WO2023169061A1

WO2023169061A1 - Electric vehicle thermal management system

Info

Publication number: WO2023169061A1
Application number: PCT/CN2022/142883
Authority: WO
Inventors: 梁杰; 张事业; 任金龙; 苏荔; 余志南; 黄帅
Original assignee: 浙江凌昇动力科技有限公司; 浙江零跑科技股份有限公司
Priority date: 2022-03-07
Filing date: 2022-12-28
Publication date: 2023-09-14
Also published as: CN115782503A

Abstract

An electric vehicle thermal management system, comprising a plurality of working modes, wherein the plurality of working modes comprise passenger compartment refrigeration, hybrid dual-refrigeration, battery refrigeration, refrigeration and dehumidification, heating and dehumidification, passenger compartment heating, waste heat recovery of a heat pump, independent PTC heating, and battery heating; the system comprises a plurality of loops on hardware connection, and the loops comprise a refrigerant loop (2), an electric motor heat dissipation water loop (1), a battery heat dissipation water loop (4), and a heating water loop (3); each working state corresponds to one or more loops; and the loops are provided with a plurality of devices, and the devices comprise a liquid-cooling heat exchanger for increasing the heat exchange amount of a thermal system, and a highly integrated seven-way valve (35).

Description

A thermal management system for electric vehicles

Technical field

The present invention relates to the technical field of electric vehicle thermal management, and in particular to an electric vehicle thermal management system.

Background technique

With the development of economy and society, the energy crisis is gradually emerging, and the environmental costs are getting higher and higher. In this context, zero emissions of pure electric vehicles have attracted more and more attention. As a key energy-consuming module of electric vehicles, thermal management has attracted more and more research attention. As users have higher and higher requirements for the cruising range and charging speed of electric vehicles, they have higher and higher requirements for the temperature comfort of the entire vehicle. The heat generated by the battery is increasing, requiring more efficient and energy-saving thermal management. However, the current thermal management of electric vehicles has insufficient high-temperature refrigeration capabilities. At the same time, the front-end heat dissipation of battery cooling during fast charging is insufficient. At the same time, there are many waterway components, which increases costs and makes control difficult. As battery overcharging power requirements become higher and higher, the heat exchange demand for the front-end condenser is getting higher and higher. The amount of front-end heat dissipation determines the quality of the system's cooling performance, affecting system energy efficiency and vehicle safety; in the actual vehicle During use, motors and batteries will generate waste heat, and the existing electric vehicle management system cannot effectively and fully utilize this energy, or it may use it but with extremely low utilization efficiency, resulting in secondary waste of resources. This situation causes A huge waste of energy.

For example, "a pure electric vehicle battery thermal management system, a pure electric vehicle" disclosed in Chinese patent documents, its announcement number CN112644337A, includes a first heating module for low-temperature charging conditions and low-temperature discharge The PTC is used to heat the battery water-cooling plate and the charger under working conditions; the second heating module is used to use the powertrain to auxiliary heat the battery water-cooling plate under low-temperature discharge conditions; the first heat dissipation module is used to heat the battery water-cooling plate under high-temperature charging conditions. The radiator is used to dissipate heat from the battery water-cooling plate and the charger; the second heat dissipation module is used to use the condenser to dissipate heat from the battery water-cooling plate under high-temperature charging conditions and high-temperature discharging conditions. This solution includes four working conditions. The conventional thermal management system is connected in series with the battery circuit through a three-way water valve and a four-way water valve to achieve simple heat recovery. At the same time, the water path uses a combination of multiple water valves to achieve different functions. There are many parts and costs. It is relatively high. The use of multiple water valves to control the water path makes the entire system control complex. The primary loop coupling needs to control the on-off of multiple water valves, which is too complicated. The heat dissipation module provides auxiliary heat for the battery water-cooling plate and charger heat dissipation. The system The coupling degree between them is low and cannot be fully coupled. It is impossible to realize the utilization of auxiliary heat and waste heat while improving the system coupling degree, and the effect of improving system efficiency is poor.

Contents of the invention

The present invention is to overcome the problem of resource waste caused by insufficient heat dissipation under high-temperature refrigeration and incomplete recovery of waste heat in the prior art. It provides a thermal management system for electric vehicles to achieve the purpose of energy saving and emission reduction. Through an integrated seven-way The water valve completes the on-off and flow adjustment control of the waterway, and highly efficiently couples the front cabin motor thermal system, battery thermal system, and passenger cabin heating system. It realizes different paths according to the different thermal management needs of each module to achieve auxiliary heat dissipation and The purpose of utilizing waste heat is to achieve energy saving for the entire vehicle.

In order to achieve the above objects, the present invention adopts the following technical solutions:

An electric vehicle thermal management system, characterized in that the system includes multiple working modes, including passenger cabin refrigeration, hybrid dual refrigeration, battery refrigeration, refrigeration dehumidification, heating dehumidification, and passenger cabin heating. Heat pump waste heat recovery, individual PTC heating, battery heating;

The system includes a variety of circuits in terms of hardware connections, including a refrigerant circuit, a motor hot water circuit, a battery hot water circuit, and a heating water circuit;

Each working state corresponds to one or more circuits;

A variety of devices are provided on the circuit; the devices include a liquid-cooled heat exchanger used to increase the heat exchange capacity of the thermal system and a highly integrated seven-way valve.

