Fan module for heat exchangers used in motor vehicle drive systems

Abstract

In order to provide a fan module (100) for a heat exchanger (40) used in a drive unit (51) of a motor vehicle (200), a fan module (100) is proposed, wherein at least one guide vane of the guide vanes (22) forces the flow of air (A) delivered by the associated fan wheel (10) to be oriented in a first partial vector (V1) in a lateral direction (CD) relative to the delivery direction (TD) and a second partial vector (V2) in the delivery direction (TD), wherein the first partial vector (V1) is greater than the second partial vector (V2).

Description

Technical Field

[0001] This invention relates to a fan module for a heat exchanger used in a motor vehicle drive unit, according to the present invention.

[0002] This invention relates to a fan module for a heat exchanger used in a motor vehicle drive unit, the fan module having at least the following components:

[0003] - At least one fan wheel for conveying air in a predetermined conveying direction;

[0004] - A frame for connection to a heat exchanger and for housing at least one fan wheel; and

[0005] - A guide device following at least one of the fan wheels in the conveying direction, the guide device having at least one guide blade for orienting the flow of air conveyed by the associated fan wheel. Background Technology

[0006] The application of fan modules in drive systems for motor vehicles is known from the prior art. These modules typically have at least one fan wheel for conveying air through a heat exchanger and are actively used as a safety device, for example, when the vehicle is stationary. Due to the reduction in engine size, increasingly higher speeds and power are being generated within limited available structural space. Similar problems arise in electric traction machines, which, although exhibiting less waste heat relative to power, must be maintained at significantly low temperature levels. Unacceptably high temperature increases within the drive system can damage it.

[0007] For example, a cooling module with an air guiding unit is known from KR 2018 0 093 283A, wherein the air guiding unit is arranged at a ventilator shroud assembly. Furthermore, a guide is known that directs the flow path of air entering during operation in a motor vehicle, thereby selectively guiding air into the cooling module within the ventilator shroud assembly by means of the air guiding unit.

[0008] Furthermore, a cooling device for a liquid-cooled internal combustion engine located in the engine compartment of a motor vehicle is known from DE 31 12 630 A1, wherein the cooling device includes an axial blower connected downstream of the internal combustion engine. Furthermore, as known from page 4, the cooling device additionally includes a cooling air passage, which is divided into a cold air inlet and a cold air outlet. The axial blower disposed therein includes a turbine-type impeller equipped with blades, wherein a guide wheel fixed to the housing is arranged in front of the impeller. In this case, the guide wall of the guide wheel is arranged such that the inclination of the guide wall corresponds to the blades of the impeller. Furthermore, the blades are curved in the opposite direction to achieve an airflow that extends substantially parallel to the axis of the axial blower.

[0009] Additionally, a cooling device with an internal combustion engine is known from the abstract of EP 1 890 019 A1, wherein the cooling device has at least one heat exchanger, a fan, and an air guide device, the air guide device having at least one bypass opening for a motor vehicle having a bottom region, controllable by a back pressure valve. Furthermore, it is known from paragraph

[0009] that the air guide device is flowably connected to the bottom region of the vehicle via one or more air guides, thereby creating a negative pressure region at a certain vehicle speed, thereby generating suction that causes the back pressure valve located in the air guide to open prematurely. When the back pressure valve is open, a higher cooling air throughput through the heat exchanger is generated due to the higher pressure drop between the back pressure in the fan hood and the negative pressure in the bottom region. Summary of the Invention

[0010] Compared to previously known fan modules, the object of this invention is to solve, by means as simple and cost-effective as possible, the following problem: In unsuitable structural space conditions (primarily when the unit is installed transversely to the main travel direction), under conditions of high air mass flow, excessive airflow may occur towards the unit directly behind it, where it bounces back, increasing pressure loss and causing backflow. Flow separation (or stall) may even occur at the fan impeller blades. Flow separation leads to the fan impeller partially or completely losing its function (depending on speed, operation, etc.).

[0011] Furthermore, the underside of current motor vehicles is very well sealed to achieve a low pressure loss (CW) value. Unfortunately, this sealing also prevents the exhaust air from the fan wheel from flowing directly out, which in turn increases pressure loss. There is no space in most current motor vehicles for an exhaust air guide section in the form of an air passage (similar to an inlet side).

