Heat exchanger system

Abstract

A heat exchanger system includes a controller configured to direct a first power signal to a first cooling fan module to operate a first motor at a first rotational speed to provide a first flow rate that meets a first desired heat dissipation rate; directing a second power signal to a second cooling fan module to operate a second motor at a second rotational speed to provide a second flow rate that meets a second desired heat dissipation rate; a rotational speed difference between the first rotational speed and the second rotational speed is maintained such that an acoustic characteristic of at least one of the first heat exchanger assembly and the second heat exchanger assembly is below a predetermined acoustic characteristic threshold.

Description

Technical Field

[0001] The present disclosure relates to a system and method for controlling a heat exchanger system for a vehicle. Background Art

[0002] A known cooling fan module for a vehicle and a method of operating the same are disclosed in US Pat. No. 11,339,707. Summary of the invention

[0003] One aspect of the disclosed embodiment includes a heat exchanger system for use in a vehicle. The heat exchanger system may include a first heat exchanger, a second heat exchanger, a first cooling fan module, a second cooling fan module, and at least one controller. The first heat exchanger may be configured to cool a first functional component of the vehicle, and the second heat exchanger may be configured to cool a second functional component of the vehicle. The first cooling fan module may have a first fan and a first motor, the first motor may be configured to drive the first fan to cool the first heat exchanger, and the first cooling fan module and the first heat exchanger may together form a first heat exchanger assembly. The second cooling fan module may be provided with a second fan and a second motor, the second motor may be configured to drive the second fan to cool the second heat exchanger, and the second cooling fan module and the second heat exchanger may together form a second heat exchanger assembly. The at least one controller can be configured to perform the following operations in response to receiving a first desired heat dissipation rate associated with the first heat exchanger and a second desired heat dissipation rate associated with the second heat exchanger, commanding the first cooling fan module to provide a first flow rate, and based on the first flow rate, commanding the second cooling fan module to provide a second air flow rate offset relative to the first air flow rate, so that one or more acoustic characteristics of at least one of the first heat exchanger assembly and the second heat exchanger assembly are below a predetermined acoustic characteristic threshold.

[0004] Another aspect of the disclosed embodiment includes another heat exchanger system for use in a vehicle. The heat exchanger system may include a first heat exchanger, a second heat exchanger, a first cooling fan module, a second cooling fan module, and at least one controller. The first heat exchanger may be configured to cool a first functional component of the vehicle, and the second heat exchanger may be configured to cool a second functional component of the vehicle. The first cooling fan module may have a first fan and a first motor, the first motor may be configured to drive the first fan to cool the first heat exchanger, and the first cooling fan module and the first heat exchanger may together form a first heat exchanger assembly. The second cooling fan module may have a second fan and a second motor, the second motor may be configured to drive the second fan to cool the second heat exchanger, and the second cooling fan module and the second heat exchanger may together form a second heat exchanger assembly. The at least one controller can be configured to: in response to receiving a first desired heat dissipation rate associated with the first heat exchanger and a second desired heat dissipation rate associated with the second heat exchanger, direct a first power signal to the first cooling fan module to operate the first motor at a first speed to provide a first flow rate to meet the first desired heat dissipation rate, and direct a second power signal to the second cooling fan module to operate the second motor at a second speed to provide a second flow rate to meet the second desired heat dissipation rate, while maintaining a speed difference between the first speed and the second speed so that the acoustic characteristics of at least one of the first heat exchanger assembly and the second heat exchanger assembly are below a predetermined acoustic characteristics threshold.

[0005] Another aspect of the disclosed embodiment includes a method of operating a heat exchanger system for use in a motor vehicle. The method may include: receiving, by a controller, a first desired heat dissipation rate associated with a first heat exchanger; receiving, by the controller, a second desired heat dissipation rate associated with a second heat exchanger; directing, by the controller, a first power signal to a first cooling fan module disposed adjacent to the first heat exchanger so that a first motor of the first cooling fan module operates at a first speed to provide a first flow rate that satisfies the first desired heat dissipation rate; directing, by the controller, a second power signal to a second cooling fan module disposed adjacent to the second heat exchanger so that a second motor of the second cooling fan module operates at a second speed to provide a second flow rate; and maintaining, by the controller, a speed difference between the first speed and the second speed such that an acoustic characteristic of the heat exchanger system is below a predetermined acoustic characteristic threshold. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 A schematic top view of a vehicle is shown according to one or more embodiments.

