An integrated cooling system for the powertrain of a large desert transport vehicle

Abstract

This invention discloses an integrated cooling system for the powertrain of a large desert transport vehicle, comprising two parts: an engine integrated cooling module and a transfer case cooling module. The engine integrated cooling module includes a main cooling module and a secondary cooling module. The main cooling module is installed in a high-level gap between the cab and the cargo box, integrating a main radiator, intercooler, and fan to cool the engine and intercooler. The secondary cooling module is installed on the side of the vehicle body to cool the transmission. The transfer case cooling module is installed in front of the transfer case and includes an oil cooler and an electric fan. This invention utilizes the space between the cab and the cargo box to concentrate the heat dissipation of major components such as the engine, transmission, and intercooler at a high level. This integrated design not only combines some functional piping, but also provides excellent ventilation, avoids water wading issues, and meets the cooling requirements of large vehicles.

Description

Technical Field

[0001] This invention relates to automotive cooling systems, and more particularly to an integrated powertrain cooling system suitable for desert transport vehicles. Background Technology

[0002] Desert transport vehicles require off-road capabilities as well as strong load-bearing capacity. For 100T-class large desert transport vehicles, the power performance requirements are extremely high, the power system structure is very special, and the power output is relatively large. A long-range drive connection is needed between the engine and the transmission. Furthermore, desert transport vehicles frequently travel on desolate, uninhabited roads, necessitating an increased number of drive wheels. Therefore, a transfer case is configured to function as an auxiliary transmission. Long driveshafts are required to connect the transmission and the transfer case, as well as between the transfer case and each axle.

[0003] The cooling of a powertrain system requires six functions: engine cooling, transmission cooling, retarder cooling, intercooler cooling, hydraulic oil cooling, and transfer case cooling. This necessitates a system with robust cooling capabilities. The sheer size of the powertrain makes standardized cooling system configuration difficult. Engine cooling is paramount; the engine cooling system ensures optimal engine temperature operation under all conditions, achieving ideal power output and good fuel economy. Without a cooling system, the engine cannot function properly. The transfer case also requires enhanced cooling. Furthermore, the system must exhibit linear cooling capacity that changes linearly with the temperature of the cooling medium, and possess self-protection capabilities in the event of no signal input or power failure. Additionally, for special road conditions, the vehicle chassis should not be too low, preventing the cooling system from being located under the vehicle. Summary of the Invention

[0004] To address the current situation, this invention provides an integrated cooling system for the powertrain of a 100-ton-class large desert transport vehicle. This system employs a modular design, integrating five major functions: engine cooling, transmission cooling, retarder cooling, intercooler cooling, and hydraulic oil cooling. Transfer case cooling is provided independently. This improved cooling system allows large transport vehicles to utilize high-power engines, transmissions, and transfer cases, enabling them to meet the demands of heavy-load transport operations.

[0005] The technical solution adopted in this invention is as follows: A powertrain integrated cooling system for a large desert transport vehicle, characterized by comprising two parts: an engine integrated cooling module and a transfer case cooling module, wherein... The engine integrated cooling module includes a main cooling module and a secondary cooling module. The main heat dissipation module is installed in the high gap between the cab and the cargo box. The main heat dissipation module integrates the main radiator, intercooler and fan. The main radiator, intercooler and fan are arranged side by side. The water in the engine water jacket circulates through the main radiator and the gas in the turbocharger circulates through the intercooler. The auxiliary cooling module is installed on the side of the vehicle body and is equipped with an auxiliary radiator. Water in the engine water jacket circulates through the auxiliary radiator, and oil in the transmission circulates through the auxiliary radiator.

[0006] Furthermore, the main heat dissipation module also includes a hydraulic oil tank.

[0007] Furthermore, a controller is installed on the fan, a water temperature sensor is installed on the main radiator, an air temperature sensor is installed on the intercooler, and an oil temperature sensor is installed on the hydraulic oil tank. When the value measured by any of the sensors exceeds the threshold, the controller controls the fan to start.

[0008] Furthermore, the auxiliary radiator is an oil-water heat exchanger, wherein the water is the water in the engine water jacket, and the oil is the oil in the transmission.