The invention has the thermal management function of LGC, and can combine the refrigerant circuit, the motor cooling circuit, and the passenger cabin heating circuit through the liquid-cooled heat exchanger to increase the heat dissipation capacity of the system; at the same time, the system realizes the motor, The battery and passenger compartment circuits are fully coupled to achieve the purpose of waste heat recovery, and the system has a higher integrated circuit. Combining the two can highly couple the vehicle's motor, battery, and passenger compartment to achieve stronger cooling performance and better energy-saving effects.

Preferably, the device includes a front drive motor, a rear drive motor, a front drive motor controller, a rear drive motor controller, a DCDC low-voltage conversion controller & on-board charger, an automatic driving controller, a motor cooling water pump, a low-temperature water tank, Outdoor condenser, fan, electric compressor, solenoid valve, gas-liquid separator/integrated intermediate heat exchanger, evaporator, internal cooling condenser, heater core, electronic expansion valve, heating electronic water pump, water PTC heater, Battery water pumps, batteries and battery cooling plate heat exchangers;

The number of battery cooling plate heat exchangers is one. The battery cooling plate heat exchanger includes a battery cooling plate heat exchanger for battery coolant in and out, a battery cooling plate heat exchanger circuit interface for refrigerant in and out, and a battery cooling plate heat exchanger refrigerant for refrigerant in and out. Loop interface; the seven-way valve is used to control the on and off of the circuits including the motor water dissipation circuit, the battery water dissipation circuit, the heating water circuit and the non-working channel circuit, and to realize the coupling between the circuits;

The number of liquid-cooled heat exchangers is one. The liquid-cooled heat exchanger includes three channels. Each channel contains interfaces on both sides, with a total of six interfaces, each of which is two liquid-cooled heat exchangers connected to the refrigerant circuit. Refrigerant circuit interface and four liquid-cooled heat exchanger motor cooling/heating circuit interfaces connected to the motor cooling water circuit and heating water circuit;

The number of the solenoid valves is four, namely the first solenoid valve, the second solenoid valve, the third solenoid valve and the fourth solenoid valve;

There are three electronic expansion valves, namely a first electronic expansion valve, a second electronic expansion valve and a third electronic expansion valve.

As a preference, in the passenger compartment cooling mode, the refrigerant circuit and the motor water dissipation circuit work,

The motor water cooling circuit includes front drive motor, rear drive motor, front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & vehicle charger, automatic driving controller, motor cooling water pump, low temperature water tank and liquid cooling A series circuit composed of the first liquid cooling channel of the heat exchanger motor cooling/heating circuit interface, the fifth interface of the seven-way valve, and the third interface of the seven-way valve;

The refrigerant circuit includes an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface and the first solenoid valve connected in series. The evaporator/integrated intermediate heat exchanger is also connected to a series circuit consisting of an evaporator, a second electronic expansion valve, and a fourth solenoid valve.

As an option, in the hybrid dual refrigeration mode, the refrigerant circuit, motor water dissipation circuit and battery water dissipation circuit work;

The battery hot water circuit includes the first interface of the seven-way valve, the battery cooling plate heat exchanger battery hot water circuit interface, a series circuit composed of the battery, battery water pump and the second interface of the seven-way valve;

The refrigerant circuit includes a circuit composed of an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface and the first solenoid valve connected in series. It also includes one end of the evaporator connected to the gas-liquid separator/integrated intermediate heat exchanger and one end of the refrigerant circuit interface of the battery cooling plate heat exchanger, and the other end of the refrigerant circuit interface of the battery cooling plate heat exchanger is connected to the third electronic expansion valve One end is connected, the other end of the third electronic expansion valve is connected to one end of the second electronic expansion valve and one end of the fourth solenoid valve, the other end of the second electronic expansion valve is connected to the other end of the evaporator, and the other end of the fourth solenoid valve is the gas-liquid separator/ Integrated intermediate heat exchanger connection.

Preferably, in the battery refrigeration mode, the refrigerant circuit, motor hot water circuit and battery hot water circuit work; the motor hot water circuit includes a front drive motor, a rear drive motor, a front drive motor controller, a rear drive motor controller, DCDC Low-voltage conversion controller & on-board charger, automatic driving controller, motor cooling water pump, low-temperature water tank and liquid-cooled heat exchanger, motor cooling/heating circuit interface, the first liquid cooling channel and the fifth interface of the seven-way valve and the seven-way valve A series loop composed of the third interface;

The refrigerant circuit includes a circuit composed of an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface and the first solenoid valve connected in series. It also includes a series circuit composed of a battery cooling plate heat exchanger refrigerant circuit interface, a third electronic expansion valve, and a fourth solenoid valve that are connected in series to the gas-liquid separator/integrated intermediate heat exchanger. The two series circuits are connected by gas-liquid Separator/integrated intermediate heat exchanger in parallel.