[0007] Figure 2 A perspective view of an exemplary cooling fan module is shown.

[0008] Figures 3 to 6 An exemplary control schematic is shown in accordance with one or more embodiments.

[0009] Figure 7 A graph depicting fan speed versus power signal is shown.

[0010] Figure 8 A graph depicting fan speed and desired cooling rate versus time is shown. DETAILED DESCRIPTION

[0011] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples, and other embodiments may take various forms and alternative forms. The drawings are not necessarily drawn to scale; some features may be exaggerated or minimized to show the details of specific components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as restrictive, but only as a representative basis for teaching those skilled in the art to adopt the embodiments in various ways. As will be understood by those of ordinary skill in the art, the various features shown and described with reference to any one of the figures may be combined with the features shown in one or more other figures to produce embodiments that are not explicitly shown or described. The combination of the features shown provides representative embodiments for typical applications. However, for specific applications or embodiments, it may be desirable to have various combinations and modifications of the features that conform to the teachings of the present disclosure.

[0012] The present invention is not limited to the specific embodiments and methods described below, as specific components and / or conditions may of course vary. Furthermore, the terminology used herein is for the purpose of describing specific embodiments of the present invention only and is not intended to be limiting in any way.

[0013] As used in the specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. For example, reference to a component in the singular is intended to include a plurality of components.

[0014] The terms "substantially" or "approximately" may be used herein to describe the disclosed or claimed embodiments. The terms "substantially" or "approximately" may modify a value or relative property disclosed or claimed in the present disclosure. In such cases, "substantially" or "approximately" may mean that the value or relative property it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, or 10% of the value or relative property.

[0015] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, directly engaged to, directly connected to, or directly coupled to another element or layer, or there may be intermediate elements or layers. Conversely, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). The term "and / or" includes any and all combinations of one or more associated listed items.

[0016] Although the terms first, second, third, etc. can be used to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or section from another region, layer or section. Terms such as "first", "second" and other digital designation terms do not imply sequence or order when used in this article unless the context clearly indicates. Therefore, without departing from the teaching of the exemplary embodiment, the first element, component, region, layer or part discussed below can be referred to as the second element, component, region, layer or section.

[0017] For ease of description, spatially relative terms such as "inside", "outside", "lower", "below", "lower", "above", "upper", "inside", "outside" and the like may be used to conveniently describe the relationship between one element or feature as shown in the figure and another element or feature. Spatially relative terms may be intended to cover different orientations of the device in use or operation in addition to the orientation depicted in the accompanying drawings. For example, if the device in the figure is turned over, the element described as "below" or "below" will then be oriented to be "above" other elements or features. Therefore, the example term "below" can cover the orientation of above and below. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially relative descriptors used herein are interpreted accordingly.

[0018] Certain vehicles, particularly battery electric vehicles (BEVs), may require two or more heat exchangers (e.g., radiators, oil coolers, condensers, battery coolers) and one or more cooling devices (e.g., cooling fan modules) to cool each heat exchanger. Typically, a cooling fan module can be arranged relative to two heat exchangers so that one cooling fan module can cool two heat exchangers. This arrangement is disclosed in U.S. Publication No. 2022 / 0388361 A1, which is incorporated herein by reference. In other vehicles, a cooling fan module with two fan assemblies can be used to cool one or more heat exchangers.