[0009] Furthermore, the transfer case cooling module is separately configured from the engine integrated cooling module.

[0010] Furthermore, the transfer case cooling module consists of an oil cooler and an electric fan. The transfer case and the oil cooler form an inlet and outlet oil circulation system, and the electric fan is installed on the side of the oil cooler.

[0011] Furthermore, a temperature sensor is installed on the oil cooler, and the electronic fan is controlled by a controller. The temperature sensor transmits a sensing signal to the controller. When the temperature sensing signal reaches a certain value, the controller controls the electronic fan to accelerate. When the temperature sensor does not transmit a sensing signal to the controller, the electronic fan operates at its maximum speed.

[0012] Furthermore, a water wading sensor is installed at the bottom of the transfer case heat dissipation module. The water wading sensor is electrically connected to the controller of the electronic fan. When the water wading sensor detects that the water level has reached a certain value, the controller controls the electronic fan to stop abruptly.

[0013] Compared with existing technologies, this invention addresses the complex structures, numerous pipelines, and enlarged component specifications of large transport vehicles exceeding 100 tons, especially special transport vehicles used in deserts and wading. For power system cooling, considering the difficulties in under-vehicle layout and wading challenges, it utilizes the space between the cab and the cargo box to create a mounting frame. This high-mounted frame concentrates the cooling of major components such as the engine, transmission, and intercooler, employing an integrated modular design. This solution not only merges some functional pipelines but also reduces pipeline length. The integrated installation also reduces the number of cooling components, and the good ventilation further enhances cooling. The high-mounted installation avoids wading issues, enabling the vehicle to meet heavy-load transport requirements. Testing has verified that the actual total maximum cooling capacity of the vehicle equipped with a DC16-317A and 6620SP automatic transmission is 433 kW, with a turbocharged intercooler intake and an intercooler cooling capacity of 100 kW, which is sufficient to meet cooling requirements. Furthermore, since the transfer case is relatively far from the engine cooling module and not suitable for centralized cooling, the invention incorporates additional cooling measures for the transfer case. An electric fan and oil cooler are installed at the front end of the transfer case. The transfer case's oil passages are cooled by the oil cooler, and the electric fan starts, stops, and accelerates according to the oil temperature. A wading sensor is also included to prevent the fan from getting wet. In summary, the integrated cooling solution of this invention is unprecedented and has practical application value in the field. Attached Figure Description

[0014] The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of the invention.

[0015] Figure 1 Schematic diagram of the cooling principle of the integrated heat dissipation module for the engine; Figure 2 Main view of the structural layout of the engine integrated cooling module; Figure 3 Top view of the structural layout of the engine integrated cooling module; Figure 4 Installation diagram of the main cooling module fan and hydraulic oil tank; Figure 5 Installation diagram of the main heat dissipation module radiator and intercooler; Figure 6 Side view of the main heat dissipation module installation; Figure 7 Main view of the transfer case cooling module installation; Figure 8 Top view of the transfer case cooling module installation. Detailed Implementation

[0016] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. Those skilled in the art should understand that the following embodiments are not the only limitations on the technical solutions of the present invention. Any equivalent transformations or modifications made under the spirit and essence of the technical solutions of the present invention should be considered as falling within the protection scope of the present invention.

[0017] The cooling system of the present invention is for power cooling of a 100-ton desert transport vehicle, comprising two parts: an integrated engine cooling module and a transfer case cooling module. The integrated engine cooling module includes cooling for the engine, transmission, retarder, and intercooler.

[0018] (a) Engine integrated cooling module The cooling system of this invention is for the power cooling of a 100-ton desert transport vehicle. The engine system cooling principle is as follows: Figure 1 As shown, the structural layout is as follows Figure 2 , 3 As shown, the integrated engine cooling module includes a main cooling module 1 and an auxiliary cooling module 2, serving the engine's large and small cooling loop systems respectively. The engine water jacket 3 is connected to both the large and small cooling loop systems. In the large cooling loop system, the main cooling module 1, auxiliary cooling module 2, and engine water jacket 3 are connected in series. The main cooling module 1 cools the engine and also the auxiliary cooling module 2. The transmission 4 (including the retarder) oil pipes pass through the auxiliary cooling module 2, which also cools the transmission 4. In the small cooling loop system, the auxiliary cooling module 2 and engine water jacket 3 are connected in series. The auxiliary cooling module 2 cools the engine and also the transmission 4 oil pipes pass through it, which also cools the transmission 4. A thermostat 5 controls the switching between the large and small cooling loop systems. When the thermostat senses a temperature below a preset value, the small loop is activated; when the temperature exceeds the preset value, the large loop is activated.