[0012] According to the invention, the above-mentioned task is achieved by at least one of the guide vanes forcing the flow of air delivered by the associated fan wheel to be oriented with a first partial vector in the transverse direction relative to the delivery direction and a second partial vector in the delivery direction, wherein the first partial vector is greater than the second partial vector.

[0013] Advantageous improvements of the invention are shown in the various embodiments.

[0014] This invention relates to a fan module for a heat exchanger used in a motor vehicle drive unit, the fan module having at least the following components:

[0015] - At least one fan wheel for conveying air in a predetermined conveying direction;

[0016] - A frame for connection to a heat exchanger and for housing at least one fan wheel; and

[0017] - A guide device following at least one of the fan wheels in the conveying direction, the guide device having at least one guide blade for orienting the flow of air conveyed by the associated fan wheel.

[0018] The fan module is particularly characterized in that at least one of the guide vanes forces the flow of air delivered by the associated fan wheel to be oriented with a first partial vector in the transverse direction relative to the delivery direction and a second partial vector in the delivery direction, wherein the first partial vector is greater than the second partial vector.

[0019] For the fan impeller, purely by reference to the understanding of the above-cited literature, the object of the cited literature becomes, at least in this respect, part of the disclosure. For example, the fan impeller is implemented with an axial (i.e., parallel to the axis of rotation of the fan impeller) conveying direction. The rotating fan impeller blades are preferably optimal in terms of conveying capacity, sound intensity, operational smoothness, and / or similar properties for air in the range of -40°C to +90°C, for example, well close to room temperature.

[0020] In a heat exchanger, the frame is a preferably one-piece structural element used to assemble and hold several or all components of the fan module. In installation settings (e.g., engine compartment), the frame can be assembled independently of the heat exchanger. Alternatively, the frame can be directly fixed to the heat exchanger. For example, the frame is a structural element that is filament-machined and / or flow-optimized at least in the flow path for the air to be delivered. For example, the frame is a cast component. For example, the frame comprises aluminum and / or plastic.

[0021] For example, the delivery direction is set to allow the air to flow through the heat exchanger with the lowest possible flow resistance, such as a delivery direction parallel to the orientation of the fluid path (preferably the entire) in the middle or on the side of the fan wheel for conveying the air through the heat exchanger.

[0022] The guiding device is configured to force the flow of air delivered by means of the fan wheel to be oriented. For example, there is necessarily a vortex component in a fan wheel with an axial delivery direction. Preferably, this vortex component is eliminated or at least significantly reduced by means of the guiding device.

[0023] In one embodiment, the fan module is arranged after the heat exchanger in the conveying direction.

[0024] It should be noted that while the fan module or associated heat exchanger is preferably used in a traction machine, such as an internal combustion engine or electric motor for propelling a motor vehicle, it can also be used in other components (preferably for the drive unit for propelling a motor vehicle), such as a transmission, battery, or power electronics.

[0025] In an advantageous embodiment of the fan module, the guide blades of the guiding device for forcibly directing the flow include a first blade section and a second blade section, wherein the first blade section is configured to reduce the swirling flow of the conveyed air induced by the associated fan wheel.

[0026] In one embodiment, in at least one guide blade, preferably all guide blades, two blade segments are formed integrally with each other. In an alternative embodiment, in at least one guide blade, preferably all guide blades, two blade segments are formed independently with each other. In one embodiment, the first blade segment is implemented at least functionally in a conventional manner.

[0027] In an advantageous embodiment of the fan module, the guide device includes guide elements independent of the frame.

[0028] In an advantageous embodiment of the fan module, the guide element is secured by means of a central fastener in the frame.

[0029] In an advantageous embodiment of the fan module, at least one of the guide blades is implemented according to the embodiment described above, wherein a first blade section is integrally formed with the frame and a second blade section is integrally formed with the guide element.