[0019] However, due to the layout or location of two or more heat exchangers, some vehicles may require two cooling fan modules spaced apart from each other, so that one heat exchanger is cooled by one cooling fan module and the other heat exchanger is cooled by another cooling fan module. Whether arranged in a single shroud or arranged in two separate cooling fan modules with separate shrouds, the operation of the two fan assemblies may result in unpleasant acoustic characteristics (e.g., noise vibration (NVH) tone, vibration, sound or loudness), especially when the cooling fan module is operated at a relatively high speed. However, in some cases, including, but not limited to, the natural frequencies of the cooling fan module, the heat exchanger, and the surrounding support configured to carry the cooling fan module and / or the heat exchanger, unpleasant acoustic characteristics may also be prevalent at lower speeds. Although it may be economical to use two identical cooling fan modules, which will allow economies of scale and reduced processing costs compared to processing and producing two different cooling fan modules, the implementation of two identical cooling fan modules and operating the two identical cooling fan modules at substantially the same speed may also result in unpleasant acoustic performance.

[0020] The present disclosure is directed to addressing one or more of the above-mentioned issues.

[0021] Figure 1 An exemplary vehicle 100 having a heat exchanger system according to one or more embodiments is shown. The heat exchanger system may include a first heat exchanger assembly 102 and a second heat exchanger assembly 104, the first heat exchanger assembly 102 may be configured to cool a first vehicle feature 112, and the second heat exchanger assembly 104 may be configured to cool a second vehicle feature 114. The first vehicle feature 112 and the second vehicle feature 114 may be a traction battery, an electric drive motor, an electric wheel end, an inverter, a climate compressor, an internal combustion engine, or one or more vehicle components requiring cooling.

[0022] The first heat exchanger assembly 102 and the second heat exchanger assembly 104 may include one or more heat exchangers, including, but not limited to, a condenser, an oil cooler, a radiator, a battery cooler, and a heat pump. The first heat exchanger assembly 102 may also include a first cooling fan module 106, and the second heat exchanger assembly 104 may also include a second cooling fan module 106'. The first cooling fan module 106 may be substantially the same as the second cooling fan module 106', and as described above, using cooling fan modules that are substantially the same as each other may be economically advantageous because common tools and assembly equipment may be utilized. As will be described in more detail below, one or more controllers or electronic control units, such as a vehicle controller 115, may be provided to control one or more of the first cooling fan module 106 and the second cooling fan module 106', the first heat exchanger 108 and the second heat exchanger 110, and the first vehicle function vehicle component 112 and the second vehicle function vehicle component 114.

[0023] The vehicle 100 may include a plurality of frame components that may be configured to support or carry the first heat exchanger assembly 102 and the second heat exchanger assembly 104. The frame components may include one or more side rails 116 that may extend parallel to the longitudinal axis LA of the vehicle 100 and one or more cross members 118 that may extend between the side rails 116 in a direction substantially parallel to the transverse axis TA. In one or more embodiments, the first heat exchanger assembly 102 may be disposed near the front FOV of the vehicle on one side of the longitudinal axis LA, and the second heat exchanger assembly 104 may be disposed on the other side of the longitudinal axis. As another example, the first heat exchanger assembly 102 and the second heat exchanger assembly 104 may both be disposed on the same side of the longitudinal axis LA, and the first heat exchanger assembly 102 may be disposed on one side of the transverse axis TA, and the second heat exchanger assembly 104 may be disposed on the other side of the transverse axis.

[0024] One or more frame members, such as the first frame member 120 and the second frame member 122, can support the first heat exchanger assembly 102 and the second heat exchanger assembly 104. As an example, the first frame member 120 can support the first vehicle function component 112 disposed on one side of the longitudinal axis LA and the second vehicle function component 114 disposed on the other side of the longitudinal axis LA. The second frame member 122 can be configured to carry or support the first heat exchanger 108 and the first cooling fan module 106 and the second heat exchanger 110 and the second cooling fan module 106'. It should be understood that the first frame member 120 and the second frame member 122 form one or more parts of the first heat exchanger assembly 102 and the second heat exchanger assembly 104.

[0025] The frame members 120, 122 can affect the acoustic performance of the first cooling fan module 106 and the second cooling fan module 106', the first heat exchanger 108 and the second heat exchanger 110, the first vehicle function vehicle component 112 and the second vehicle function vehicle component 114, or some combination thereof. As an example, sound waves can propagate from one or more of the first cooling fan module 106 and the second cooling fan module 106', the first heat exchanger 108 and the second heat exchanger 110, the first vehicle function vehicle component 112 and the second vehicle function vehicle component 114, which can result in unpleasant acoustic performance.

