Method for operating a thermal module in an emergency mode

Abstract

The invention relates to an emergency-mode method for a thermal module (TM) comprising a first, a second and a third liquid pump (EWP1, EWP2, EWP3). The first liquid pump (EWP1) is used to operate a liquid cooling circuit (KK), the second liquid pump (EWP2) is used to operate a liquid heating circuit (HK), and the third liquid pump (EWP3) is used to operate a liquid circuit which extends across a battery (B). An electrically controllable valve system of the thermal module (TM) is set or operated such that, in the event of a failure of the first or second liquid pump (EWP1, EWP2), the third liquid pump (EWP3) is connected fluidically in series with the failed first or second liquid pump (EWP1, EWP2) or that, in the event of a failure of the third liquid pump (EWP3), the first or second liquid pump (EWP1, EWP2) is connected fluidically in series with the failed third liquid pump (EWP3). The invention also relates to a computer program product, to a computer-readable storage medium, to a control device, to a thermal module, to a vehicle, and to an indirect heat-transfer-medium circuit system.

Description

[0001] 202500107

[0002] 1

[0003] Description

[0004] Method for operating a thermomodule in emergency mode, computer program product, computer-readable storage medium, control unit, thermomodule, vehicle and indirect heat transfer medium circuit system

[0005] The invention relates to an emergency running method or a method for operating a thermomodule in an emergency running mode.

[0006] The invention also relates to a computer program product representing this method, a computer-readable storage medium on which this computer program product is stored, a control unit, a thermo module, a vehicle or electric vehicle, and an indirect heat transfer medium circuit system.

[0007] Electric vehicles require so-called intelligent thermal management, which operates individual components of the electric vehicle within an assigned optimal temperature range.

[0008] The object of the present invention is to improve and further develop such thermal management.

[0009] This problem is solved by an emergency running method or method for operating a thermomodule in an emergency running mode as proposed and protected according to claim 1.

[0010] The proposed emergency running procedure ensures that critical components of an electric vehicle can be adequately temperature-controlled, i.e., cooled or heated, for a certain interim period until the failed or defective liquid pump is replaced.

[0011] 2

[0012] All these liquid pumps are designed and configured to provide sufficient overflow capacity in relation to the failed or defective liquid pump. This means they have the capability to function as a redundancy and adequately compensate for the failure. It also means they are able to maintain sufficient liquid pressure and system pressure, as well as sufficient liquid flow, during emergency operation to prevent damage to the individual components of the electric vehicle.

[0013] In one embodiment, it is proposed that if two of these three liquid pumps fail, the valve system of the thermomodule is adjusted in such a way that the battery and / or at least one component of an electric drive train is supplied with the liquid by the one remaining liquid pump as needed, in the best possible way, or possibly alternately, in order to compensate for the pump failure during emergency operation as best as possible.

[0014] Furthermore, a computer program product is proposed, comprising commands which, when the program is executed by a computer, cause it to perform the procedure of the type described above.

[0015] Furthermore, a computer-readable storage medium is proposed, comprising instructions which, when executed by a computer, cause it to perform the procedure of the type described above.

[0016] Furthermore, a control unit for a thermomodule is proposed, comprising a computer-readable storage medium of the type described above, on which the computer program product of the type described above is stored, wherein the control unit is either enclosed within a housing of the thermomodule or arranged at a distance from the housing of the thermomodule. 202500107

[0017] 3

[0018] Furthermore, a thermomodule for an indirect heat transfer medium circuit system is proposed, comprising:

[0019] a multi-part housing that accommodates at least three electric liquid pumps;

[0020] of which at least one first liquid pump for operating a liquid cooling circuit (run) - guided via an evaporator,

[0021] at least a second liquid pump for operating a liquid heating circuit (run) - via a capacitor, as well as

[0022] at least one third liquid pump is provided for operating a liquid circuit powered by a battery;

[0023] an electrically adjustable valve system incorporated through the housing, by which, in conjunction with a multitude of liquid channel sections formed in the housing, corresponding liquid circuits within the indirect heat transfer medium circuit system can be set,

[0024] as well as

[0025] a control unit of the type described above for adjusting the thermo module.

