Turbine structure vehicle air cooling device

Abstract

The present application relates to a kind of turbine structure vehicle air-cooled device, the air-cooled device includes motor, turbine, flow channel, electronic control unit, filter screen, front shell and rear shell, motor drives turbine rotation, generates negative pressure zone at turbine air inlet, under the action of atmospheric pressure, air is pressed into turbine, after flowing through turbine blade, from turbine air outlet, air-cooled radiator is blown.The present application abandons nylon fan blade structure and adopts new structure of built-in metal turbine, when the blade of turbine high-speed rotation, accelerated air can pass through unique flow channel, for the cooling of radiator;Compared with traditional nylon fan blade, metal turbine can promote the upper limit of blade speed, suitable for high-torque vehicle platform;Unique annular flow channel structure, adopt hollow design, plus filter screen, can avoid the accumulation of dust and other impurities, thereby prolong the service life of the present application.

Description

Technical Field

[0001] This invention relates to the cooling system of new energy commercial vehicles, specifically to a turbine-structured air-cooled device for vehicles. Background Technology

[0002] In the field of new energy commercial vehicles, electric drive systems and battery packs often require cooling due to their high heat generation. Traditional cooling systems mainly consist of electric fans and radiators. The electric fan, driven by a brushless motor, rotates nylon blades, creating an airflow that generates an atmospheric pressure difference across the radiator, thus forming airflow that acts on the radiator surface. The radiator primarily cools by lowering the temperature of the coolant inside the inlet and outlet, combined with the airflow from the electric fan, which removes a significant amount of excess heat.

[0003] With the development of new energy commercial vehicles, the output torque of electric drive systems is increasing, and the size of power supply battery packs is also increasing. Consequently, the size of radiators is also increasing, and the requirements for cooling systems are gradually rising. Currently, for radiators with high heat dissipation requirements, either large-diameter electric fans are used, or multiple small-diameter electric fans are connected in series to achieve cooling. Large-diameter fan blades mean greater noise during rotation, and higher energy consumption for the brushless motor. Large-diameter electric fans are also heavier, generating greater bending moments during arrangement, resulting in greater imbalance and vibration during blade rotation, which can affect driver safety and ride comfort. The series design of small-diameter electric fans often causes internal airflow interference and turbulence, resulting in lower overall airflow efficiency and additional energy consumption.

[0004] With the deployment of new energy vehicles in the commercial vehicle sector and the national requirements for carbon emissions and compliance, new energy commercial vehicles face the challenge of high performance and low emissions. The key lies in the cooling system: on the one hand, the cooling system needs continuous improvement in cooling capacity to meet the challenges of high vehicle performance; on the other hand, as the cooling system is the largest energy-consuming unit in the vehicle, it also needs continuous optimization to reduce energy consumption. The point of maximum power consumption in the cooling system is the electric fan. Currently, most mainstream electric fans use nylon materials. Due to nylon's strength limitations, the maximum fan speed is restricted, preventing high-speed, long-term operation to avoid cracking and damage. Large-diameter fans constantly rub against the air during rotation, resulting in high unnecessary heat loss and low efficiency. When the vehicle operates in harsh environments, both suction and blowing electric fans accumulate dust on the blades, affecting fan imbalance, increasing noise, causing discomfort for end users, and in severe cases, affecting fan performance and even reducing its lifespan. Currently, matching electric fans with vehicles requires additional control equipment. Due to different fan types and different design philosophies of equipment developers, the corresponding control equipment varies greatly, hindering widespread adoption. Summary of the Invention

[0005] To address the above problems, this invention provides a turbine-structured automotive air-cooling device. This device uses a bladeless turbine structure and adopts a blowing mode, which improves heat dissipation capacity while reducing noise.

[0006] The technical solution adopted in this invention is: a turbine-structured automotive air-cooling device, fixedly installed at the rear end of a radiator, used to blow air onto the radiator. Its features include: a motor, a turbine, a flow channel, an electronic control unit, a front housing, and a rear housing. Both the front and rear housings are bolted to the flow channel. The electronic control unit is located inside the rear housing. The motor and turbine are positioned between the front and rear housings. The motor is fixed to the rear housing, and the turbine is fixedly connected to the motor. The motor drives the turbine to rotate, creating a negative pressure zone at the turbine inlet. Under atmospheric pressure, air is forced into the turbine, flows through the turbine's long and short blades, and exits from the turbine outlet, thus cooling the radiator.