[0026] Figure 2 A perspective view of a first cooling fan module 106 and a second cooling fan module 106' is shown. Because the first cooling fan module and the second cooling fan module are substantially identical, reference numerals 106, 106' are used. The first cooling fan module 106 and the second cooling fan module 106' can each include a shroud 138 having a sidewall 154 and a fan assembly 144. The sidewall 154 can define an opening 148 that can receive the fan assembly 144. The fan assembly 144 can include a motor mounting ring 150 and a motor 152 mounted to the motor mounting ring 150. One or more fan blades 146 extend radially outward from the motor 152. One or more struts 140 can extend from the sidewall 154 to the motor mounting ring 150. In one or more embodiments, one or more of the first cooling fan module and the second cooling fan module, such as the first cooling fan module 106, can include a controller such as a first electronic control unit 124, and the second cooling fan module 106' can include another controller such as a second electronic control unit 126.

[0027] Figure 3 An exemplary schematic diagram of a control layout 156 for a heat exchanger system is shown. Figure 4 An exemplary schematic diagram of a control layout 158 ​​for a heat exchanger system is shown according to another embodiment. Figure 5 An exemplary schematic diagram of a control layout 160 of a heat exchanger system according to another embodiment is shown. Figure 6An exemplary schematic diagram of a control layout 162 of a heat exchanger system according to another embodiment is shown. The first heat exchanger assembly 102 includes a first cooling fan module 106, which can be fluidly coupled to a first heat exchanger 108 via one or more fluid lines 132. The second heat exchanger assembly 104 includes a second cooling fan module 106', which can be fluidly coupled to a second heat exchanger 110 via one or more fluid lines 132. The first heat exchanger 106 and the second heat exchanger 106' can be electrically connected 134 to a vehicle controller 115, and can be fluidly connected to a first functional component 112 and a second functional component 114 via one or more fluid lines 132.

[0028] In one or more embodiments, the first cooling fan module 106 and the second cooling fan module 106' can be structurally connected to the first heat exchanger 108 and the second heat exchanger 110 through one or more structural interfaces 133, and the one or more structural interfaces 133 can structurally connect the first vehicle function component 112 and the second vehicle function component 114 to the first heat exchanger 108 and the second heat exchanger 110, respectively. As an example, the one or more structural interfaces 133 can be composed of a plurality of brackets, which can extend between the first cooling fan module 106 and the second cooling fan module 106', the first heat exchanger 108 and the second heat exchanger 110, and the first vehicle function component 112 and the second vehicle function component 114 and support the first cooling fan module 106 and the second cooling fan module 106', the first heat exchanger 108 and the second heat exchanger 110, and the first vehicle function component 112 and the second vehicle function component 114. The structural interface can also include one or more of the frame members 116-122.

[0029] Specific reference Figure 3 , the first cooling fan module 106 can be operatively connected to the first electronic control unit 124, and the second cooling fan module can be operatively connected to the second electronic control unit 126. In one or more embodiments, the first electronic control unit 124 and the second electronic control unit 126 can be integrated into the motors 152 of the first cooling fan module 106 and the second cooling fan module 106', respectively. The first electronic control unit 124 and the second electronic control unit 126 can each be electrically connected to the vehicle controller 115 via one or more electrical connections 134. The vehicle controller 115 can be configured to receive or derive a desired heat dissipation rate from the first heat exchanger 108, the second heat exchanger 110, or both.

[0030] The required heat dissipation rate may refer to the amount of heat that needs to be dissipated so that the first vehicle feature 112 and the second vehicle feature 114, the first heat exchanger 108 and the second heat exchanger 110, or some combination thereof, operate as intended. The required heat dissipation rate may be based on measured temperature values ​​of one or more of the first heat exchanger 108 and the second heat exchanger 110, the first vehicle feature 112 and the second vehicle feature 114, or some combination thereof. As another example, the required heat dissipation rate may be predicted or determined based on operating parameters of one or more of the first vehicle feature 112 and the second vehicle feature 114, including, but not limited to, vehicle speed, the amount of required heating or cooling of the cabin, ambient temperature, and charging state (e.g., active charging, active fast charging).