[0026] It is proposed that the thermomodule incorporate a plurality of sensors, such as temperature sensors, pressure sensors and / or temperature and pressure sensors, for monitoring the individual fluid circuits (flows) through the housing of the thermomodule.

[0027] Furthermore, a vehicle or electric vehicle with a control unit of the type described above is proposed.

[0028] Furthermore, an indirect heat transfer system for an electric vehicle is proposed, wherein the heat transfer system includes a control unit of the type described above. Such an indirect heat transfer system is also referred to as an indirect thermal management system or heat management system. 202500107

[0029] 4

[0030] The invention will now be explained in detail with reference to the figures. Further advantageous embodiments of the invention will become apparent from the dependent claims and the subsequent description of preferred embodiments. These are shown schematically and functionally:

[0031] Fig. 1 shows an indirect heat transfer medium circuit system of an electric vehicle in a first operating mode or emergency running mode and

[0032] Fig. 2 shows the heat transfer medium circuit system shown in Fig. 1 in a second operating mode or emergency mode.

[0033] The indirect heat transfer medium circuit system 2 - also called thermal management system or heat management system - according to Figs. 1 and 2 of an electric vehicle has a refrigerant circuit 4 that is dimensioned as small or compactly as possible and a liquid circuit system 6, which is thermally connected to the refrigerant circuit 4 via a first heat exchanger 8 in the form of an evaporator - for the cold section of the refrigerant circuit 4 - and a second heat exchanger 10 in the form of a condenser - for the hot section of the refrigerant circuit 4.

[0034] The refrigerant circuit 4 – also referred to as CRU (Compact Refrigerant Unit) – comprises, in addition to the two heat exchangers 8 and 10, a compressor for circulating a refrigerant and an expansion valve. Furthermore, at least one pressure sensor and at least one temperature sensor are provided or arranged in the refrigerant circuit 4 upstream and downstream of the compressor. Additionally, at least one further pressure sensor and one further temperature sensor may be provided or arranged between the expansion valve and the heat exchanger 10.

[0035] In such an indirect heat transfer medium circuit system 2, heat or energy can be transferred indirectly, i.e., indirectly via the liquid circuit system 6 up to 202500107

[0036] 5

[0037] transported or distributed to the individual heat sinks of the electric vehicle.

[0038] In this process, heat and energy distribution can largely be implemented via the liquid cycle system, i.e., based on a liquid, for example in the form of a water-glycol mixture.

[0039] This has the advantage that the refrigerant circuit or the CRU (Compact Refrigerant Unit) can be greatly simplified and designed to be very compact or as small as possible. Consequently, the amount of refrigerant used, whether a synthetic refrigerant like R134a or R1234yf, or a natural refrigerant like R744 or R290, can be reduced to a minimum.

[0040] Thus, such a heat transfer medium circuit system 2 contributes to saving weight and costs.

[0041] The fluid circuit system 6 features a proposed thermomodule TM with an electrically adjustable valve system (not illustrated), which allows for the selective and energy-efficient setting of various heating scenarios or heating modes as well as cooling scenarios or cooling modes.

[0042] This thermomodule TM has a multi-part housing to which the electric vehicle's heat sources and heat sinks are connected via fluid lines – for example, in the form of hoses and / or pipes – that are linked to the housing (see connections Ai to Au). Connections Ar and As 1 and Au 1 In contrast, these are connections that are provided, arranged, or formed within the housing of the thermomodule TM. This housing of the thermomodule TM is schematically illustrated as a rectangle in Figures 1 and 2. 202500107

[0043] 6

[0044] By means of the valve system of the thermomodule TM, in conjunction with a large number of liquid channel sections formed in the housing of the thermomodule TM, corresponding liquid circuits of the heat transfer medium circuit system 2 can be adjusted as required.