[0007] Preferably, the turbine includes a blade base plate, long blades, and short blades, with the long blades and short blades evenly spaced on the blade base plate.

[0008] Furthermore, the leaf angle θ of the long and short blades is 25° to 38°.

[0009] Furthermore, the length difference Δl between the long blade and the short blade is 1 to 15 mm.

[0010] Preferably, the flow channel includes a flow field sealing structure, a connecting channel structure, and an annular multiplier structure. The distance between the flow field sealing structure and the turbine blade tip is 1-3 mm, which is used to increase the air pressure difference between the turbine inlet and the turbine outlet. The connecting channel structure connects the flow field sealing structure and the annular multiplier structure, and plays a role in guiding airflow. The chamfer between the connecting channel structure and the annular multiplier structure is R10-R20. The annular multiplier structure multiplies the air pressure of the incoming air based on the Coanda effect and directs the air towards the radiator. The annular multiplier structure has a teardrop-shaped structure at the outlet for adsorbing air.

[0011] Preferably, the electronic control unit reads the vehicle's thermal signal through the CAN bus and outputs a PWM signal with the required speed according to the internal algorithm to drive the motor to rotate and drive the turbine to move; the flow sensor feeds back the turbine's flow rate to the electronic control unit in real time and continuously corrects the required speed; the wiring harness and the flow sensor wiring harness are connected to the electronic control unit through the rear housing and fixed to the wiring harness fixing buckle on the outside of the flow channel along the rear housing.

[0012] Preferably, a circular filter screen is arranged at the turbine inlet to block dust and large particles of stone to protect the turbine blades; the filter screen thickness is 0.5-1mm, and the diameter of the filter screen needs to match the diameter of the turbine inlet; the filter screen is made of metal, preferably carbon steel, tin bronze or stainless steel, and can be formed by stamping or weaving, and the number of meshes with a diameter greater than 1mm in the filter screen does not exceed 5%; the surface of the filter screen is smooth and it is fixed to the flow channel with bolts.

[0013] The beneficial effects of this invention are as follows: This invention abandons the nylon fan blade structure and adopts a novel structure with an internal metal turbine. When the turbine blades rotate at high speed, the accelerated air can pass through a unique flow channel for radiator cooling. The turbine in this invention is made of metal, which, compared to traditional nylon fan blades, can increase the upper limit of blade speed, making it suitable for high-torque vehicle platforms. The unique annular flow channel structure, with its hollow design and filter, can prevent the accumulation of dust and other impurities, thereby extending the service life of this invention. This invention has an internal control unit, which ensures rapid response and high precision in turbine blade speed adjustment under most operating conditions, reducing the energy consumption of the cooling system. This invention has CAN communication capabilities, allowing it to interface with the entire vehicle for data interaction, facilitating data collection and feedback of the cooling device's status. Compared to existing fans, it has the following advantages:

[0014] 1. Based on the Coanda effect, this invention designs an axial annular flow channel. When the air moves inside the flow channel, it will form a laminar flow phenomenon. Compared with the traditional channelless design of fans, it reduces the disordered movement of cooling air, thus reducing turbulent noise. At the same time, due to the laminar flow phenomenon of cooling air, the imbalance of the entire air-cooling device is reduced, the vibration is reduced, and the end-customer experience is optimized.

[0015] 2. The turbine in this invention is made of steel alloy, which can withstand higher speeds. Therefore, it provides stronger heat dissipation capacity compared to traditional nylon fans. At the same time, because the metal is stronger, the lifespan of the fan is also greatly improved.

[0016] 3. Because the turbine in this invention has a higher rotational speed and a smaller size than the fan, and the flow channel diameter can be adjusted according to the heat dissipation requirements, the entire air-cooling device occupies less space and is easier to arrange.

[0017] 4. The turbine in this invention has a small air intake area, which reduces the probability of dust and small particles entering. Combined with the filter screen, it can effectively reduce the impact of dust and impurities, thus improving the reliability of this invention.

[0018] 5. This invention has a built-in electronic control unit that forms a closed-loop control with the help of a flow sensor, which can accurately and quickly control the turbine speed. At the same time, it has reserved a CAN module for the whole vehicle, which can communicate with the whole vehicle ECU in the future, and has better scalability and platformability.