[0031] Specific reference Figure 4 , one or more sensors may be disposed within the first heat exchanger assembly 102 and the second heat exchanger assembly 104. As an example, the first sensor 128 may be fixed to or operatively connected to the first heat exchanger 108, and the second sensor 130 may be fixed to or operatively connected to the second heat exchanger 110. The first sensor 128 and the second sensor 130 may be accelerometers configured to measure vibrations generated or transmitted from or through one or more parts of the first heat exchanger assembly 102 and the second heat exchanger assembly 104 (such as the first heat exchanger 108, the second heat exchanger 110, the first cooling fan module 106, the second cooling fan module 106', or some combination thereof). In another embodiment, one or more of the first sensor 128 and the second sensor 130 may be microphones configured to measure one or more acoustic characteristics such as sound pressure, amplitude, loudness, and pitch.

[0032] Specific reference Figure 5 , one of the first cooling fan module 106 and the second cooling fan module 106' may include a dedicated controller operatively connected to the vehicle controller 115 and a cooling fan module that does not include a dedicated controller. As an example, the first cooling fan module 106 may have a first electronic control unit 124, and the first electronic control unit 124 may be configured to control the first cooling fan module 106 and communicate 134 to control the second cooling fan module 106'. Specific reference Figure 6, the first cooling fan module 106 and the second cooling fan module 106′ may be connected to a central cooling fan module electronic control unit 136 and configured to communicate 134 with the central cooling fan module electronic control unit 136. As an example, the central cooling fan module electronic control unit 136 may be integrated into the first cooling fan module 106, the second cooling fan module 106′, or into the vehicle electronic control unit 115. As another example, the central cooling fan module electronic control unit 136 may be an independent control unit separate from the first heat exchanger assembly 102 and the second heat exchanger assembly 104. Figure 5 and Figure 6 The illustrated configuration may provide one or more advantages, such as reduced cost due to using only one cooling fan module controller.

[0033] Figure 7 A graph depicting the fan speed of the first cooling fan module 106 and the second cooling fan module 106' relative to the amount of power or electrical power provided to the motors 142 of the first cooling fan module 106 and the second cooling fan module 106' is shown. The controller 115 or one or more of the electronic control units 124, 126, 136 may provide an electronic power signal to the first cooling fan module 106 and the second cooling fan module 106' to change the fan speed and, in turn, the flow rate generated by the first cooling fan module 106 and the second cooling fan module 106. The electronic power signal may be a pulse width modulation (PWM), a current (e.g., a current), or a local interconnect network (LIN) command.

[0034] The solid line CFM1 represents the fan speed of the first cooling fan module 106, which extends from a minimum speed of approximately 480 rpm and 10% power to a maximum speed of approximately 2,600 rpm and 90% power. The dashed line represents the fan speed of the second cooling fan module 106', which extends from a minimum speed of approximately 470 rpm and 10% power to approximately 2,400 rpm at 90% power. In one or more embodiments, the lines CFM1, CFM2 may represent median or average speeds relative to the percentage power of the first cooling fan module 106 and the second cooling fan module 106, and the actual speeds may fluctuate by a predetermined percentage.

[0035] Operating two machines or noise sources (e.g., the first cooling fan module 106 and the second cooling fan module 106') simultaneously may result in inconsistent acoustic performance. In order to provide suitable acoustic performance, it may be desirable to maintain a speed difference between the first cooling fan module 106 and the second cooling fan module 106'. Maintaining a speed difference or offset between the speed of the first cooling fan module 106 and the speed of the second cooling fan module 106 may mitigate or prevent certain objectionable acoustic characteristics.