Preferably, in the cooling and dehumidification mode, the refrigerant circuit, motor water dissipation circuit, battery water dissipation circuit, and heating water circuit work;

The refrigerant circuit includes a circuit composed of an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface and the first solenoid valve connected in series. It also includes a series loop composed of an evaporator, a second electronic expansion valve, and a fourth solenoid valve connected in series to the gas-liquid separator/integrated intermediate heat exchanger. The two series loops are connected through the gas-liquid separator/integrated intermediate heat exchanger. devices in parallel;

The heating water circuit includes the sixth interface of the seven-way valve, the second liquid cooling channel of the liquid-cooled heat exchanger motor cooling/heating circuit interface, the heater core, the water PTC heater, the heating electronic water pump and the seventh interface of the seven-way valve. A series circuit composed of interfaces.

Preferably, in the heating and dehumidification mode, the refrigerant circuit, motor water dissipation circuit, battery water dissipation circuit, and heating water circuit work;

The motor water dissipation circuit includes the third interface of the seven-way valve, front drive motor, rear drive motor, front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & vehicle charger, automatic driving controller, and motor cooling A series circuit composed of the water pump and the fourth interface of the seven-way valve;

The refrigerant circuit includes an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface, a second solenoid valve, an internal cooling condenser, evaporator, second electronic expansion valve, first electronic expansion valve and third solenoid valve;

Preferably, in the passenger compartment heating mode, the refrigerant circuit, motor water dissipation circuit, battery water dissipation circuit, and heating water circuit work;

The refrigerant circuit includes an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface, a second solenoid valve, an internal cooling condenser, The first electronic expansion valve and the third solenoid valve; the heating water circuit includes the sixth interface of the seven-way valve, the second liquid cooling channel of the liquid cooling heat exchanger motor cooling/heating circuit interface, the warm air core, and the water PTC heater , a series circuit composed of the seventh interface of the heating electronic water pump and the seven-way valve.

As an option, in the heat pump waste heat recovery mode, the refrigerant circuit, motor hot water circuit, battery hot water circuit, and heating water circuit work; the motor hot water circuit includes the third interface of the seven-way valve, the front drive motor, the rear drive motor, A series circuit composed of the fourth interface of the front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & on-board charger, automatic driving controller, motor cooling water pump and seven-way valve;

The refrigerant circuit includes a gas-liquid separator/integrated intermediate heat exchanger, electric compressor, refrigerant channel of the liquid-cooled heat exchanger, second solenoid valve, internal cooling condenser, and battery cooling plate heat exchanger refrigerant circuit interface and a third electronic expansion valve;

As a preference, in the separate PTC heating mode, the heating water circuit works;

The heating water circuit includes the sixth interface of the seven-way valve, the second liquid cooling channel of the liquid-cooled heat exchanger motor cooling/heating circuit interface, the heater core, the water PTC heater, the heating electronic water pump and the seventh interface of the seven-way valve. A series loop composed of interfaces;

As a preference, in the battery heating mode, the heating water circuit and the battery water dissipation circuit work;

The heating water circuit includes the seventh interface of the seven-way valve, the heating electronic water pump and the water PTC heater.

Therefore, the present invention has the following beneficial effects:

1. The seven-way valve is used to complete the coupling of the motor circuit, battery circuit, and passenger cabin circuit to achieve heat recovery and reuse between each module and achieve energy saving effects;

2. The high-pressure heat dissipation module of the refrigeration system is coupled with the motor cooling circuit and the passenger cabin heating circuit through a liquid-cooled heat exchanger to achieve optimal heat dissipation performance. In cooling mode, the heat exchanger area of the low-temperature motor water tank is used to increase the system Dissipate heat and improve cooling capacity; when the heat pump is working, use the in-vehicle warm air radiator and in-vehicle condenser to exchange heat, increase the heat transfer amount, and improve the energy-saving effect of the system.

Description of the drawings

Figure 1 is a system connection diagram of the prior art.

Figure 2 is an overall system connection diagram of Embodiment 1.

Figure 3 is a working diagram of Embodiment 1 in the passenger compartment cooling mode.

Figure 4 is a working diagram of Embodiment 1 in the hybrid dual cooling mode.

Figure 5 is a working diagram of Example 1 in battery cooling mode.

Figure 6 is a working condition diagram of Embodiment 1 in the cooling and dehumidification mode.

Figure 7 is a working diagram of Example 1 in the heating and dehumidification mode.

Figure 8 is a working diagram of Embodiment 1 in the passenger compartment heating mode.

Figure 9 is a working diagram of Example 1 in the heat pump waste heat recovery mode.

Figure 10 is a working diagram of Example 1 in the separate PTC heating mode.

Figure 11 is a working diagram of Example 1 in the battery heating mode.

Figure 12 is an overall system connection diagram of Embodiment 2.