[0019] 6. Compared with traditional fans, this invention reduces the design of the fan shield, thereby reducing scratches between the fan and the fan shield during assembly, and improving the reliability and cost of the heat dissipation system. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the air-cooling device of the present invention mounted on a radiator;

[0021] Figure 2-3 This is a schematic diagram of the air-cooling device structure of the present invention;

[0022] Figure 4 This is a cross-sectional schematic diagram of the air-cooling device of the present invention;

[0023] Figure 5 This is a schematic diagram of a turbine structure;

[0024] Figure 6 This is a schematic diagram of a turbine blade structure;

[0025] Figure 7 This is a cross-sectional view of a turbine blade;

[0026] Figure 8 A schematic diagram of the interior of the housing after the electronic control unit is installed;

[0027] Figure 9 This is a schematic diagram showing the wiring harness being fixed to the rear housing.

[0028] Figure 10 This is the control logic diagram of the present invention;

[0029] The components include: 1. Radiator; 2. Air-cooled device; 3. Motor; 31. Motor spindle; 32. Motor wiring harness; 4. Turbine; 41. Turbine mounting hole; 42. Turbine air inlet; 43. Turbine air outlet; 44. Blade base plate; 45. Long blade; 451. Suction surface; 452. Pressure surface; 46. Short blade; 47. Turbine blade tip; 5. Flow channel; 51. Flow field sealing structure; 52. Connecting channel structure; 53. Annular multiplication structure; 54. Connecting chamfer; 56. Flow channel air outlet; 57. Teardrop-shaped structure; 58. Inner wall of flow channel outlet; 59. Fixing structure; 511. Wiring harness fixing buckle; 6. Electrical control unit; 61. Flow sensor wiring harness; 62. Wiring harness; 63. Flow sensor; 7. Filter screen; 8. Front housing; 9. Rear housing; 91. Rear housing reinforcing rib; 92. Outer surface of rear housing; 93. Motor fixing structure. Detailed Implementation

[0030] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0031] like Figure 1 As shown, a turbine-structured automotive air-cooling device 2 of the present invention is installed at the rear end of the radiator 1 for blowing air to cool the radiator 1, and is fixed to the radiator 1 by screws.

[0032] Combination Figure 2-4 As shown, the turbine-structured automotive air-cooling device of the present invention includes a motor 3, a turbine 4, a flow channel 5, an electronic control unit 6, a front housing 8, and a rear housing 9. The front housing 8 and the rear housing 9 are both fixed to the flow channel 5 by bolts. The electronic control unit 6 is arranged inside the rear housing 9. The motor 3 and the turbine 4 are arranged between the front housing 8 and the rear housing 9. The motor 3 is fixed to the rear housing 9, and the turbine 4 is fixedly connected to the motor 3. The motor 3 drives the turbine 4 to rotate, generating a negative pressure zone at the turbine air inlet 42. Under the action of atmospheric pressure, air is forced into the turbine 4, flows through the turbine long blades 45 and short blades 46, and flows out from the turbine air outlet 43 to cool the radiator 1.

[0033] Motor 3 is a three-phase brushless motor, fixed on the rear housing 9. Its voltage range is 400V to 800V, and its rated power is 5 to 15KW. The motor spindle 31 has a diameter of Φ31mm and is fixedly connected to the turbine mounting hole 41 via a spline, thus fixing motor 3 and turbine 4 together. When turbine 4 rotates at high speed, the spline prevents slippage between turbine 4 and motor spindle 31.

[0034] Combination Figure 5-6 As shown, the turbine 4 is made of metal and adopts a crownless structure, including a blade base plate 44, long blades 45 and short blades 46. The long blades 45 and short blades 46 are evenly spaced on the blade base plate 44. The long blades 45 include a suction surface 451 and a pressure surface 452.

[0035] The turbine blades consist of 8 to 10 sets of long blades 45 and short blades 46, evenly arranged on the blade base plate 44, located between the flow field sealing structure 51 of the flow channel 5 and the blade base plate 44. The flow field sealing structure 51 of the flow channel 5 draws external air into the suction surface 451 of the turbine 4 along the axial direction of the turbine inlet 42. The external air is guided by the pressure surface 452 and discharged along the annular structure to the turbine inlet 43. Compared with the traditional "open" or "semi-open" design, the turbine's flow rate and efficiency are improved.