[0036] As the fan speed increases, it is possible that the offset or difference may increase due to the increase in the required heat dissipation rate. Due to the relative increase in speed, the overall noise or sound pressure may increase, and therefore, the offset or difference may increase to mitigate certain unpleasant acoustic characteristics. As an example, at a 30% power signal, the fan speed of CFM1 may be approximately 950rpm, and the fan speed of CFM2 may be approximately 850rpm, and the first offset or difference D1 may be approximately 100rpm. As the power signal increases to 60%, the fan speed of CFM1 may be approximately 1,800rpm, the fan speed of CFM2 may be approximately 1,650, and the second offset or difference D2 may be approximately 150rpm. As the power signal increases to 90%, the fan speed of CFM1 may be approximately 2,750rpm, the fan speed of CFM2 may be approximately 1,900, and the third offset or difference D3 may be approximately 300 to 400rpm. The first difference D1 , the second difference, and the third difference D3 may be defined based on optimal acoustic performance while satisfying desired thermal management requirements (eg, desired heat dissipation rates) of the first vehicle function component 112 and the second vehicle function component 114 .

[0037] The controller 115 or one or more of the electronic control units 124, 126, 136 may be configured to increase the offset or difference between the fan speeds of CFM1 and CFM2. As an example, the first region R1 may extend from a 10% power signal to about an 80% power signal, and the second region R2 may extend from about an 80% power signal to about a 90% power signal. The offset or difference may be increased between the first region R1 and the second region R2. Although only two regions are depicted, it should be understood that one or more regions may be provided as desired. It should be understood that the offset or difference may be referred to as a factor.

[0038] Ideally, the first cooling fan module 106 and the second cooling fan module 106' are each capable of meeting the required heat dissipation rate of the first heat exchanger 108 and the second heat exchanger 110 while maintaining the speed difference between CFM1 and CFM2. In some cases, such as when a relatively high required heat dissipation rate is required, the speeds of CFM1 and CFM2 can be alternated, such that CFM1 rotates at a higher speed (compared to the speed of CFM2) for a predetermined period of time, and then, CFM2 rotates at a higher speed (compared to the speed of CFM1) for a predetermined period of time.

[0039] Figure 8A graph depicting the fan speed in percentage of the first cooling fan and the second cooling fan relative to time (seconds) and the required heat dissipation rate in percentage relative to time (seconds) is shown. The fan speed of the first cooling fan module 106 is represented by line CFM1, and the fan speed of the second cooling fan module 106' is represented by line CFM2. The first required heat dissipation rate is represented by line DHR1, and the second required heat dissipation rate is represented by DHR2. The controller 115 or one or more of the electronic control units 124, 126, 136 can be configured to overcool the first heat exchanger 108 or the second heat exchanger 110 in order to reduce the required heat dissipation rate so that the other heat exchanger can be cooled while maintaining the offset or speed difference. As an example, in response to the first required heat dissipation rate DHR1 reaching about 85%, the fan speed CFM1 can be increased to about 95%. This increase can allow the fan speed CFM2 to subsequently increase in response to the second required heat dissipation rate DHR2 increasing.

[0040] Parts List

[0041] The following is a list of reference numerals shown in the accompanying drawings. However, it should be understood that the use of these terms is for illustrative purposes only with respect to one embodiment. Also, the use of reference numerals associated with specific terms shown in the drawings and present in the claims is not intended to limit the claims to cover only the illustrated embodiments.

[0042] Vehicle 100

[0043] The first heat exchanger assembly 102

[0044] Second heat exchanger assembly 104

[0045] The first cooling fan module 106

[0046] Second cooling fan module 106'

