Technical Disassembly of Zeekr 007 Thermal Management System

I. System Architecture: Precision Design with Dual-Loop Collaboration

The thermal management system of Zeekr 007 adopts a dual-loop collaborative architecture consisting of a refrigerant loop and a water loop. The refrigerant loop includes core components such as a compressor, condenser, evaporator, expansion valve, three-way valve, and four-way valve, which realize heat transfer through refrigerant phase change. The water loop is composed of three subsystems: in-vehicle auxiliary heating, battery thermal management, and drive system cooling. Each subsystem is equipped with an independent circulating water pump, and the flow path switching is realized through 1 four-way valve and 2 three-way valves, which together form the basis for 12 operating modes. In addition, the system is also integrated with an accumulator, a water storage tank, and an HVAC system, forming a complete temperature control system.

II. Working Principle: Energy Regulation Logic of Dual Circuits

(1) Refrigerant Circuit: Four-Stage Energy Conversion

Compression stage: The compressor compresses low-temperature and low-pressure refrigerant vapor into a high-temperature and high-pressure state, with the temperature reaching over 70℃;

Condensation stage: High-temperature vapor releases heat and liquefies in the in-vehicle condenser, and the released heat can be used for cabin heating or battery preheating;

Expansion stage: The liquid refrigerant is decompressed through the expansion valve and converted into low-temperature and low-pressure wet vapor;

Evaporation stage: The wet vapor absorbs heat and evaporates in the evaporator (either inside or outside the vehicle) to achieve the refrigeration effect.

(2) Water Circuit: Intelligent Regulation with 12 Modes

The water circuit realizes flexible heat distribution through the combination of water pump start/stop and flow valve direction (2×3×2=12 modes). For example, under winter working conditions, the four-way valve switches to the “waste heat recovery” mode, and the coolant absorbs the waste heat from the battery and drive system to provide heating for the cabin, thereby improving energy utilization efficiency.

III. Typical Mode: Precise Temperature Control Logic for Dehumidification and Heating

In the dehumidification and heating mode, the system achieves dual functions through valve control: after closing the on-off valve B and expansion valve C, the high-temperature and high-pressure refrigerant first releases heat and liquefies in the in-vehicle condenser, and then branches to the in-vehicle evaporator and the external condenser for evaporation and heat absorption. The air is cooled to below the dew point by the evaporator for dehumidification, and then secondarily heated by the condenser. The refrigerant flow is precisely controlled by adjusting the opening degree of the expansion valve to realize synchronous regulation of temperature and humidity. When the heating capacity is insufficient, the auxiliary heating function of the water circuit is automatically activated to ensure cabin comfort.

IV. Analysis of Multiple Operating Modes

(1) Cooling Mode

In the cooling mode, the refrigerant circuit of the Zeekr 007 thermal management system operates as the main component. The compressor compresses the low-temperature and low-pressure refrigerant vapor into a high-temperature and high-pressure state, after which the high-temperature and high-pressure refrigerant vapor flows into the condenser. In the condenser, the refrigerant releases heat to the external environment, thus liquefying into high-pressure liquid refrigerant. Subsequently, the liquid refrigerant passes through the expansion valve, where its pressure drops sharply, transforming into low-temperature and low-pressure wet vapor. Finally, the low-temperature and low-pressure wet vapor enters the in-vehicle evaporator, where it absorbs heat from the air inside the vehicle, reducing the temperature of the in-vehicle air to achieve the cooling effect. At this point, the air near the in-vehicle evaporator is cooled and then blown into the cabin by the fan, creating a cool environment for the occupants.

(2) Heating Mode Using External Air

In this mode, the system cleverly utilizes heat from the external environment. The thermal management system absorbs heat from the outside air through a specific heat exchanger structure. The refrigerant circulates in the circuit, first being compressed into a high-temperature and high-pressure state by the compressor, then entering the heat exchanger. In the heat exchanger, the refrigerant exchanges heat with the outside air, and the heat from the outside air is transferred to the refrigerant, enabling it to carry more heat. Next, the high-temperature and high-pressure refrigerant enters the in-vehicle condenser, where it releases heat to the air inside the vehicle, achieving heating of the in-vehicle air. Meanwhile, to ensure heating efficiency and stability, the water circuit may also be involved to assist in regulating heat distribution. For example, when the outside air temperature is low and the heat absorbed by the refrigerant from the outside alone is insufficient, the auxiliary heating system in the water circuit may start up, working together with the refrigerant circuit to provide sufficient heat for the interior of the vehicle.

(3) Heating Mode Using Waste Heat Recovery

The Zeekr 007 is equipped with an efficient waste heat recovery mechanism. During vehicle operation, components such as the drive system and battery generate a large amount of waste heat. The water circuit of the thermal management system collects this waste heat; for instance, the heat generated by the battery is absorbed by the coolant, causing the coolant temperature to rise. The coolant carrying the waste heat flows into the heat exchanger, where heat exchange occurs with the refrigerant circuit. After absorbing the waste heat from the coolant, the refrigerant temperature rises and enters the in-vehicle condenser, releasing the heat into the vehicle interior to heat the cabin air. At the same time, the waste heat generated by the drive system can also be recovered and utilized in a similar manner. This mode makes full use of the waste heat produced during vehicle operation, greatly improving energy utilization efficiency and reducing additional energy consumption.

(4) Cooler Function for Cooling Water

The cooler plays a crucial role in the thermal management system. When components such as the battery and drive system reach excessively high temperatures, the temperature of the coolant in the water circuit rises accordingly. At this point, the cooler starts to operate, and the coolant flows into the cooler to exchange heat with the external environment or the refrigerant. If heat exchange is performed with the external environment, the cooler dissipates the heat from the coolant into the outside air through its own heat-dissipating structure, reducing the coolant temperature. The cooled coolant then returns to components such as the battery and drive system to continue the cooling process. If heat exchange is conducted with the refrigerant, the high-temperature coolant and low-temperature and low-pressure refrigerant transfer heat in the heat exchanger. The refrigerant absorbs heat from the coolant and evaporates, causing the coolant temperature to drop, thereby effectively cooling components such as the battery and drive system and ensuring their stable operation within an appropriate temperature range.

V. Technical Advantages: Functional Integration and Energy Efficiency Upgrade

1. Multi-functional integration: The system integrates functions such as dehumidification and heating, refrigeration, and waste heat recovery to meet the needs of all working conditions;

2. Efficient refrigeration cycle: Compared with competitors, it realizes more air conditioning modes, and the refrigeration efficiency is significantly improved;

3. Complex circuit design: Multiple valves are controlled collaboratively to ensure precise distribution of refrigerant and coolant flow;

4. Intelligent control strategy: Dynamically adjust 12 operating modes based on sensor data to achieve full-scenario adaptive temperature control.