[0036] Combination Figure 7 As shown, the blade bend angle θ of the turbine blades is between 25° and 38°; each set of blades adopts a double-blade structure with high and low differences, which can effectively reduce the noise generated by turbulence at the inlet; the difference in length Δl between the front and rear blades is between 10 and 15 mm. (As shown in the table below: θ = 32° to 38°, Δl = 10° to 12°, the turbine performance is optimal).

[0037]

[0038] The thickness of turbine blades ranges from 1 to 3 mm, and the specific thickness can be varied depending on parameters such as turbine flow rate and efficiency.

[0039] like Figure 4 As shown, the material of the flow channel 5 is nylon, and it can be divided into three structural parts: flow field sealing structure 51, connecting channel structure 52, and annular multiplication structure 53.

[0040] The turbine flow field seal 51 prevents air leakage and increases the pressure difference between the turbine inlet 42 and the turbine outlet 43. The thickness of the turbine flow field seal 51 is 2-5 mm, and ribs can be added to the outer part to increase rigidity if necessary. The distance between the turbine flow field seal 51 and the turbine blade tip 47 is 1-3 mm, and the clearance size is larger when the turbine speed is higher.

[0041] The connecting channel structure 52 serves both as a support and as an air guide. The connecting channel structure 52 is located between the annular multiplier structure 53 and the flow field sealing structure 51. The chamfer 0504 connecting the connecting channel structure 52 and the annular multiplier structure 53 has a size of R10 to R20. The thickness of the connecting channel structure 52 is 3 to 5 mm, and the cross-section is a polygonal structure, which can effectively support the overall structure of the present invention.

[0042] Based on the Coanda effect, the annular multiplier structure 53 can multiply the air pressure of the incoming air, pressurize it and blow it toward the radiator 1. The thickness of the annular multiplier structure 53 is 5 to 10 mm.

[0043] A teardrop-shaped structure 57 is provided at the air outlet 56 of the annular multiplication structure 53, which can effectively adsorb the flowing air and flow out at high speed and stably along the inner wall 58 of the outlet.

[0044] The outer side of the annular multiplication structure 53 is evenly distributed with 3 to 6 fixing structures 59, the thickness of the fixing structure 59 is 20 to 30 mm; the fixing structure 59 is provided with waist holes for fixed connection with the radiator 1, and the bolt passes through the waist holes on the fixing structure 59 to fix the air-cooling device 2 to the radiator 1. Rubber pads can be added at the fixing point to reduce rigid impact and friction vibration.

[0045] As attached Figure 8-10 As shown, the electronic control unit 6 can read the vehicle's thermal signals via the CAN bus and, based on its internal algorithm, output a PWM signal with the required rotational speed to drive the motor 3 to rotate, thereby influencing the turbine 4. The flow sensor 63 can provide real-time feedback of the turbine 4's flow rate to the electronic control unit 6 to continuously adjust the required rotational speed. This closed-loop control can quickly and accurately control the turbine 4's rotational speed. The electronic control unit 6 transmits various signals from the vehicle's thermal system to the motor 3 via the motor wiring harness 62 and the internal flow sensor 63, which in turn sends speed commands to the motor 3 via the flow sensor wiring harness 61, thereby driving the turbine 4 to rotate and adjusting the airflow. The electronic control unit 6 has an intelligent control module that, through communication with the vehicle's ECU, can read real-time parameters of the vehicle's thermal system, including the BMS and electric drive system, and then control the required flow rate of the radiator via algorithms, improving the efficiency of the motor 3 and the air-cooling device 2.

[0046] The electronic control unit 6 is located inside the rear housing 9. The motor wiring harness 32 and the flow sensor wiring harness 61 are connected to the electronic control unit 6 through the rear housing 9 and are fixed to the wiring harness fixing buckle 511 on the outside of the flow channel 5 along the rear housing 9.

[0047] Filter 7 (circular filter) is located at the turbine inlet 42 to block dust and large particles of stone, thus protecting the turbine blades. Filter 7 has a thickness of 0.5–1 mm, and its diameter must match the diameter of the turbine inlet 42. Filter 7 is made of metal, preferably carbon steel, tin bronze, or stainless steel, and can be formed by stamping or weaving. The number of mesh openings larger than 1 mm in diameter in filter 7 does not exceed 5%. Filter 7 has a smooth surface and is bolted to the flow field sealing structure.