[0030] For example, the guide element is a structural element that is filament-machined and / or flow-optimized at least in the flow path for the air to be conveyed. For example, the frame is a cast component. For example, the frame comprises aluminum and / or plastic. Preferably, the guide element is an add-on structural element, wherein the use of the guide element is determined based on specific structural space conditions during initial commissioning of the fan module and during testing. For example, the decision is made based on the measured back pressure level and / or flow separation. Alternatively or additionally, the guide element can be used as an add-on component in the existing structure.

[0031] In one advantageous embodiment of the fan module, the corresponding orientations of the forced flow are different from each other among the multiple guide vanes.

[0032] To minimize flow resistance, in this embodiment, the flow direction is fanned out to the smallest possible extent to avoid compression-based stagnation. Preferably, a flow diffuser is formed for orientation in the conveying direction, for example, before the guide vanes, and preferably before the second vane section (e.g., axially). In one embodiment, a portion of the volume flow having a recently forced, larger first partial vector points downward, a portion of the volume flow points to the left, and a portion of the volume flow points to the right, and / or other portions of the volume flow having vector components of the first partial vector are transverse to the conveying direction in the aforementioned directions.

[0033] According to another aspect, a motor vehicle is proposed that has at least the following components:

[0034] - A drive mechanism used to generate propulsive torque;

[0035] - An engine compartment for housing at least a portion of the drive unit,

[0036] - At least one propulsion wheel, by means of which the propulsion torque of the drive unit can be converted into the propulsion force of the motor vehicle;

[0037] - At least one heat exchanger for temperature regulation of at least a portion of the drive unit;

[0038] - At least one fan module for conveying air through at least one heat exchanger, according to the embodiment described above.

[0039] Drive systems for propelling motor vehicles include traction machines, such as internal combustion engines and / or at least one electric drive machine, and preferably also include traction batteries, transmissions, differentials and / or others.

[0040] In one advantageous embodiment of the motor vehicle, the conveying direction of at least one fan wheel of the fan module is opposite to the main driving direction of the motor vehicle.

[0041] In one advantageous embodiment of the motor vehicle, the engine compartment is enclosed, wherein the minimum distance between at least one fan wheel of the fan module and the directly adjacent unit is less than 5 cm, preferably less than 3 cm. Attached Figure Description

[0042] The embodiments of the present invention will now be explained in detail with reference to the accompanying drawings. Wherein:

[0043] Figure 1 The previous view shows a ventilation module with a guide device.

[0044] Figure 2 A detailed cross-sectional view is shown with... Figure 1 The second fan wheel fan module,

[0045] Figure 3 A detailed cross-sectional view is shown with... Figure 1 The first fan wheel of the fan module,

[0046] Figure 4 The illustrations are detailed in three dimensions and show the data based on... Figure 1 and Figure 3 The first fan wheel of the fan module, and

[0047] Figure 5 A motor vehicle with an engine compartment is shown. Detailed Implementation

[0048] Figure 1 The previous view shows a fan module 100 with a guide device 21. In this embodiment, the fan module 100 includes a first fan wheel 10 and a second fan wheel 11, which are configured to convey air A in a predetermined conveying direction TD. The conveying direction TD is axially oriented here, i.e., parallel to the rotation axis RA of the respective fan wheels 10, 11, which is oriented perpendicular to the drawing plane. When conveying air A, the fan wheels 10, 11 induce swirling flow RM within the conveyed air A due to the conservation of angular momentum (exemplarily shown in the second fan wheel 11). The swirling flow can only be guided in a restricted manner along the conveying direction TD, therefore, guide devices 21 are correspondingly arranged at the fan wheels 10, 11. The guide devices 21 are configured to reduce the swirling flow RM.