In the picture: 1. Motor water dissipation circuit 2. Refrigerant circuit 3. Heating water circuit 4. Battery water dissipation circuit 5. Front drive motor 6. Rear drive motor 7. Front drive motor controller 8. Rear drive motor controller 9 , DCDC low-voltage conversion controller & vehicle charger 10. Automatic driving controller 11. Motor cooling water pump 12. Low-temperature water tank 13. Liquid-cooled heat exchanger motor cooling/heating circuit interface 14. Liquid-cooled heat exchanger refrigerant circuit interface 15. Outdoor condenser 16. Fan 17. Electric compressor 18. Gas-liquid separator/integrated intermediate heat exchanger 19. Evaporator 20. Internal cooling condenser 21. Warm air core 22. First solenoid valve 23. Second solenoid valve 24, third solenoid valve 25, fourth solenoid valve 26, first electronic expansion valve 27, second electronic expansion valve 28, third electronic expansion valve 29, heating electronic water pump 30, water PTC heater 31, battery Water pump 32, battery 33, battery cooling plate heat exchanger battery hot water circuit interface 34, battery cooling plate heat exchanger refrigerant circuit interface 35, seven-way valve 3501, first interface 3502, second interface 3503, third interface 3504 , the fourth interface 3505, the fourth interface 3506, the sixth interface 3507, and the seventh interface.

Detailed ways

The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

The implementation of the present invention aims to solve the problems of existing solutions with many parts, high cost, and inability to couple and control complex loops. Before implementing the present invention, the motor circuit of the conventional management system is first introduced. As shown in Figure 1, the motor circuit is connected in series with the battery circuit only through the water valve to realize simple heat recovery. The heat dissipation of the refrigeration system is only externally dissipated through the outdoor heat exchanger, and the water circuit adopts Multiple water valves are combined to achieve different functions, with many parts, high costs, and complex control.

Example 1:

This embodiment provides an electric vehicle thermal management system, which improves the circuit and components on the basis of the existing solution. As shown in Figure 2, the overall structure of the system is as follows, including a front drive motor 5 and a rear drive motor 6 , front drive motor controller 7, rear drive motor controller 8, DCDC low voltage conversion controller & on-board charger 9, automatic driving controller 10, motor cooling water pump 11, low temperature water tank 12, liquid cooling heat exchanger motor cooling/ Heating circuit interface 13, liquid cooling heat exchanger refrigerant circuit interface 14, outdoor condenser 15, fan 16, electric compressor 17, gas-liquid separator/integrated intermediate heat exchanger 18, evaporator 19, internal cooling condenser 20 , warm air core 21, first solenoid valve 22, second solenoid valve 23, third solenoid valve 24, fourth solenoid valve 25, first electronic expansion valve 26, second electronic expansion valve 27, third electronic expansion valve 28. Heating electronic water pump 29, water PTC heater 30, battery water pump 31, battery 32, battery cooling plate heat exchanger battery hot water circuit interface 33, battery cooling plate heat exchanger refrigerant circuit interface 34 and seven-way valve 35;

In the liquid-cooled heat exchanger motor cooling/heating circuit interface 13 and the liquid-cooled heat exchanger refrigerant circuit interface 14 in the figure, from top to bottom they are the first liquid cooling channel, the refrigerant channel and the second liquid cooling channel;

The third interface 3503 of the seven-way valve 35 is connected to the front drive motor 5. The front drive motor 5 is also connected to the rear drive motor 6. The rear drive motor 6 is also connected to the front drive motor controller 7. The front drive motor controller 7 is also connected to The rear drive motor controller 8 is connected, the rear drive motor controller 8 is connected to the DCDC low voltage conversion controller & vehicle charger 9, the DCDC low voltage conversion controller & vehicle charger 9 is connected to the automatic driving controller 10, the automatic driving controller 10 It is connected to the motor cooling water pump 11. The motor cooling water pump 11 is also connected to the fourth interface 3504 of the seven-way valve 35 and one side of the low-temperature water tank 12. The other side of the low-temperature water tank 12 passes through the liquid-cooled heat exchanger motor cooling/heating circuit interface. The first liquid cooling channel 13 is connected to the fifth interface 3505 of the seven-way valve 35, and the sixth interface 3506 of the seven-way valve 35 is connected to the warm air through the second liquid cooling channel 13 of the liquid cooling heat exchanger motor cooling/heating circuit interface 13. One side of the core body 21 is connected, the other side of the warm air core body 21 is connected to one side of the water PTC heater 30, the other side of the water PTC heater 30 is connected to one side of the heating electronic water pump 29, the other side of the heating electronic water pump 29 is connected to The seventh interface 3507 of the seven-way valve 35 is connected, one side of the outdoor condenser 15 is connected to one side of the first solenoid valve 22, and the other side of the first solenoid valve is connected to one side of the second solenoid valve 23 and the liquid cooling heat exchanger respectively. One side of the refrigerant channel of the refrigerant circuit interface 14 is connected, and the other side of the refrigerant channel of the liquid cooling heat exchanger refrigerant circuit interface 14 is connected to the electric compressor 17 through

The gas-liquid separator/integrated intermediate heat exchanger 18 is connected, the gas-liquid separator/integrated intermediate heat exchanger 18 is connected to the other side of the outdoor condenser 15, and the gas-liquid separator/integrated intermediate heat exchanger 18 is also connected to the fourth electromagnetic One side of the valve 25 is connected to one side of the third solenoid valve 24, and the gas-liquid separator/integrated intermediate heat exchanger 18 is also connected to the other side of the third solenoid valve 24, the evaporator 19 side and the battery cooling plate heat exchanger respectively. One side of the refrigerant circuit interface 34 is connected, the other side of the battery cooling plate heat exchanger refrigerant circuit interface 34 is connected to one side of the third electronic expansion valve 28, and the other side of the third electronic expansion valve 28 is connected to the second electronic expansion valve 17 respectively. One side and the other side of the fourth solenoid valve 25 are connected to one side of the first electronic expansion valve 26, and the other side of the first electronic expansion valve 26 is connected to one side of the outdoor condenser 15; the first interface 3501 of the seven-way valve 35 is connected to One side of the battery cooling plate heat exchanger's battery hot water circuit interface 33 is connected, the other side of the battery cooling plate heat exchanger's battery hot water circuit interface 33 is connected to one side of the battery 32, and the other side of the battery 32 is connected to one side of the battery water pump 31. , the other side of the battery water pump 31 is connected to the second interface 3502 of the seven-way valve 35 .