[0019] Therefore, considering the rationality of the spatial layout, this invention adopts an integrated main heat dissipation module 1, which can simultaneously dissipate heat for the engine, transmission, retarder, intercooler, and hydraulic oil. The main heat dissipation module 1 includes: a main radiator 11, an intercooler 12, a fan 13, and a hydraulic oil tank 14, as shown below. Figure 4 , 5 As shown. The main radiator 11 provides heat dissipation for the aforementioned engine large-circulation cooling system, and the intercooler 12 provides circulating cooling gas for the engine turbocharger 6; the fan 13 activates air cooling to dissipate heat from the main radiator module 11 and the intercooler 12 when the temperature of the main radiator module 1 reaches a certain level; the hydraulic oil tank 14 dissipates heat from the hydraulic system oil. The main radiator 11 uses an oil-water heat exchanger, and the fan 13 is an intake fan.

[0020] This invention innovatively integrates the cooling of the engine, transmission, intercooler, and hydraulic oil into a single unit, reducing the number of heat dissipation components. Furthermore, to accommodate this integrated design and ensure sufficient installation space for the main cooling module 1, the invention innovatively positions it in a high-level gap between the cab and the cargo box, using a mounting bracket 7. This also saves space, as there is no frontal draft at this location; air is drawn in from both sides of the cab, passes through the radiator, and is then dissipated through the cargo box, resulting in excellent ventilation. Additionally, positioning the main cooling module 1 in this high-level gap allows for the relocation of the cooling system piping from the undercarriage to the upper part of the vehicle, and this high-level installation avoids the problem of engine water ingress. Moreover, by integrating the main radiator 11 and intercooler 12, the invention eliminates the need for the cooling fan at the front of the turbocharger 6, also preventing fan water ingress. These are features not found in other vehicles.

[0021] The main radiator 11, intercooler 12, fan 13, and hydraulic oil tank 14 are installed in the mounting bracket 7. The main radiator 11, intercooler 12, and fan 13 are integrated into a single unit, arranged side-by-side, ideally with the intercooler in the middle. This allows for cooling from both the main radiator 11 and the fan 13. The hydraulic oil tank 14 is installed on one side. This invention intelligently controls the cooling system by rationally controlling the start-up timing and speed of the fan 13, thus saving energy. Figure 6 As shown, a controller 15 is installed on the fan, a water temperature sensor is installed on the main radiator, an air temperature sensor is installed on the intercooler, and an oil temperature sensor is installed on the hydraulic oil tank. The controller takes the values ​​of the water temperature sensor, air temperature sensor, and oil temperature sensor and performs a weighted calculation. When the temperature of any sensor exceeds the preset value, the controller outputs a control signal to the fan control valve block to control the fan to turn on and increase its speed as the temperature rises, thus preventing the heat dissipation module from overheating. If the temperature of any sensor does not exceed the preset value, the fan idles.

[0022] like Figure 1 As shown, the auxiliary cooling module 2 provides low-temperature cooling when the engine temperature has not reached the high-temperature limit. It is located in any open space on the side of the vehicle body or the front of the vehicle. The auxiliary cooling module 2 includes an auxiliary radiator 21, which is an oil-water heat exchanger that uses the water in the engine water jacket and the transmission oil to cool each other. During the initial start-up of the vehicle, the engine needs to be preheated. At this time, the temperature of the transmission oil is used to raise the temperature of the engine water jacket. After the engine water jacket temperature rises and enters the large circulation cooling, the water then cools the transmission oil.

[0023] Therefore, the engine integrated cooling module only uses two cooling modules, the main and auxiliary cooling modules are connected in series, which saves space, reduces the number of components, reduces the number of pipes, and greatly improves the heat dissipation. The high-position installation also solves the problem of engine water immersion.