[0049] Here, the fan wheels 10 and 11 (optionally) are housed in a common, one-piece frame 20, which, in addition to housing the fan wheels 10 and 11, is also configured for connection to the heat exchanger 40. This is not shown here; see [link to relevant documentation]. Figure 2 and / or Figure 5In an alternative embodiment, separate frames 20 may be provided for the fan wheels 10, 11, and / or the frames 20 may be multi-piece. Furthermore, the frames 20 at least partially surround the guide device 21 (here, surrounding the first blade section 23), and / or are configured to accommodate the entire guide device 21, or another portion of the guide device 21 (here, the separate guide element 30). In this embodiment, the guide element 30 is fastened to the frame 20 by means of fasteners 32. In this embodiment, the guide element 30 is fastened to the frame 20 using three fasteners 32. For example, the fasteners 32 may be implemented as bolts, rivets, adhesives, or welds, wherein, in this embodiment, the fasteners 32 are implemented as clips. The guide device 21 includes (optionally multiple) guide blades 22 having the first blade section 23, which are here part of the frame 20. See details Figure 2 Furthermore, the guiding device 21 includes (optionally multiple) guide blades 22 having a second blade section 31, which (optionally) serve as part of a separate guiding element 30. It should be noted that not all guide blades 22 must have both a first blade section 23 and a second blade section 31. Preferably, all guide blades 22 include at least a first blade section 23.

[0050] At least one guide vane of the guide vanes 22 or (at least exemplary herein) a corresponding first vane section 23 is configured to force the flow to be oriented along the conveying direction TD and thereby reduce swirl RM. At least one guide vane of the guide vanes 22 or (at least exemplary herein) a corresponding second vane section 31 is configured to force the flow to be oriented transversely to the conveying direction TD.

[0051] The guide vanes 22, having a second blade section 31, are oriented such that the guide vanes diffuse the flow of air A, or the transport direction TD, with the largest possible first partial vector V1 (i.e., transverse to the transport direction TD) and further dispersed as much as possible due to their different orientations, thus transporting the air flow away from the fan module 100 along the straightest possible path, schematically indicated here by arrows at the first fan wheel 10. As a result, the remaining volumetric flow along the transport direction of the first fan wheel 10 (i.e., parallel to the axis of rotation RA) is smaller. This reduces the back pressure caused by a nearby wall (not shown here) of adjacent components and almost eliminates flow separation caused at the fan blades of the first fan wheel 10. Such a nearby wall is, for example, a component fixed to the unit or auxiliary unit 55 (generator, oil separator, piping, etc.). This nearby wall is, for example, at a minimum distance of 3 cm from the first fan wheel 10 on the outlet side. See [link to details] for further information. Figure 2 and Figure 3.

[0052] Figure 2 The detailed cross-sectional view shows the data based on... Figure 1 The second fan wheel 11 of the fan module 100, wherein the cross section is parallel to Figure 1 The rotational axes RA shown are offset and guided through the fan blades of the second fan wheel 11 and the associated guide vanes 22 of the guide device 21. The second fan wheel 11 delivers air A along the delivery direction TD from the heat exchanger 40, which is arranged on the left side as shown and delivers hot air A to the engine compartment 50 in the main operating state. The direction of this flow is away from the fan module 100 toward the directly adjacent unit (e.g., engine 52 or its enclosure 56 or other attachments 55), which reduces turbulence in the vehicle 200 during operation, i.e., for c w The value has a positive impact, but it also serves as insulation and restricts structural space. A guide device 21 is arranged after the second fan wheel 11 in the flow direction, wherein the guide device 21 includes multiple guide blades 22. In this embodiment, the guide blades 22, integrally formed with the frame 20, have a unique first blade section 23, which forces the flow of (hot) air A away from direct contact with the rear member 55 and reduces or eliminates only the induced swirl RM. Thus, flow obstruction or heat accumulation occurs very close to the wall (which is formed here by the rear member 55), resulting in a power loss of the drive unit 51. As shown, this reversal of orientation is also possible, potentially causing flow separation at the fan blades of the second fan wheel 11 and thus loss of function. For example, the wall here is only 3 cm to 5 cm away from the second fan wheel 11 on the outlet side.

[0053] In this embodiment, the guide vane 22 or the first vane section 23 is configured only to reduce the swirling flow RM (as in...). Figure 1 As indicated in the diagram), and configured to orient the flow in the transport direction TD with the least possible swirling fraction.