This embodiment can realize nine working modes, as shown in Figure 3-11 respectively. Under various working conditions, by controlling the on and off of each interface of the seven-way valve, the liquid cooling heat exchanger, each solenoid valve and the electronic expansion valve The open/close/throttle mode realizes the on-off coupling between the refrigerant circuit 2, the motor water dissipation circuit 1, the heating water circuit 3 and the battery water dissipation circuit 4, etc., and realizes the following multiple working modes to cooperate with each other to achieve energy saving and Control simplification purposes.

Figure 3 shows the passenger cabin cooling mode. In the passenger cabin cooling mode, the refrigerant circuit 2 and the motor water dissipation circuit 1 work.

The status of each corresponding solenoid valve, electronic expansion valve and seven-way valve in this mode in Figure 1 is as shown in Table 1:

Table 1

In the passenger cabin cooling mode, the first solenoid valve is open, the second solenoid valve is closed, the third solenoid valve is closed, the fourth solenoid valve is open, the first electronic expansion valve is closed, the second electronic expansion valve is throttled, and the third electronic expansion valve When closed, the sixth interface of the seven-way valve is connected to the seventh interface, the first interface is connected to the second interface, the fifth interface is connected to the third interface, and the fourth interface is disconnected.

As shown in Figure 4, the hybrid dual refrigeration mode is shown. In the hybrid dual refrigeration mode, the refrigerant circuit 2, the motor water dissipation circuit 1 and the battery water dissipation circuit 4 work;

The status of each corresponding solenoid valve, electronic expansion valve and seven-way valve in this mode is shown in Table 2:

Form 2

In the hybrid dual cooling mode, the first solenoid valve is open, the second solenoid valve is closed, the third solenoid valve is closed, the fourth solenoid valve is open, the first electronic expansion valve is closed, the second electronic expansion valve is throttling, and the third electronic expansion valve For throttling, the sixth interface of the seven-way valve is connected to the seventh interface, the first interface is connected to the second interface, the fifth interface is connected to the third interface, and the fourth interface is disconnected.

As shown in Figure 5, the battery cooling mode is shown. In the battery cooling mode, the refrigerant circuit 2, the motor hot water circuit 1 and the battery hot water circuit 4 work;

The status of each corresponding solenoid valve, electronic expansion valve and seven-way valve in this mode in Figure 1 is as shown in Table 3:

Form 3

In the battery cooling mode, the first solenoid valve is opened, the second solenoid valve is closed, the third solenoid valve is closed, the fourth solenoid valve is opened, the first electronic expansion valve is closed, the second electronic expansion valve is closed, and the third electronic expansion valve is throttled. , the sixth interface of the seven-way valve is connected to the seventh interface, the first interface is connected to the second interface, the fifth interface is connected to the third interface, and the fourth interface is disconnected.

Figure 6 shows the cooling and dehumidification mode. In the cooling and dehumidification mode, the refrigerant circuit 2, the motor water dissipation circuit 1, the battery water dissipation circuit 4, and the heating water circuit 3 work;

The status of each corresponding solenoid valve, electronic expansion valve and seven-way valve in this mode in Figure 1 is as shown in Table 4:

Form 4

In the cooling and dehumidification mode, the first solenoid valve is open, the second solenoid valve is closed, the third solenoid valve is closed, the fourth solenoid valve is opened, the first electronic expansion valve is closed, the second electronic expansion valve is throttled, and the third electronic expansion valve is closed. The sixth interface and the seventh interface of the seven-way valve are connected, the first interface and the fourth interface are connected, the second interface and the third interface are connected, and the fifth interface is disconnected. The sixth and seventh interfaces of the seven-way heating circuit valve are connected, the first and second interfaces of the battery circuit are connected, the fifth and third interfaces of the motor circuit are connected, and the fourth interface is disconnected.

Figure 7 shows the heating and dehumidification mode. In the heating and dehumidification mode, the refrigerant circuit 2, the motor water dissipation circuit 1, the battery water dissipation circuit 4, and the heating water circuit 3 work;

The status of each corresponding solenoid valve, electronic expansion valve and seven-way valve in this mode in Figure 1 is as shown in Table 5:

Form 5

In heating and dehumidification mode, the first solenoid valve is closed, the second solenoid valve is open, the third solenoid valve is open, the fourth solenoid valve is closed, the first electronic expansion valve is throttling, the second electronic expansion valve is throttling, and the third electronic expansion valve is throttling. The valve is closed, the sixth interface of the seven-way valve is connected to the seventh interface, the first interface is connected to the second interface, the fifth interface is connected to the third interface, and the fourth interface is disconnected.