[0024] (ii) Transfer case cooling module This invention provides auxiliary heat dissipation for the transfer case, such as... Figures 7-8 As shown, a front-mounted transfer case cooling module, consisting of an oil cooler 8 and an electric fan 9, is installed on the side of the vehicle frame. The oil inlet and outlet pipes of the transfer case 10 are connected in series with the oil cooler 8, forming a loop through the oil cooler 8, which contains cooling oil. A duct is installed on the side of the oil cooler 8, and the electric fan 9 is mounted on the side of the duct. A temperature sensor is installed on the oil cooler 8, and the electric fan 9 is controlled by a controller. The temperature sensor transmits a sensing signal to the controller, and the electric fan 9 increases its speed as the oil temperature rises, thereby realizing the real-time variation of heat dissipation power. The speed control strategy is as follows: the controller takes the sensor signal, and when the sensor temperature reaches the control threshold, the controller outputs a PWM control signal to the electric fan driver, thereby controlling the fan speed to increase accordingly as the temperature rises.

[0025] Furthermore, since the transfer case cooling module is mounted on the side of the vehicle body at a relatively low position, posing a risk of wading, a wading control strategy is also implemented for the fan. A wading sensor (also called a water level sensor) is installed at the bottom of the transfer case cooling module. The wading sensor is electrically connected to the controller. When the wading sensor detects that the water level has reached a certain limit, the controller outputs a PWM control signal with a ratio of "zero" to the electric fan, causing the electric fan to stop abruptly. Once the fan is out of the water, the controller outputs a normal PWM control signal to the electric fan driver, and the fan resumes operation. When the sensor has a fault signal and there is no feedback, the controller controls the electric fan to run at its maximum speed. In the event of a fan malfunction, the controller uploads fault information to the instrument panel, which displays a fan malfunction as a warning. In terms of priority, wading control has the highest priority, fault control takes precedence over speed control, and speed control has the lowest priority.

[0026] In summary, by modularizing the heat dissipation of the power system, this invention not only makes the heat dissipation system more compact, but also reduces many redundant components and pipes, achieves centralized control, and avoids water-related problems.

Claims

1. A powertrain integrated heat sink system for a large desert transport vehicle, characterized by: It consists of two parts: an integrated engine cooling module and a transfer case cooling module. The engine integrated cooling module includes a main cooling module and a secondary cooling module. The main cooling module is installed in the high gap between the cab and the cargo box. The main cooling module integrates the main radiator, intercooler, hydraulic oil tank and fan. The main radiator, intercooler and fan are arranged side by side. The water in the engine water jacket circulates through the main radiator and the gas in the turbocharger circulates through the intercooler. The hydraulic oil tank is used for cooling the oil in the hydraulic system, the main radiator is an oil-water heat exchanger, and the fan is a suction fan. A controller is installed on the fan, a water temperature sensor is installed on the main radiator, an air temperature sensor is installed on the intercooler, and an oil temperature sensor is installed on the hydraulic oil tank. When the value measured by any of the sensors exceeds the threshold, the controller controls the fan to start. The auxiliary cooling module is installed on the side of the vehicle body and is equipped with an auxiliary radiator, which is an oil-water heat exchanger. The water is water from the engine water jacket and the oil is oil from the transmission. The water from the engine water jacket circulates through the auxiliary radiator, and the oil from the transmission circulates through the auxiliary radiator. The transfer case cooling module is separately installed from the engine integrated cooling module. The transfer case cooling module consists of an oil cooler and an electric fan. The transfer case and the oil cooler form an inlet and outlet oil circulation. The electric fan is installed on the side of the oil cooler. A temperature sensor is installed on the oil cooler. The electric fan is controlled by a controller. The temperature sensor transmits a sensing signal to the controller. When the temperature sensing signal reaches a certain value, the controller controls the electric fan to accelerate. When the temperature sensor does not transmit a sensing signal to the controller, the electric fan operates at its highest speed. A water wading sensor is installed at the bottom of the transfer case heat dissipation module. The water wading sensor is electrically connected to the controller of the electric fan. When the water wading sensor detects that the water level has reached a certain value, the controller controls the electric fan to stop suddenly.

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