumps 11 to 14 are operated, the four-way valve 26 is in switching mode 1, the integrated valve 23 is in switching mode 2, and the integrated valve 24 is in switching mode 1. In addition, the grill shutter 37 is opened, and the electric heater 33 is not operated.

[0072] As a result, the high-temperature refrigerant discharged from the compressor 44 of the refrigerant circuit 3 radiates heat in the radiator 46 to the heat medium flowing in the heating section 16, and in the heat absorber 48, the refrigerant decompressed in the expansion valve 47 evaporates and absorbs heat from the heat medium flowing in the cooling section 17. The refrigerant that has left the heat absorber 48 is separated into gas and liquid in the accumulator 49, and then is sucked into the compressor 44.

[0073] On the other hand, the heat medium discharged from the pump 12 of the heat medium circuit 2 reaches the heating section 16, where it is heated by the refrigerant (the refrigerant releases heat). The heat medium heated in the heating section 16 flows into port C of the integrated valve 23, flows out from port B, and reaches the indoor heat exchanger 19. The heat medium that has left the indoor heat exchanger 19 flows into port L of the integrated valve 23, flows out from port D, and flows into port A of the four-way valve 26. The heat medium that has flowed into port A of the four-way valve 26 flows out from port D, flows into port C of the integrated valve 24, and flows out from port D.

[0074] The heat medium that flows out from port D of the integrated valve 24 reaches the outdoor heat exchanger 22, where it dissipates heat into the outside air. After passing through the outdoor heat exchanger 22, the heat medium flows into port H of the integrated valve 24, flows out from port G, is sucked into the pump 14, and is discharged. The heat medium discharged from the pump 14 flows sequentially into the power control unit 8, the inverter 7, and the driving motor 6. The heat medium is heated by the waste heat thereof, then passes through the electric heater 33, flows into port B of the four-way valve 26, flows out from port C, and returns to the pump 11, repeating this cycle (indicated by the arrows next to the heat medium piping 34 in FIG. 7).

[0075] On the other hand, the heat medium discharged from the pump 11 reaches the cooling unit 17, where it is cooled by the refrigerant (the refrigerant absorbs heat). The heat medium cooled in the cooling unit 17 flows into port J of the integrated valve 23, flows out from port I, and reaches the indoor heat exchanger 18. The heat medium that flows out of this indoor heat exchanger 18 flows into port E of the integrated valve 23, flows out from port F, and flows into port I of the integrated valve 24. The heat medium that flows into port I of the integrated valve 24 flows out from port J and repeats the circulation returning to the pump 11 (indicated by the arrows next to the heat medium piping 34 in FIG. 7).

[0076] Furthermore, the heat medium discharged from the pump 13 is discharged to the battery 4. After passing through the battery 4, the heat medium flows into port F of the integrated valve 24, flows out from port B, and returns to the pump 13, repeating this cycle (as indicated by the arrows next to the heat medium pipe 34 in FIG. 7).

[0077] As a result, in the fourth operation mode, the heat medium releases heat in the indoor heat exchanger 19, and absorbs heat in the indoor heat exchanger 18. Since the air blown into the vehicle cabin flows through the indoor heat exchangers 18 and 19, the air cooled in the indoor heat exchanger 18 is reheated in the indoor heat exchanger 19 and then blown into the vehicle cabin, thereby dehumidifying the vehicle cabin (temperature-controlled area).

[0078] At this time, the heat medium is simply circulated through the battery 4, and the heat medium circulating through the battery 4 has no heat dissipation or absorption source other than the battery 4, so the temperature of the battery 4 cannot be controlled. Therefore, this fourth operating mode is not essential for the thermal management system 1, but is an additional operating mode in the present invention.

[0079] (2-5) Fifth operation mode Next, Fig. 8 shows a fifth operation mode by the control device 9. In this fifth operation mode, the compressor 44, the outdoor blower 36, the indoor blower 41, and the pumps 11 to 14 are operated, the four-way valve 26 is in switching mode 1, the integrated valve 23 is in switching mode 6, and the integrated valve 24 is in switching mode 6. In addition, the grill shutter 37 is opened, and the electric heater 33 is not operated.