[0047] The first heat exchanger 108

[0048] Second heat exchanger 110

[0049] First vehicle functional component 112

[0050] Second vehicle functional component 114

[0051] Vehicle controller 115

[0052] Side rail 116

[0053] Frame cross member 118

[0054] First frame member 120

[0055] Second frame member 122

[0056] CFM ECU 1124

[0057] CFM ECU 2126

[0058] First sensor 128

[0059] Second sensor 130

[0060] Fluid pipeline 132

[0061] Structural Interface 133

[0062] Communication lines, sensor wiring, electrical wiring 134

[0063] Public ECU136

[0064] Shield 138

[0065] Pillar 140

[0066] Motor 142

[0067] Fan assembly 144

[0068] Fan blade 146

[0069] Opening 148

[0070] Motor mounting ring 150

[0071] Motor 152

[0072] Side wall 154

[0073] Control Layout 156

[0074] Control Layout 158

[0075] Control Layout 160

[0076] Control Layout 162

[0077] Although exemplary embodiments are described above, these embodiments are not intended to describe all possible forms covered by the claims. The words used in the specification are descriptive words rather than limiting words, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. As mentioned above, the features of various embodiments can be combined to form other embodiments of the present disclosure that may not be explicitly described or shown. Although various embodiments may have been described as providing advantages or being superior to other embodiments or prior art implementations in terms of one or more desired characteristics, it is recognized by those of ordinary skill in the art that one or more features or characteristics can be compromised to achieve the desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. Therefore, if any embodiment is described as not as ideal as other embodiments or prior art implementations in terms of one or more features, these embodiments are not outside the scope of the present disclosure, but can be expected to be used for specific applications.

Claims

1. A heat exchanger system for a vehicle, the heat exchanger system comprising: a first heat exchanger configured to cool a first functional component of the vehicle; a second heat exchanger configured to cool a second functional component of the vehicle; a first cooling fan module having a first fan and a first motor configured to drive the first fan to cool the first heat exchanger, the first cooling fan module and the first heat exchanger together forming a first heat exchanger assembly; a second cooling fan module having a second fan and a second motor configured to drive the second fan to cool the second heat exchanger, the second cooling fan module and the second heat exchanger together forming a second heat exchanger assembly; at least one controller configured to, in response to receiving a first desired heat rejection rate associated with the first heat exchanger and a second desired heat rejection rate associated with the second heat exchanger, commanding the first cooling fan module to provide a first air flow rate, and Based on the first air flow rate, commanding the second cooling fan module to provide a second air flow rate offset from the first air flow rate so that one or more acoustic properties of at least one of the first heat exchanger assembly and the second heat exchanger assembly are below a predetermined acoustic property threshold.

2. The heat exchanger system according to claim 1, wherein: The first cooling fan module and the second cooling fan module are substantially identical.

3. The heat exchanger system according to claim 1, wherein: The one or more acoustic characteristics include pitch amplitude, loudness, and sound pressure.

4. The heat exchanger system according to claim 1, wherein: The first desired cooling rate and the second desired cooling rate are each configured to vary with respect to time, wherein the controller is further configured to reduce the first flow rate by a first factor and increase the second flow rate by a second factor, wherein the first factor is substantially the same as the second factor.

5. The heat exchanger according to claim 1, wherein: The at least one controller is a vehicle controller or is integrated into at least one of the first cooling fan module and the second cooling fan module, and wherein the at least one controller is further configured to: The first cooling fan module and the second cooling fan module are commanded to maintain a predetermined flow rate difference between the first flow rate and the second flow rate.

6. The heat exchanger according to claim 5, wherein: The predetermined flow rate difference increases based on an amount of power provided to the first cooling fan module.

7. The heat exchanger according to claim 1, wherein: The controller is further configured to provide the second flow rate offset relative to the first flow rate by an offset value, wherein the offset value is based at least in part on a natural frequency of at least one of the first and second heat exchanger assemblies.

8. The heat exchanger according to claim 7, wherein: The vehicle includes one or more frame members, and the first heat exchanger assembly includes a first frame member of the one or more frame members, the first frame member being configured to carry at least one of the first cooling fan module and the first heat exchanger, wherein the second heat exchanger assembly includes a second frame member of the one or more frame members, the second frame member being configured to carry at least one of the second cooling fan module and the second heat exchanger.