[0048] In this embodiment, both the front housing 8 and the rear housing 9 are made of nylon and are injection molded. The front housing 8 has a streamlined design and a thickness of 1-2 mm, which serves to guide airflow and protect the main structure of the flow channel 5. The rear housing 9 is used to fix the motor 3, wiring harness 62, electronic control unit 6, and flow sensor 63. The wiring harness 62 extending from the rear housing 9 is fixed to a wiring harness fixing clip 511 on the outside of the flow channel 5. The wiring harness fixing clip 511 and the wiring harness 62 are interference-fitted to prevent the wiring harness from loosening and vibrating. The size of the wiring harness fixing clip 511 is 0.5-1 mm smaller than that of the wiring harness 62.

[0049] The rear housing 9 has internal reinforcing ribs 91 to improve its rigidity. Air flowing out of the air outlet 56 flows along the surface of the rear housing 9. The outer surface 92 of the rear housing adopts a streamlined structure, and a fixed motor structure 93 is located at the center of the rear housing 9, which increases the heat dissipation area of ​​the motor 3 and improves the reliability of the motor 03.

[0050] The foregoing has shown and described the basic principles and main structural features of the present invention. The present invention is not limited to the above examples; various changes and modifications can be made without departing from the spirit and scope of the invention, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A turbine-structured automotive air-cooling device, fixedly installed at the rear end of a radiator, for blowing air onto the radiator, characterized in that: It includes motor, turbine, flow channel, electric control unit, filter screen, front shell and rear shell, the materials of the front shell and the rear shell are nylon, and they are fixed on the flow channel by bolts; the electric control unit is arranged inside the rear shell, the motor and the turbine are arranged between the front shell and the rear shell, the motor is fixed on the rear shell, and the turbine is made of metal material and is fixedly connected with the motor; the motor drives the turbine to rotate, a negative pressure area is generated at the turbine air inlet, air is pressed into the turbine under the action of atmospheric pressure, flows through the turbine blades and then flows out from the turbine air outlet to blow and cool the radiator; the turbine includes blade bottom plate, long blades and short blades, the long blades and the short blades are uniformly arranged on the blade bottom plate; The flow channel includes flow field sealing structure, connecting channel structure and annular multiplication structure, the turbine flow field sealing can prevent air leakage and improve the air pressure difference between the turbine air inlet and the turbine air outlet, the thickness of the turbine flow field sealing is 2-5 mm, and the distance between the turbine flow field sealing and the turbine blade tip is 1-3 mm; the greater the turbine speed is, the greater the gap size is; The connecting channel structure plays a supporting role and an air guiding role, is located between the annular multiplication structure and the flow field sealing structure, and has a connecting chamfer size of R10-R20, and a thickness of 3-5 mm and a polygonal structure in cross section; The annular multiplication structure realizes air pressure multiplication function for the flowing air, pressurizes and blows the air to the radiator, and has a thickness of 5-10 mm; a water drop-shaped structure is arranged at the flow channel air outlet of the annular multiplication structure, effectively absorbs the flowing air and flows out along the inner wall of the flow channel outlet. Based on the Coanda effect, the wind forms a laminar flow phenomenon when moving in the flow channel, reduces the disordered movement of the cooling wind and reduces the turbulent noise.

2. The turbo-structure vehicle air cooling device according to claim 1, characterized in that: The blade bending angle θ of the long blades and the short blades is 25°-38°.

3. The turbo-structure automotive air-cooling device according to claim 1, characterized in that: The length difference Δl of the long blades and the short blades is 1-15 mm.

4. The turbo-structure automotive air-cooling device according to claim 1, characterized in that: The electric control unit reads the whole vehicle heat signal through the CAN bus and outputs the required rotating speed PWM signal to drive the motor to rotate and drive the turbine to move according to the internal algorithm; the flow sensor feeds back the turbine flow to the electric control unit in real time to continuously correct the required rotating speed; the electric control wire harness and the flow sensor wire harness are connected on the electric control unit through the rear shell and are fixed on the wire harness fixing buckle outside the flow channel along the rear shell.

5. The turbo-structure automotive air-cooling device according to claim 1, characterized in that: The filter screen is arranged at the turbine air inlet, has a thickness of 0.5-1 mm, and has a diameter matching the diameter of the turbine air inlet; the number of mesh holes with a diameter greater than 1 mm in the filter screen is not more than 5%.

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