[0080] As a result, the high-temperature refrigerant discharged from the compressor 44 of the refrigerant circuit 3 radiates heat in the radiator 46 to the heat medium flowing in the heating section 16, and in the heat absorber 48, the refrigerant decompressed in the expansion valve 47 evaporates and absorbs heat from the heat medium flowing in the cooling section 17. The refrigerant that has left the heat absorber 48 is separated into gas and liquid in the accumulator 49, and then is sucked into the compressor 44.

[0081] On the other hand, the heat medium discharged from the pump 12 of the heat medium circuit 2 reaches the heating section 16, where the heat medium is heated by the refrigerant (the refrigerant releases heat). The heat medium heated in the heating section 16 flows into port C of the integrating valve 23, flows out from port D, and flows into port A of the four-way valve 26. The heat medium that flows into port A of the four-way valve 26 flows out from port D, flows into port C of the integrating valve 24, and flows out from port D.

[0082] The heat medium that flows out from port D of the integrated valve 24 reaches the outdoor heat exchanger 22, where it dissipates heat into the outside air. After passing through the outdoor heat exchanger 22, the heat medium flows into port H of the integrated valve 24, flows out from port G, is sucked into the pump 14, and is then discharged. The heat medium discharged from the pump 14 flows sequentially into the power control unit 8, the inverter 7, and the driving motor 6. The heat medium is heated by the waste heat thereof, then passes through the electric heater 33, flows into port B of the four-way valve 26, flows out from port C, and returns to the pump 11, repeating this cycle (indicated by the arrows next to the heat medium piping 34 in FIG. 8).

[0083] On the other hand, the heat medium discharged from the pump 11 reaches the cooling unit 17, where it is cooled by the refrigerant (the refrigerant absorbs heat). The heat medium cooled in the cooling unit 17 flows into port J of the integrated valve 23, flows out from port B, and reaches the indoor heat exchanger 19. The heat medium that flows out of this indoor heat exchanger 19 flows into port L of the integrated valve 23, flows out from port I, and reaches the indoor heat exchanger 18. The heat medium that flows out of this indoor heat exchanger 18 flows into port E of the integrated valve 23, flows out from port F, and flows into port I of the integrated valve 24. The heat medium that flows into port I of the integrated valve 24 flows out from port B, is sucked into the pump 13, and is discharged.

[0084] Furthermore, the heat medium discharged from the pump 13 is discharged to the battery 4. After passing through the battery 4, the heat medium flows into port F of the integrated valve 24, flows out from port J, and returns to the pump 11, repeating this cycle (as indicated by the arrows next to the heat medium pipe 34 in FIG. 8).

[0085] As a result, in the fifth operation mode, the heat medium absorbs heat in the indoor heat exchangers 18 and 19. Since the air blown into the vehicle cabin flows through the indoor heat exchangers 18 and 19, the air cooled by the indoor heat exchangers 18 and 19 is blown into the vehicle cabin, thereby cooling the vehicle cabin (temperature-controlled target).

[0086] At this time, the heat medium is circulated through the battery 4 after passing through the cooling unit 17, the indoor heat exchanger 19, and the indoor heat exchanger 18 in this order, so that the target temperature is adjusted using the remaining heat used for cooling the vehicle interior. This fifth operation mode is a basic mode for cooling the vehicle interior, which is an essential function required of the thermal management system 1 in this embodiment, and is an essential operation mode in the present invention.

[0087] (2-6) Switching operation modes The operation mode determination unit 51 of the control device 9 switches between the above-mentioned operation modes based on the outside air temperature Tamb detected by the sensor 56, the target value (target heater temperature) TCO of the air temperature on the downwind side of the indoor heat exchanger 19, the temperature Tbatt of the battery 4, etc.

[0088] (3) Failure prediction and life extension control by the control device 9 Next, an example of failure prediction and life extension control of the thermal management system 1 by the control device 9 will be described with reference to Figures 2 and 9. Figure 9 is a flowchart illustrating an embodiment of failure prediction and life extension control of the integrated valve 24 by the control device 9.