[0054] Figure 3 A detailed cross-sectional view is shown with... Figure 1 and Figure 2 The first fan wheel 10 is the fan module 100. Here, without excluding generalities, for purely visibility reasons, the illustrated embodiment is similar to... Figure 2The only difference is that the guide device 21 additionally has a guide element 30 (optionally independent of the frame 20), and the guide blade 22 additionally includes a second blade section 31 in addition to the first blade section 23. Therefore, the function of the first blade section 23 and the fan wheel 10 is described above. In the figures, the second blade section 31 is arranged to the right of the first blade section 23. In this embodiment, the guide blade 22 is implemented as a two-piece unit, wherein the first blade section 23 is optionally formed as a single piece with the frame 20, and the second blade section 31 is formed as a single piece with the guide element 30. The guide element 30 with the second blade section 31 is arranged here directly adjacent to the first blade section 23, so that no flow separation occurs at the contact point of the blade sections 23, 31, preferably providing an undisturbed flow transition. The function of the second blade section 31 is to force the flow of air A delivered by the first fan wheel 10 to be oriented transversely to the delivery direction TD, thereby significantly reducing the share of volumetric flow toward the rear component 55. The rear component 55 (which forms the wall of the directly adjacent unit, i.e., the engine 52) has a minimum distance mD from the first fan wheel 10 on the outlet side, for example, from 3 cm to a maximum of 5 cm.

[0055] In the polar coordinate system on the rotation axis RA of the first fan wheel 10, the conveying direction TD can be divided into two vector components V1 and V2. The second vector component V2 is oriented parallel to the rotation axis RA (i.e., axially), and the first vector component V1 is oriented transversely to the rotation axis RA (i.e., in the transverse direction CD), as illustrated. Thus, the first vector component V1 is oriented radially (i.e., inward or outward) and / or circumferentially or tangentially. The tangential vector component of the first vector component V1 is shown here according to the drawing plane. Nevertheless, individually or preferably further, the vector component of the first vector component V1 is oriented radially (preferably outward). Therefore, as... Figure 2 Compared to the embodiment shown, an extended working length is achieved on the guide vane 22. This allows for a gentle forced orientation of the flow, as illustrated, such that the first vector V1 (i.e., in the lateral direction CD) is greater than the second vector V2 (i.e., in the transport direction TD). The resulting flow, in the transport direction TD, ultimately oriented parallel to the directly adjacent wall (i.e., the rearward component 55 or engine 52). This allows for a power increase of the ventilation module 100 within the spatially constrained engine compartment 50 without causing high back pressure or even flow separation on the first ventilation wheel 10.

[0056] Figure 4 The illustrations are detailed in three dimensions and show the data based on... Figure 1 and Figure 3The first fan wheel 10 has a fan module 100, in which the guide vanes 22, implemented as a two-piece unit, are particularly well seen in the figure. Each guide vane 22 in the guide device 21 (optionally, only here) includes a first blade section 23 and a second blade section 31, wherein, in this embodiment, the first blade section 23 is integrally formed with the frame 20, and the second blade section 31 is integrally formed with the guide element 30. The guide element 30 is arranged to directly contact the first blade section 23 and is fastened to the frame 20 by means of fasteners 32 (three separate points here), thereby forming a working surface of the guide vane 22 that is uninterrupted in terms of flow technology and preferably continuous.

[0057] The guide device 21 can also be seen here. In this embodiment, the guide device includes a guide element 30 having a second blade section 31 and a first blade section 23 integrally formed with the frame 20 in the first fan wheel 10.

[0058] Figure 5 A schematic diagram from above illustrates a motor vehicle 200 having an engine compartment 50, wherein this portion or part of the engine compartment 50 is enclosed. A drive unit 51 is arranged within the engine compartment 50, wherein, in this embodiment, the drive unit 51 includes, for example, an engine 52 implemented as an electric traction machine and a transmission 53. It should be noted that the drive unit 51 includes other components not shown here, such as a battery and / or a differential, and these components are not necessarily arranged within the enclosed portion 56. For the advantageous c of the motor vehicle 200 w The encapsulation section 56 is arranged to surround the engine compartment 50 and is forced to have high fluid tightness and high thermal insulation performance. The drive unit 51 is configured to generate propulsive torque, which rotates the two propulsion wheels 54 via a shaft and thereby transmits the propulsive torque to the ground, thus driving the vehicle 200 in the main direction of travel MD, and preferably also in the opposite direction. The drive unit 51 generates waste heat, which must be removed from the engine 52. This heat removal is achieved by means of a heat exchanger 40, which is in fluid contact with the engine 52 of the drive unit 51. Here, the heat exchanger 40 is configured to regulate the temperature of the engine 52, wherein a fan module 100 is used to improve convection on the heat exchanger 40 and to avoid heat accumulation within the isolated engine compartment 50. The fan module 100 is configured to deliver air A through the heat exchanger 40 and is preferably implemented as described above with corresponding guide vanes 22.