[0045] The heat sources and heat sinks of the electric vehicle include a first heat exchanger 12 (also called HVAC heater; HVAC

[0046]

[0047] Heating, Ventilation and Air Conditioning) for heating a vehicle cabin (not shown), a second heat exchanger 14 (also called HVAC Cooler) for cooling the vehicle cabin, a first radiator 16 for heat exchange with an environment, at least one component of an electric powertrain 18, a second radiator 20 for heat exchange with the environment (optionally or as required) via a proportional valve P, a battery B, and the evaporator 8 as well as the condenser 10 of the CRU (Compact Refrigerant Unit).

[0048] The aforementioned at least one component of the electric powertrain 18 includes at least one electric motor or e-motor for propelling the electric vehicle, as well as at least one power electronic component, for example in the form of an inverter, an on-board charger (OBC), or a DC / DC converter.

[0049] called a DC-DC converter - and / or possibly in the form of at least one additional control unit in the form of a high-performance computer.

[0050] The fluid circuit system 6 also includes a heating element HE, located approximately downstream of the capacitor 10, which can be activated to heat the pumped fluid as needed. This heating element HE can, for example, be housed within an associated fluid line section and located between the capacitor 10 and connection A4, i.e., outside the housing of the thermomodule TM. Alternatively, or in addition, such a heating element HE can also be housed within the housing of the thermomodule TM and be located on the housing and / or at least partially within the housing.

[0051] 7

[0052] The housing of the thermomodule TM is designed in the form of a multi-part housing with liquid-carrying channels, through which, in addition to the valve system, a first electric liquid pump EWPi for pumping liquid in a liquid cooling circuit (run) KK of the liquid circuit system 6 and a second electric liquid pump EWP2 for pumping liquid in a liquid heating circuit (run) HK of the liquid circuit (run) system 6 are accommodated.

[0053] This housing of the thermomodule TM also accommodates a third electric liquid pump EWP3, by means of which liquid can be pumped in a liquid circuit via a battery B.

[0054] The heat transfer medium circuit system 2 also includes a large number of temperature sensors, whereby each heat source and each heat sink - for example in relation to an associated liquid pipe section - is or can be assigned at least one temperature sensor in order to be able to detect or determine a temperature of a liquid flowing around and / or through the heat source / heat sink.

[0055] Battery B can be thermally connected to the liquid circuit system 6 indirectly via at least one coupling element, for example, in the form of a plate-like coupling element, wherein the coupling element, located on battery B, is through which and / or around which the liquid of the liquid circuit system 6 flows. Additionally or alternatively, battery B itself can also be supplied with a liquid, such as the aforementioned liquid of the liquid circuit system 6 itself and / or a separate liquid, whereby in the latter case battery B has its own liquid circuit, which as such is thermally connected to the liquid circuit system 6 via an associated heat exchanger.

[0056] 8

[0057] The method underlying the invention is explained below:

[0058] For clarity, Figures 1 and 2 illustrate a liquid cooling circuit (CC) with dashed lines and a liquid heating circuit (HC) with solid lines. This makes it easier to distinguish between these two liquid circuits.

[0059] Figure 1 illustrates a first operating mode or emergency mode of system 2, in which the valve system of the thermomodule TM is set such that the liquid heating circuit HK includes both the liquid pump EWP2 and the liquid pump EWP3. The liquid cooling circuit KK, on ​​the other hand, includes only the liquid pump EWP1.

[0060] The liquid heating circuit (circuit) HK is routed, for example, via the capacitor 10, the heat exchanger 12, the radiator 16, at least one component of the electric drive train 18, optionally or if necessary the second radiator 20 and via the battery B.

[0061] The liquid cooling circuit (KK), on the other hand, is routed, for example, via the evaporator 8 and the heat exchanger 14.

[0062] The liquid pumps EWP2 and EWP3 are connected in series. This has the advantage that, in the event of a failure of one of the two liquid pumps EWP2 or EWP3, the other liquid pump can ensure a certain emergency operation or emergency running behavior of the liquid circuit system 6 – for an interim period or a short time.

[0063] It is therefore proposed that the liquid pump EWP2 or the liquid pump EWP2 located near or associated with the capacitor 10 be designated as a 202500107

[0064] 9

[0065] To use a backllp solution or, in the sense of redundancy, for the liquid pump EWP3 located near or associated with battery B, or vice versa.