Figure 8 shows the passenger cabin heating mode. In the passenger cabin heating mode, the refrigerant circuit 2, the motor hot water circuit 1, the battery hot water circuit 4, and the heating water circuit 3 work;

The status of each corresponding solenoid valve, electronic expansion valve and seven-way valve in this mode in Figure 1 is as shown in Table 6:

Form 6

In the passenger cabin heating mode, the first solenoid valve is closed, the second solenoid valve is opened, the third solenoid valve is opened, the fourth solenoid valve is closed, the first electronic expansion valve is throttled, the second electronic expansion valve is closed, and the third electronic expansion valve The valve is closed, the sixth interface of the seven-way valve is connected to the seventh interface, the first interface is connected to the second interface, the fifth interface is connected to the third interface, and the fourth interface is disconnected.

Figure 9 shows the heat pump waste heat recovery mode. In the heat pump waste heat recovery mode, the refrigerant circuit 2, the motor hot water circuit 1, the battery hot water circuit 4, and the heating water circuit work 3;

The status of each corresponding solenoid valve, electronic expansion valve and seven-way valve in this mode in Figure 1 is as shown in Table 7:

Form 7

In the heat pump waste heat recovery mode, the first solenoid valve is closed, the second solenoid valve is open, the third solenoid valve is closed, the fourth solenoid valve is closed, the first electronic expansion valve is closed, the second electronic expansion valve is closed, and the third electronic expansion valve is closed. flow, the sixth interface of the seven-way valve is connected to the seventh interface, the first interface is connected to the fourth interface, the second interface is connected to the third interface, and the fifth interface is disconnected.

Figure 10 shows the independent PTC heating mode. In the independent PTC heating mode, the heating water circuit 3 works;

The status of each corresponding solenoid valve, electronic expansion valve and seven-way valve in this mode in Figure 1 is as shown in Table 8:

Form 8

In the independent PTC heating mode, the first solenoid valve, the second solenoid valve, the third solenoid valve, the fourth solenoid valve, the first electronic expansion valve, the second electronic expansion valve, and the third electronic expansion valve are all closed, and the seven-way valve The sixth interface is connected to the seventh interface, the first interface is connected to the second interface, the fifth interface is connected to the third interface, and the fourth interface is disconnected.

Figure 11 shows the battery heating mode. In the battery heating mode, the heating water circuit 3 and the battery hot water circuit 4 work; the battery hot water circuit includes the first interface of the seven-way valve, the battery cooling plate heat exchanger battery hot water circuit interface , a series circuit composed of the second interface of the battery, battery water pump and seven-way valve;

The status of each corresponding solenoid valve, electronic expansion valve and seven-way valve in this mode in Figure 1 is as shown in Table 9:

Form 9

In the battery heating mode, the first solenoid valve, the second solenoid valve, the third solenoid valve, the fourth solenoid valve, the first electronic expansion valve, the second electronic expansion valve, and the third electronic expansion valve are all closed, and the seven-way valve is closed. The interface, the first interface and the second interface are connected, the fifth interface and the third interface are connected, and the fourth interface and the sixth interface are disconnected.

The invention uses an integrated seven-way water valve to complete the on-off and flow adjustment control of the waterway, and highly efficiently couples the front cabin motor thermal system, battery thermal system, and passenger cabin heating system, and realizes it according to the different thermal management needs of each module. Different channels achieve the purpose of auxiliary heat dissipation and waste heat utilization, thereby achieving energy saving for the entire vehicle.

The function implementation of the seven-way valve is as shown in Table 10:

Example 2:

In this embodiment, as shown in Figure 2, the implementation of a seven-way valve is replaced by two three-way water valves and a four-way water valve. The remaining implementation parts are the same as in Embodiment 1.

The specific description of the present invention in the above embodiments is only used to further illustrate the present invention and cannot be understood as limiting the protection scope of the present invention. It is fallable for engineers skilled in the art to make some non-essential improvements and adjustments to the present invention based on the content of the above invention. into the protection scope of the present invention.

Claims

An electric vehicle thermal management system, characterized in that the system includes multiple working modes, including passenger cabin refrigeration, hybrid dual refrigeration, battery refrigeration, refrigeration dehumidification, heating dehumidification, and passenger cabin heating. Heat pump waste heat recovery, individual PTC heating, battery heating;

The system includes a variety of circuits in terms of hardware connections, including a refrigerant circuit, a motor hot water circuit, a battery hot water circuit, and a heating water circuit;

Each working state corresponds to one or more circuits;

A variety of devices are provided on the circuit; the devices include a liquid-cooled heat exchanger used to increase the heat exchange capacity of the thermal system and a highly integrated seven-way valve.
An electric vehicle thermal management system according to claim 1, characterized in that the device includes a front drive motor, a rear drive motor, a front drive motor controller, a rear drive motor controller, a DCDC low-voltage conversion controller & vehicle-mounted Charger, automatic driving controller, motor cooling water pump, low-temperature water tank, outdoor condenser, fan, electric compressor, solenoid valve, gas-liquid separator/integrated intermediate heat exchanger, evaporator, internal cooling condenser, warm air Core body, electronic expansion valve, heating electronic water pump, water PTC heater, battery water pump, battery and battery cooling plate heat exchanger;