[0059] List of reference numerals in the attached diagram:

[0060] 100 ventilation fan module

[0061] 200 motor vehicles

[0062] 10 First Ventilation Fan Wheel

[0063] 11 Second Ventilation Fan Wheel

[0064] 20 frames

[0065] 21 Guiding Device

[0066] 22 guide blades

[0067] 23 First blade section

[0068] 30 guiding elements

[0069] 31 Second blade section

[0070] 32 fasteners

[0071] 40 heat exchanger

[0072] 50 engine compartment

[0073] 51 drive unit

[0074] 52 engine

[0075] 53 transmission

[0076] 54 propulsion wheels

[0077] 55. Components located at the rear

[0078] 56 Package

[0079] 60 cockpit

[0080] A air

[0081] CD horizontal direction

[0082] MD Main driving direction

[0083] minimum spacing mD

[0084] RA rotation axis

[0085] RM Vortex

[0086] TD conveying direction

[0087] V1 First Part Vector

[0088] V2 Part Two Vector

Claims

1. A fan module (100) for a heat exchanger (40) used in a drive unit (51) of a motor vehicle (200), the fan module having at least the following components: - At least one fan wheel (10, 11) for conveying air (A) in a predetermined conveying direction (TD); - A frame (20) for connection to the heat exchanger (40) and for housing the at least one fan wheel (10, 11); and - A guide device (21) following at least one of the fan wheels (10) in the conveying direction (TD), the guide device having at least one guide vane (22) for orienting the flow of air (A) conveyed by the associated fan wheel (10), in, At least one of the guide vanes (22) forces the flow of air (A) delivered by the associated fan wheel (10) to be oriented with a first partial vector (V1) in the lateral direction (CD) relative to the delivery direction (TD) and a second partial vector (V2) in the delivery direction (TD). Wherein, the first part vector (V1) is greater than the second part vector (V2), characterized in that For the forced orientation of the flow, the guide vanes (22) of the guide device (21) include a first vane section (23) and a second vane section (31), wherein the first vane section (23) is configured to reduce the vortex (RM) induced by the associated fan wheel (10) in the flow of the transported air (A), and The guiding device (21) includes a guiding element (30) separate from the frame (20), wherein the guiding element (30) is fastened by means of a central fastener (32) of the frame (20), and wherein the first blade section (23) is formed integrally with the frame (20), and the second blade section (31) is formed integrally with the guiding element (30).

2. The ventilation fan module (100) according to claim 1, wherein, In the multiple guide vanes (22), the corresponding orientations of the forced flow are different from each other.

3. A motor vehicle (200) having at least the following components: - A drive device (51) for generating propulsive torque; - An engine compartment (50) for accommodating at least a portion of the drive unit (51), - At least one propulsion wheel (54) by means of which the propulsion torque of the drive device (51) can be converted into the propulsion force of the motor vehicle (200); - At least one heat exchanger (40) for temperature regulation of at least a portion of the drive unit (51); - At least one fan module (100) according to any one of the preceding claims for conveying air (A) through the at least one heat exchanger (40).

4. The motor vehicle (200) according to claim 3, wherein, The conveying direction (TD) of at least one fan wheel (10, 11) of the fan module (100) is opposite to the main driving direction (MD) of the motor vehicle (200).

5. The motor vehicle (200) according to claim 3 or claim 4, wherein, The engine compartment (50) is enclosed, wherein the minimum distance (mD) between at least one fan wheel (10) of the fan module (100) and the directly adjacent unit is less than 5 cm.

6. The motor vehicle (200) according to claim 5, wherein, The minimum distance (mD) between at least one fan wheel (10) of the fan module (100) and the directly adjacent unit is less than 3 cm.

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