[0089] The failure prediction unit 63 of the control device 9 in this embodiment predicts the occurrence of a failure of the integrated valve 24 (a device constituting the heat medium circuit 2 of the thermal management system 1). Specifically, the failure prediction unit 63 in this embodiment accumulates the number of times the integrated valve 24 has operated (number of operations) as information related to the life of the integrated valve 24. If the accumulated number of operations N of the motor of the integrated valve 24 becomes equal to or greater than a predetermined value N1 in step S1 of the flowchart in FIG. 9, the failure prediction unit 63 determines that the life of the integrated valve 24 is nearing the end of its life and that the probability of failure is high (predicts the occurrence of a failure of the integrated valve 24: failure prediction), and proceeds to step S2. This predetermined value N1 is set to a value close to the durability life of the integrated valve 24. For example, if the life measured in advance by experiment is Nx in terms of the accumulated number of operations, the value N1 close to the durability life is N1 = Nx - predetermined value α (predetermined margin), e.g., 100,000 times.

[0090] When the failure prediction unit 63 predicts the occurrence of a failure in the integrated valve 24 in step S1, the life extension control unit 64 of the control device 9 executes life extension control in step S2 based on the failure prediction to delay the occurrence of a failure in the integrated valve 24. Specifically, the life extension control unit 64 of the embodiment prohibits the integrated valve 24 from being switched to switching mode 1, switching mode 4, and switching mode 5, and further prohibits the grill shutter 37 from being closed (life extension control).

[0091] The integrated valve 24 is in switching mode 1 in the aforementioned fourth operating mode (FIG. 7), and in switching mode 4 in the aforementioned first operating mode (FIG. 4). The integrated valve 24 is in switching mode 5 in the aforementioned third operating mode (FIG. 6), both of which are additional operating modes. As described above, the fourth operating mode cannot regulate the temperature of the battery 4. Therefore, if the integrated valve 24 fails and is fixed in this fourth operating mode, there is a risk that the temperature of the battery 4 will become abnormally higher than the optimum temperature.

[0092] Furthermore, in the first operation mode, as described above, the battery 4 cannot be cooled, and if the integrated valve 24 fails and the operation mode is fixed to this first operation mode, there is a risk that the temperature of the battery 4 will become abnormally high. Furthermore, in the third operation mode, as described above, the temperature of the heat medium exchanging heat with the battery 4 is low, and therefore even if the battery 4 falls below the optimum temperature range, the battery 4 cannot be heated without stopping the refrigerant circuit 3. Stopping the refrigerant circuit 3 also means stopping the heating of the vehicle interior.

[0093] The life extension control unit 64 of the embodiment reduces the operation frequency of the integrated valve 24 and delays the occurrence of a failure of the integrated valve 24 by prohibiting the additional operation modes (first operation mode, third operation mode, and fourth operation mode) that have a high risk of causing an accident such as the battery 4 catching fire if the integrated valve 24 fails as described above. In particular, prohibiting the first operation mode that heats and warms up the battery 4 prevents the battery 4 from catching fire. On the other hand, the life extension control unit 64 does not prohibit the second and fifth operation modes, which are essential operation modes, so heating and cooling of the vehicle cabin are ensured.

[0094] Next, when the life extension control as described above is executed, the notification control unit 66 of the control device 9 notifies the outside in step S3 of Fig. 9. Specifically, the notification control unit 66 notifies the user, dealer, or business owner of the electric vehicle EV via the router 60 by email or the like that a failure of the integrated valve 24 is predicted and that life extension control is being executed.

[0095] In the above embodiment, the failure prediction unit 63 performs failure prediction based on the cumulative number of operations of the integrating valve 24. However, this is not limiting. In the case of a valve device that switches flow paths using the rotational position of a motor, such as the integrating valve 24, failure prediction may be performed using the cumulative value of the rotational angle of the motor (cumulative rotation angle) as information regarding the lifespan. In this case, when the cumulative rotation angle reaches a predetermined value (a value close to the lifespan in terms of durability), it is determined that there is a risk of failure occurring in the integrating valve 24. For example, if the lifespan measured in advance by experiment is X degrees in terms of cumulative rotation angle, this value close to the lifespan in terms of durability is X degrees - a predetermined value β degrees (a predetermined margin).

[0096] Furthermore, in the embodiment, the life extension control unit 64 prohibits the aforementioned additional operation modes (first operation mode, third operation mode, fourth operation mode), but the present invention is not limited to this and may limit the execution of these additional operation modes. Specifically, for example, in the case of the first operation mode, the threshold value (temperature threshold value of the battery 4) for completing the warm-up (heating) of the battery 4 is lowered by a predetermined value γ compared to that in normal operation, thereby limiting the period during which the first operation mode is executed to be shorter. Similarly, in the case of the third operation mode and the fourth operation mode, the factor used as the criterion for terminating the operation mode is changed to shorten the period during which the operation mode is executed or reduce the frequency of switching to the operation mode.