The number of battery cooling plate heat exchangers is one. The battery cooling plate heat exchanger includes a battery cooling plate heat exchanger for battery coolant in and out, a battery cooling plate heat exchanger circuit interface for refrigerant in and out, and a battery cooling plate heat exchanger refrigerant for refrigerant in and out. loop interface;

The seven-way valve is used to control the on and off of the circuits including the motor water dissipation circuit, the battery water dissipation circuit, the heating water circuit and the non-working channel circuit, and to realize the coupling between the circuits;

The number of liquid-cooled heat exchangers is one. The liquid-cooled heat exchanger includes three channels. Each channel contains interfaces on both sides, with a total of six interfaces, each of which is two liquid-cooled heat exchangers connected to the refrigerant circuit. Refrigerant circuit interface and four liquid-cooled heat exchanger motor cooling/heating circuit interfaces connected to the motor cooling water circuit and heating water circuit;

The number of the solenoid valves is four, namely the first solenoid valve, the second solenoid valve, the third solenoid valve and the fourth solenoid valve;

There are three electronic expansion valves, namely a first electronic expansion valve, a second electronic expansion valve and a third electronic expansion valve.
An electric vehicle thermal management system according to claim 2, characterized in that, in the passenger compartment cooling mode, the refrigerant circuit and the motor water dissipation circuit operate,

The motor water cooling circuit includes front drive motor, rear drive motor, front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & vehicle charger, automatic driving controller, motor cooling water pump, low temperature water tank and liquid cooling A series circuit composed of the first liquid cooling channel of the heat exchanger motor cooling/heating circuit interface, the fifth interface of the seven-way valve, and the third interface of the seven-way valve;

The refrigerant circuit includes an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface and the first solenoid valve connected in series. The evaporator/integrated intermediate heat exchanger is also connected to a series circuit consisting of an evaporator, a second electronic expansion valve, and a fourth solenoid valve.
An electric vehicle thermal management system according to claim 2, characterized in that, in the hybrid dual cooling mode, the refrigerant circuit, the motor water dissipation circuit and the battery water dissipation circuit work;

The motor water cooling circuit includes front drive motor, rear drive motor, front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & vehicle charger, automatic driving controller, motor cooling water pump, low temperature water tank and liquid cooling A series circuit composed of the first liquid cooling channel of the heat exchanger motor cooling/heating circuit interface, the fifth interface of the seven-way valve, and the third interface of the seven-way valve;

The battery hot water circuit includes the first interface of the seven-way valve, the battery cooling plate heat exchanger battery hot water circuit interface, a series circuit composed of the battery, battery water pump and the second interface of the seven-way valve;

The refrigerant circuit includes a circuit composed of an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface and the first solenoid valve connected in series. It also includes one end of the evaporator connected to the gas-liquid separator/integrated intermediate heat exchanger and one end of the refrigerant circuit interface of the battery cooling plate heat exchanger, and the other end of the refrigerant circuit interface of the battery cooling plate heat exchanger is connected to the third electronic expansion valve One end is connected, the other end of the third electronic expansion valve is connected to one end of the second electronic expansion valve and one end of the fourth solenoid valve, the other end of the second electronic expansion valve is connected to the other end of the evaporator, and the other end of the fourth solenoid valve is the gas-liquid separator/ Integrated intermediate heat exchanger connection.
An electric vehicle thermal management system according to claim 2, characterized in that, in the battery cooling mode, the refrigerant circuit, the motor water dissipation circuit and the battery water dissipation circuit operate;

The motor water cooling circuit includes front drive motor, rear drive motor, front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & vehicle charger, automatic driving controller, motor cooling water pump, low temperature water tank and liquid cooling A series circuit composed of the first liquid cooling channel of the heat exchanger motor cooling/heating circuit interface, the fifth interface of the seven-way valve, and the third interface of the seven-way valve;

The battery hot water circuit includes the first interface of the seven-way valve, the battery cooling plate heat exchanger battery hot water circuit interface, a series circuit composed of the battery, battery water pump and the second interface of the seven-way valve;

The refrigerant circuit includes a circuit composed of an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface and the first solenoid valve connected in series. It also includes a series circuit composed of a battery cooling plate heat exchanger refrigerant circuit interface, a third electronic expansion valve, and a fourth solenoid valve that are connected in series to the gas-liquid separator/integrated intermediate heat exchanger. The two series circuits are connected by gas-liquid Separator/integrated intermediate heat exchanger in parallel.
An electric vehicle thermal management system according to claim 2, characterized in that, in the refrigeration and dehumidification mode, the refrigerant circuit, the motor water dissipation circuit, the battery water dissipation circuit, and the heating water circuit work;

The motor water cooling circuit includes front drive motor, rear drive motor, front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & vehicle charger, automatic driving controller, motor cooling water pump, low temperature water tank and liquid cooling A series circuit composed of the first liquid cooling channel of the heat exchanger motor cooling/heating circuit interface, the fifth interface of the seven-way valve, and the third interface of the seven-way valve;