[0066] For this purpose, the - not illustrated - valve system of the thermomodule TM is adjusted accordingly to compensate for the pump failure during emergency operation.

[0067] Figure 2, however, illustrates a second operating mode or emergency mode, in which the (not illustrated) valve system of the thermomodule TM is set such that the liquid cooling circuit KK includes both the liquid pump EWP1 and the liquid pump EWP3. The liquid heating circuit HK, on ​​the other hand, includes only the liquid pump EWP2.

[0068] The liquid heating circuit (circuit) HK is routed, for example, via the capacitor 10, the radiator 16, at least one component of the electric drive train 18 and optionally or if necessary via the second radiator 20.

[0069] The liquid cooling circuit (KK), on the other hand, is routed, for example, via the evaporator 8, the heat exchanger 14 and the battery B.

[0070] The liquid pumps EWP1 and EWP3 are connected in series. This has the advantage – analogous to the previously described operating mode or emergency running mode – that in the event of a failure of one of the two liquid pumps EWP1 or EWP3, the other liquid pump can ensure a certain emergency operation or emergency running behavior of the liquid circuit system 6 – for an interim period or a short time.

[0071] It is therefore proposed to use the liquid pump EWP1, or the liquid pump EWP1 located near or associated with the evaporator 8, as a backup solution or for redundancy purposes for the liquid pump EWP3 located near or associated with battery B, or vice versa. 202500107

[0072] 10

[0073] For this purpose, the - not illustrated - valve system of the thermomodule TM is adjusted accordingly to compensate for the pump failure during emergency operation.

[0074] All these liquid pumps EWP-i, EWP2, and EWP3 are designed and intended to provide a certain overflow capability in relation to the failed or defective liquid pump. This means they have the ability to function as a redundancy and adequately compensate for the failure. It also means they are able to maintain the required and sufficient liquid pressure, system pressure, and flow rate during emergency operation to prevent damage to the individual components of the electric vehicle or the thermal management system.

[0075] The shut-off valve or shut-off valve for interrupting the liquid cooling circuit KK shown in the two figures 1 and 2 can be represented, adjusted, or implemented accordingly by the valve system of the thermomodule.

[0076] The previously proposed emergency run – which can be described as an emergency run procedure – is implemented by a computer program. This computer program includes instructions that, when executed by a computer, cause it to perform the emergency run or emergency run procedure of the type described above.

[0077] This computer program product is stored on a computer-readable storage medium or data carrier, which as such comprises instructions that, when the program is executed by the computer, cause it to perform the emergency running procedure of the type described above. 202500107

[0078] 11

[0079] This emergency operation is set based on sensor monitoring of the previously described liquid pumps EWP-i, EWP2, EWP3.

[0080] This emergency operation is also based on sensor monitoring of the fluid circuit system, which has a number of temperature and pressure sensors.

[0081] A control unit for the thermomodule TM incorporates such a storage medium or data carrier. This control unit can be integrated into the housing of the thermomodule TM or positioned at a distance from the housing of the thermomodule TM.

[0082] This control unit also includes a digital microprocessor unit (CPU) connected to a bus system and a working memory (RAM). The CPU is configured to execute instructions stored as a program in a higher-level memory system or on the aforementioned storage medium or data carrier, to acquire input signals from the data bus, and to output signals to the data bus. The memory system and / or the aforementioned storage medium or data carrier can be various storage media in the form of magnetic, solid-state, and other non-volatile media, on which a corresponding computer program or computer program product for carrying out the proposed method and its advantageous embodiments is stored.