[0097] As described above in detail, in the present invention, the control device 9 is equipped with a failure prediction unit 63 that predicts the occurrence of a failure in the thermal management system 1 based on information regarding the lifespan of the equipment that constitutes the thermal management system 1 (in this embodiment, the integrated valve 24 of the heat medium circuit 2), and a life extension control unit 64 that executes life extension control to delay the occurrence of the failure based on the failure prediction of the thermal management system 1 by the failure prediction unit 63.Therefore, based on information regarding the lifespan of the equipment that constitutes the thermal management system 1, the failure prediction unit 63 predicts whether or not a failure will occur in the thermal management system 1, and if there is a high possibility (probability) of a failure occurring, the life extension control unit 64 executes life extension control to delay the occurrence of the failure.

[0098] This reduces or avoids the risk of an accident occurring in the battery 4, which is the temperature control target, due to a failure of the equipment that makes up the thermal management system 1, making it possible to control the temperature of the temperature control target (the passenger compartment of an electric vehicle EV and the battery 4) more safely and for longer periods of time.

[0099] In addition, in the embodiment, the control device 9 is equipped with a notification control unit 66 that notifies the outside that life extension control is being executed, so that when a failure is predicted in an equipment that constitutes the thermal management system 1 (the integrated valve 24 of the heat medium circuit 2), the outside is notified that life extension control is being executed to delay the occurrence of the failure, making it possible to encourage early response regarding maintenance, replacement, etc., and also making it possible to avoid the inconvenience of the system continuing to operate with reduced efficiency due to life extension control.

[0100] In addition, in the embodiment, the control device 9 switches between essential operating modes (second operating mode and fifth operating mode) that are essential for the functions required of the system and additional operating modes (first operating mode, third operating mode, fourth operating mode) other than these essential operating modes, and the life extension control unit 64 prohibits or restricts the execution of the additional operating modes during life extension control.This reduces the number of operating mode switches while ensuring the execution of the essential operating modes that are essential for the system, extends the life of the equipment (integrated valve 24) that constitutes the heat transfer medium circuit 2 of the heat management system 1, and delays the occurrence of failures in the heat transfer medium circuit 2 of the heat management system 1.

[0101] In particular, in the case where the temperature control target is a battery 4 mounted on an electric vehicle EV as in the embodiment, and the control device 9 has a first operating mode in which the flow path of the heat medium is switched by the integrated valve 24 to heat the battery 4, the life extension control unit 64 prohibits or restricts the execution of the first operating mode in which the battery 4 is heated, thereby making it possible to avoid an accident in which the temperature of the battery 4 continues to rise and lead to a fire. [Example]

[0102] In the above embodiment, the integrated valve 24, which is most involved in regulating the temperature of the battery 4, has been taken as an example of the equipment constituting the heat medium circuit 2 of the thermal management system 1. However, the present invention is not limited to this. It is also possible to predict the occurrence of failures in the other integrated valve 23 and the four-way valve 26, which are flow path switching devices constituting the heat medium circuit 2, based on the accumulated number of operations and accumulated rotation angles of these valves, and to perform life extension control.

[0103] Furthermore, in addition to or instead of the above-described embodiment, the control device 9 may also perform similar failure prediction and life extension control on the devices that constitute the refrigerant circuit 3 of the thermal management system 1, not limited to the devices that constitute the heat medium circuit 2. For example, the case of the compressor 44 as a device that constitutes the refrigerant circuit 3 of the thermal management system 1 will be described with reference to Fig. 10. Fig. 10 is a flowchart illustrating an embodiment of failure prediction and life extension control of the compressor 44 by the control device 9.