The battery hot water circuit includes the first interface of the seven-way valve, the battery cooling plate heat exchanger battery hot water circuit interface, a series circuit composed of the battery, battery water pump and the second interface of the seven-way valve;

The refrigerant circuit includes a circuit composed of an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface and the first solenoid valve connected in series. It also includes a series loop composed of an evaporator, a second electronic expansion valve, and a fourth solenoid valve connected in series to the gas-liquid separator/integrated intermediate heat exchanger. The two series loops are connected through the gas-liquid separator/integrated intermediate heat exchanger. devices in parallel;

The heating water circuit includes the sixth interface of the seven-way valve, the second liquid cooling channel of the liquid-cooled heat exchanger motor cooling/heating circuit interface, the heater core, the water PTC heater, the heating electronic water pump and the seventh interface of the seven-way valve. A series circuit composed of interfaces.
An electric vehicle thermal management system according to claim 2, characterized in that, in the heating and dehumidification mode, the refrigerant circuit, the motor water dissipation circuit, the battery water dissipation circuit, and the heating water circuit work;

The motor water dissipation circuit includes the third interface of the seven-way valve, front drive motor, rear drive motor, front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & vehicle charger, automatic driving controller, and motor cooling A series circuit composed of the water pump and the fourth interface of the seven-way valve;

The battery hot water circuit includes the first interface of the seven-way valve, the battery cooling plate heat exchanger battery hot water circuit interface, a series circuit composed of the battery, battery water pump and the second interface of the seven-way valve;

The refrigerant circuit includes an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface, a second solenoid valve, an internal cooling condenser, evaporator, second electronic expansion valve, first electronic expansion valve and third solenoid valve;

The heating water circuit includes the sixth interface of the seven-way valve, the second liquid cooling channel of the liquid-cooled heat exchanger motor cooling/heating circuit interface, the heater core, the water PTC heater, the heating electronic water pump and the seventh interface of the seven-way valve. A series circuit composed of interfaces.
An electric vehicle thermal management system according to claim 2, characterized in that, in the passenger compartment heating mode, the refrigerant circuit, the motor water dissipation circuit, the battery water dissipation circuit, and the heating water circuit work;

The motor water dissipation circuit includes the third interface of the seven-way valve, front drive motor, rear drive motor, front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & vehicle charger, automatic driving controller, and motor cooling A series circuit composed of the water pump and the fourth interface of the seven-way valve;

The battery hot water circuit includes the first interface of the seven-way valve, the battery cooling plate heat exchanger battery hot water circuit interface, a series circuit composed of the battery, battery water pump and the second interface of the seven-way valve;

The refrigerant circuit includes an outdoor condenser, a fan, a gas-liquid separator/integrated intermediate heat exchanger, an electric compressor, a refrigerant channel of the liquid-cooled heat exchanger refrigerant circuit interface, a second solenoid valve, an internal cooling condenser, The first electronic expansion valve and the third solenoid valve; the heating water circuit includes the sixth interface of the seven-way valve, the second liquid cooling channel of the liquid cooling heat exchanger motor cooling/heating circuit interface, the warm air core, and the water PTC heater , a series circuit composed of the seventh interface of the heating electronic water pump and the seven-way valve.
An electric vehicle thermal management system according to claim 2, characterized in that, in the heat pump waste heat recovery mode, the refrigerant circuit, the motor hot water circuit, the battery hot water circuit, and the heating water circuit work; the motor hot water circuit includes The third interface of the seven-way valve, front drive motor, rear drive motor, front drive motor controller, rear drive motor controller, DCDC low voltage conversion controller & vehicle charger, automatic driving controller, motor cooling water pump and seven-way valve A series loop composed of the fourth interface;

The battery hot water circuit includes the first interface of the seven-way valve, the battery cooling plate heat exchanger battery hot water circuit interface, a series circuit composed of the battery, battery water pump and the second interface of the seven-way valve;

The refrigerant circuit includes a gas-liquid separator/integrated intermediate heat exchanger, electric compressor, refrigerant channel of the liquid-cooled heat exchanger, second solenoid valve, internal cooling condenser, and battery cooling plate heat exchanger refrigerant circuit interface and a third electronic expansion valve;

The heating water circuit includes the sixth interface of the seven-way valve, the second liquid cooling channel of the liquid-cooled heat exchanger motor cooling/heating circuit interface, the heater core, the water PTC heater, the heating electronic water pump and the seventh interface of the seven-way valve. A series circuit composed of interfaces.
An electric vehicle thermal management system according to claim 2, characterized in that:

In the independent PTC heating mode, the heating water circuit works;

The heating water circuit includes the sixth interface of the seven-way valve, the second liquid cooling channel of the liquid-cooled heat exchanger motor cooling/heating circuit interface, the heater core, the water PTC heater, the heating electronic water pump and the seventh interface of the seven-way valve. A series loop composed of interfaces;

In battery heating mode, the heating water circuit and battery water dissipation circuit work;

The battery hot water circuit includes the first interface of the seven-way valve, the battery cooling plate heat exchanger battery hot water circuit interface, a series circuit composed of the battery, battery water pump and the second interface of the seven-way valve;

The heating water circuit includes the seventh interface of the seven-way valve, the heating electronic water pump and the water PTC heater.