[0083] At this point, it is clarified that the previously used notation of terms with brackets, such as liquid circuit system, refrigerant circuit, etc., is intended to cover possible alternative designations that, as such, describe the same thing (e.g., refrigerant circuit = refrigerant cycle;

[0084] Liquid circuit system (liquid circulation system). 202500107

[0085] 12

[0086] Although the preceding description explains exemplary embodiments, it should be noted that a multitude of variations are possible. Furthermore, it should be emphasized that the exemplary embodiments are merely examples and are not intended to restrict the scope of protection, applications, or structure in any way. Rather, the preceding description provides the skilled person with a guideline for implementing at least one exemplary embodiment, whereby various modifications, particularly with regard to the function and arrangement of the described components, can be made without departing from the scope of protection as defined by the claims and these equivalent combinations of features.

Claims

202500107 13 Patent claims 1. Method for operating a thermal module (TM), in particular an electric vehicle, in emergency mode; wherein the thermomodule (TM) is operated in a liquid circuit system (6) as part of an indirect heat transfer medium circuit system (2); wherein the thermomodule (TM) is operated with at least three electric liquid pumps (EWPi, EWP2, EWP3) accommodated by a housing of the thermomodule (TM); of which at least one first liquid pump (EWP1) for operating a liquid cooling circuit (CC) - guided via an evaporator (8) of a cold central circuit (4), at least a second liquid pump (EWP2) for operating a liquid heating circuit (HK) - which is routed via a capacitor (10) of the cold central circuit (4) and at least one third liquid pump (EWP3) is operated to operate a liquid circuit (run) - which is powered by a battery (B); where, in the event of a failure of the first or second liquid pump (EWP1, EWP2), the third liquid pump (EWP3) is fluidically connected in series with the failed first or second liquid pump (EWP1, EWP2). or where, in the event of a failure of the third liquid pump (EWP3), the first or second liquid pump (EWP1, EWP2) is fluidically connected in series with the failed third liquid pump (EWP3); by adjusting an electrically adjustable valve system of the thermomodule (TM) accordingly; to compensate for pump failure during emergency operation; wherein, by means of the valve system in conjunction with a plurality of liquid channel sections formed in the housing, corresponding liquid circuits of the indirect heat transfer medium circuit system (2) are set. 202500107 14 2. Method according to claim 1, wherein in the event of a failure of two of these three liquid pumps (EWP-i, EWP2, EWP3) the valve system of the thermomodule (TM) is adjusted such that the battery (B) and / or at least one component of an electric drive train (18) is supplied with the liquid by the one remaining liquid pump as best as possible, as required, in order to compensate for the pump failure during emergency operation.

3. Computer program product comprising instructions which, when the program is executed by a computer, cause it to execute the method according to one of claims 1 or 2.

4. Computer-readable storage medium comprising instructions which, when executed by a computer, cause the computer to execute the method according to claim 1 or 2.

5. Control unit for a thermomodule (TM) according to one of claims 1 or 2, comprising a computer-readable storage medium according to claim 4, on which the computer program product according to claim 3 is stored, wherein the control unit is received by a housing of the thermomodule (TM) or is arranged spaced apart from the housing of the thermomodule (TM).

6. Thermomodule (TM) for an indirect heat transfer medium circuit system (2), comprising: a multi-part housing through which at least three electric liquid pumps (EWP1, EWP2, EWP3) are accommodated; of which at least one first liquid pump (EWP1) is provided for operating a liquid cooling circuit (CC) - via an evaporator (8), at least one second liquid pump (EWP2) for operating a liquid heating circuit (HC) - via a condenser (10), and at least one third liquid pump (EWP3) for operating a liquid circuit - via a battery (B); 202500107 15 an electrically adjustable valve system received through the housing, by which, in conjunction with a plurality of liquid channel sections formed in the housing, corresponding liquid circuits (runs) can be set within the indirect heat transfer medium circuit (run) system (2) according to a method of the preceding claims 1 or 2, as well as a control unit according to claim 5 for adjusting the thermomodule (TM).

7. Thermomodule (TM) according to claim 6 with a plurality of sensors received through the housing of the thermomodule (TM) for monitoring the individual liquid circuits according to one of claims 1 or 2.

8. Vehicle with a control unit according to claim 5.

9. Indirect heat transfer medium circuit system (2) for an electric vehicle, wherein the heat transfer medium circuit system (2) comprises a control unit according to claim 5.

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