[0104] In this embodiment, the failure prediction unit 63 of the control device 9 predicts the occurrence of a failure of the compressor 44 (a component of the refrigerant circuit 3). Specifically, the failure prediction unit 63 accumulates the number of ON / OFF cycles (start / stop cycles) of the compressor 44 as information about the lifespan of the compressor 44. If the accumulated number of ON / OFF cycles CN of the compressor 44 is equal to or greater than a predetermined value CN1 in step S3 of the flowchart of FIG. 10, the failure prediction unit 63 determines that the lifespan of the compressor 44 is nearing the end of its lifespan and that the probability of failure is high (predicting the occurrence of a failure of the compressor 44: failure prediction), and proceeds to step S5. This predetermined value CN1 is set to a value close to the durability lifespan of the compressor 44. For example, if the lifespan measured in advance through experiments is CNx in terms of the accumulated number of ON / OFF cycles, then CN1 = CNx - predetermined value δ (predetermined margin). Furthermore, in this embodiment, the number of ON / OFF cycles is defined as one for ON and one for OFF. However, it is also possible to accumulate only ON cycles or only OFF cycles.

[0105] If the failure prediction unit 63 predicts the occurrence of a failure in the compressor 44 in step S4, the life extension control unit 64 of the control device 9 executes life extension control in step S5 based on the failure prediction to delay the occurrence of a failure in the compressor 44. Specifically, the life extension control unit 64 in this embodiment restricts the start / stop (restricts ON / OFF) of the compressor 44 (life extension control in this case).

[0106] The control device 9 basically controls the rotation speed (frequency) of the compressor 44, but in seasons with low thermal load, such as spring and autumn, the temperature of the air inside the cabin of the electric vehicle EV may fall below a target value even if the rotation speed of the compressor 44 is reduced to the minimum rotation speed under control (for example, 1000 rpm). In such a case, the control device 9 executes ON / OFF control to stop (OFF) the compressor 44 when the temperature of the air inside the cabin of the electric vehicle EV detected by the sensor 56 drops to +23°C and start (ON) the compressor 44 when it rises to +27°C. However, the life extension control unit 64 in this embodiment changes the threshold values ​​of +23°C and +27°C to, for example, +22°C and +28°C, thereby reducing the frequency of stopping and starting the compressor 44 and limiting the start / stop of the compressor 44, thereby delaying the occurrence of a breakdown of the compressor 44.

[0107] Next, when the life extension control as described above is executed, the notification control unit 66 of the control device 9 notifies the outside to that effect in step S6 of Fig. 10. Specifically, as described above, the notification control unit 66 notifies the user, dealer, or business owner of the electric vehicle EV via the router 60 by email or the like that a failure of the compressor 44 is predicted and that life extension control is being executed.

[0108] In this way, the failure prediction unit 63 predicts failure of the compressor 44 based on the operation of the compressor 44 (cumulative number of ON / OFF times), and the life extension control unit 64 delays the occurrence of failure of the compressor 44 by reducing the frequency of starting / stopping the compressor 44 in the life extension control, thereby delaying the occurrence of failure of the compressor 44 that constitutes the refrigerant circuit 3 that serves as the heat source, and making it possible to continue temperature control of the temperature control target (the passenger compartment of the electric vehicle EV and the battery 4) for a longer period of time and more safely.

[0109] In the above embodiment, failure prediction / life extension control is performed on the compressor 44 of the refrigerant circuit 3, but failure prediction and life extension control may be performed based on information about the lifespan of other devices (such as the expansion valve 47) that make up the refrigerant circuit 3. In addition, in the above embodiment, the passenger compartment of the electric vehicle EV, the battery 4, the traction motor 6, the inverter 7, and the power control unit 8 are taken as temperature control targets, but the present invention is not limited to these, and any one of these, or a combination of two to four of these, may be the temperature control targets.

[0110] Furthermore, although the refrigerant circuit 3 is used as the heat source in the embodiments, various heat sources capable of heating / cooling a heat medium can be employed in the inventions other than claims 10 and 11. Furthermore, the numerical values ​​and configurations shown in the embodiments are not limited thereto, and needless to say, they can be modified without departing from the spirit of the present invention. In particular, although the embodiments have been described using an example of a system for air-conditioning the passenger compartment of an electric vehicle (EV), the inventions of claims 1 and 2 are not limited thereto, and the present invention can be applied to various thermal management systems that circulate a heat medium to regulate the temperature of a temperature-regulating target. [Explanation of symbols]