9. A heat exchanger system for a vehicle, the heat exchanger system comprising: a first heat exchanger configured to cool a first functional component of the vehicle; a second heat exchanger configured to cool a second functional component of the vehicle; a first cooling fan module having a first fan and a first motor configured to drive the first fan to cool the first heat exchanger, the first cooling fan module and the first heat exchanger together forming a first heat exchanger assembly; a second cooling fan module disposed adjacent to the first cooling fan module and having a second fan and a second motor configured to drive the second fan to cool the second heat exchanger, the second cooling fan module and the second heat exchanger together forming a second heat exchanger assembly; at least one controller configured to, in response to receiving a first desired heat rejection rate associated with the first heat exchanger and a second desired heat rejection rate associated with the second heat exchanger, directing a first power signal to the first cooling fan module to operate the first motor at a first speed to provide a first flow rate to meet the first required heat dissipation rate, A second power signal is directed to the second cooling fan module to operate the second motor at a second speed to provide a second flow rate to meet the second desired heat dissipation rate, while maintaining a speed difference between the first speed and the second speed such that an acoustic characteristic of at least one of the first heat exchanger assembly and the second heat exchanger assembly is below a predetermined acoustic characteristic threshold.

10. The heat exchanger system according to claim 9, wherein: The at least one controller is further configured to supercool the first heat exchanger and, in response to the supercooling, reduce the first power signal and increase the second power signal while maintaining the speed difference between the first speed and the second speed.

11. The heat exchanger system according to claim 9, further comprising: At least one sensor operatively connected to at least one of the first heat exchanger assembly and the second heat exchanger assembly, the at least one sensor configured to measure one or more physical characteristics indicative of the one or more acoustic characteristics of at least one of the first heat exchanger assembly and the second heat exchanger assembly.

12. The heat exchanger system according to claim 11, wherein: The at least one sensor is an accelerometer configured to measure vibrations of the at least one heat exchanger assembly among the first heat exchanger assembly and the second heat exchanger assembly, wherein the vibrations measured by the accelerometer are indicative of the one or more acoustic characteristics of the at least one heat exchanger assembly among the first heat exchanger assembly and the second heat exchanger assembly.

13. The heat exchanger system according to claim 9, wherein: The at least one controller includes a first heat exchanger assembly controller configured to direct at least one of the first power signal to the first cooling fan module and the second power signal to the second cooling fan module.

14. The heat exchanger according to claim 13, wherein: The first heat exchanger assembly controller is configured to communicate with a vehicle controller, wherein the first heat exchanger assembly controller is configured to receive at least one of the first desired heat dissipation rate and the second desired heat dissipation rate from the vehicle controller.

15. The heat exchanger according to claim 9, wherein: The vehicle includes a first functional component and a second functional component. wherein the vehicle defines a longitudinal axis and a transverse axis, the longitudinal axis being disposed substantially at a center of the vehicle and extending between a rear end and a front end of the vehicle, the transverse axis being disposed substantially at a center of the vehicle and extending in a direction substantially orthogonal to the longitudinal axis, wherein the first heat exchanger assembly is configured to cool the first functional component, and the second heat exchanger assembly is configured to cool the second functional component, and The first functional component is disposed on one side of at least one of the longitudinal axis and the transverse axis, and the second functional component is disposed on the other side of at least one of the longitudinal axis and the transverse axis.

16. The heat exchanger according to claim 15, wherein: The first functional component includes at least one of a traction battery, an electric drive motor, and an inverter.

17. A method of operating a heat exchanger system for a motor vehicle, the method comprising: receiving, by a controller, a first desired heat rejection rate associated with a first heat exchanger; receiving, by the controller, a second desired heat rejection rate associated with a second heat exchanger; directing, by the controller, a first power signal to a first cooling fan module disposed adjacent to the first heat exchanger to operate a first motor of the first cooling fan module at a first speed to provide a first flow rate to meet the first required heat dissipation rate; directing, by the controller, a second power signal to a second cooling fan module disposed adjacent to the second heat exchanger to operate a second motor of the second cooling fan module at a second speed to provide a second flow rate; as well as A speed difference between the first speed and the second speed is maintained by the controller such that an acoustic characteristic of the heat exchanger system is below a predetermined acoustic characteristic threshold.

18. The method according to claim 17, wherein: The second flow rate does not meet the second required heat dissipation rate within the first time period.

19. The method according to claim 18, wherein: Directing the first power signal includes supercooling the first heat exchanger for the first period of time.

20. The method of claim 17, further comprising: The second power signal is changed to increase the second speed of the second motor to meet the second required heat dissipation rate.

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