[0111] EV Electric Vehicle 1. Thermal Management System 2 Heat medium circuit 3 Refrigerant circuit 4 Battery (temperature control target) 6. Travel motor (temperature control target) 7 Inverter (temperature control target) 8 Power control unit (temperature control target) 9 Control Device 11~14 Pump 16 Heating section 17 Cooling section 23, 24 Integrated valve (flow path switching device) 26 Four-way valve (flow path switching device) 34 Heat medium piping 44 Compressor 46 Heatsink 47 Expansion valve (pressure reducing device) 48 Heat absorber 63 Failure Prediction Department 64 Life Support Control Unit 66 Notification control section

Claims

1. A thermal management system including a heat medium circuit that circulates a heat medium that has exchanged heat with a heat source to a temperature control target, and a control device that controls the heat medium circuit to control the temperature of the temperature control target, The control device The system switches between an essential operation mode that is essential for the functions required of the system and an additional operation mode other than the essential operation mode, and executes the operation. a failure prediction unit that predicts the occurrence of a failure in the system based on information about the lifespan of devices that constitute the system; a life extension control unit that executes predetermined life extension control to delay the occurrence of a system failure based on the prediction of the system failure by the failure prediction unit; A thermal management system characterized in that the life extension control unit prohibits or limits execution of the additional operating mode during the life extension control.

2. The thermal management system according to claim 1 , wherein the control device includes a notification control unit that notifies an external device when the life extension control is executed.

3. 2. The thermal management system according to claim 1, wherein the temperature control target includes any one of a passenger compartment of an electric vehicle, a battery mounted on the electric vehicle, a traction motor of the electric vehicle, an inverter that drives the traction motor, and a power control unit of the electric vehicle, or a combination of these, or all of these.

4. The heat medium circuit includes a flow path switching device that switches the flow path of the heat medium, The failure prediction unit predicts the occurrence of a failure in the flow path switching device, and The thermal management system of claim 1, characterized in that the life extension control unit delays the occurrence of a failure of the flow path switching device by reducing the operating frequency of the flow path switching device during the life extension control.

5. A thermal management system comprising a heat medium circuit that circulates a heat medium that has exchanged heat with a heat source to a temperature control target, and a control device that controls the heat medium circuit to control the temperature of the temperature control target, the heat medium circuit includes a flow path switching device that switches a flow path of the heat medium, The control device a failure prediction unit that predicts the occurrence of a failure in the system based on information about the lifespan of devices that constitute the system; a life extension control unit that executes predetermined life extension control to delay the occurrence of a system failure based on the prediction of the system failure by the failure prediction unit; The failure prediction unit predicts the occurrence of a failure in the flow path switching device, and A thermal management system characterized in that the life extension control unit delays the occurrence of a failure of the flow path switching device by reducing the operation frequency of the flow path switching device during the life extension control.

6. 6. The thermal management system according to claim 5, wherein the failure prediction unit predicts a failure of the flow path switching device based on the number of times the flow path switching device operates.

7. the flow path switching device switches the flow path of the heat medium depending on a rotation position, 6. The thermal management system according to claim 5, wherein the failure prediction unit predicts a failure of the flow path switching device based on an integrated value of a rotation angle of the flow path switching device.

8. the temperature control target is a battery mounted on an electric vehicle, the control device has an operation mode in which the flow path of the heat medium is switched by the flow path switching device to heat the battery, 6. The thermal management system according to claim 5, wherein the life extension control unit prohibits or limits execution of an operation mode that heats the battery.

9. The thermal management system according to claim 8 , wherein the life extension control unit limits execution of the operation mode for heating the battery by lowering a threshold for completing the operation mode.

10. the heat source is composed of a refrigerant circuit having a compressor that compresses a refrigerant, a radiator that radiates heat from the high-temperature refrigerant discharged from the compressor, a pressure reducing device that reduces the pressure of the refrigerant that has radiated heat in the radiator, and a heat absorber that absorbs heat from the refrigerant that has been decompressed by the pressure reducing device, 10. The thermal management system according to claim 1, wherein the heat medium circuit has a heating section that heats the heat medium and a cooling section that cools the heat medium, the heating section exchanging heat with the heat radiator, and the cooling section exchanging heat with the heat absorber.

11. The failure prediction unit predicts a failure of the compressor based on an operation of the compressor, and The thermal management system according to claim 10, characterized in that the life extension control unit delays the occurrence of a failure of the compressor by reducing the frequency of starting / stopping the compressor during the life extension control.

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