Highly integrated high power resistive device for continuous braking equipment

Abstract

The invention relates to a highly integrated high-power resistive device (100) comprising: a high-power resistor (108) integrated into a heat sink, the high-power resistor (108) being designed to efficiently discharge heat generated during a continuous braking process of a continuous braking device; the radiator is provided with a radiator shell (102); a stainless steel cover sleeve (104); the invention relates to a high-power resistor module (112) comprising a high-power resistor (108), a stainless steel cover (104), an insulating layer (106), and at least one first high-voltage electrical connection (110.1) and a second high-voltage electrical connection (110.2), at least the high-power resistor (108), the stainless steel cover (104) and the insulating layer (106) forming a high-power resistor module (112).

Description

Field of the Invention

[0001] The present invention relates to a highly integrated high-power resistor device, which includes a high-power resistor integrated into a radiator, and the high-power resistor is used to efficiently dissipate the heat generated during a continuous braking process. Background Art

[0002] Based on the regulations of the United Nations Economic Commission for Europe, which have been incorporated into Article 41 of the Road Traffic Licensing Regulations (StVZO), continuous braking devices are required for buses with an allowable gross mass (zGM) of more than 5.5 tons and for other motor vehicles with an allowable gross mass of more than 9 tons.

[0003] In vehicles with a conventional drive train based on an internal combustion engine, this is usually achieved by preconnecting a hydraulic retarder with hydraulic power between the transmission and the drive shaft. This retarder is also considered as a secondary retarder. In electric commercial vehicles with an allowable gross weight of more than nine tons, using a high-power resistor connected as an electrical load element to a high-voltage DC circuit is an alternative to meet legal requirements. Here, the kinetic energy of the vehicle is converted into electrical energy and finally into heat energy by means of an electric motor and a high-power resistor. However, the heat energy (about 250 kW according to the minimum requirements of Paragraph 15 of Article 41 of the Road Traffic Licensing Regulations (StVZO), depending on the driving resistance of the vehicle) can be discharged to the surrounding environment by means of a coolant, an electric pump, a heat exchanger, or a radiator and a fan, and thus affects the energy efficiency and driving range, structural space, installation location, and cost of the electric vehicle. Due to the low energy density (kWh / kg, kWh / m3) of battery cells and due to the transportation tasks of commercial vehicles, heavier ("high-capacity") energy storage devices cannot be arbitrarily installed in commercial vehicles, so these vehicles must be optimized to the maximum energy efficiency. In addition, for business owners, the use of commercial vehicles is largely for business economic considerations. Summary of the Invention

[0004] According to the present invention, a highly integrated high-power resistor device is provided, wherein the high-power resistor is integrated into a radiator (Radiator), and the high-power resistor is configured to efficiently dissipate the heat generated during the continuous braking process of the continuous braking device, and has a radiator housing, a stainless steel jacket, an insulating layer, and at least one first high-voltage electrical connector and a second high-voltage electrical connector, wherein at least the high-power resistor, the stainless steel jacket, and the insulating layer form a high-power resistor module.

[0005] In the context of the present invention, a continuous braking device is a device that enables wear-free continuous braking without reducing the braking power. The continuous braking device plays a decisive role for reliable and efficient driving, for example, in heavier commercial vehicles with a weight of more than 5.5 tons. The continuous braking device has been specifically improved for heavier commercial vehicles. Its task is to cope with the increased vehicle mass and inertia. In this case, repeated braking power is required over a longer period of time in order to reliably control the energy generated due to the large weight and to prevent "fade" of the braking equipment.

[0006] The proposed invention defines a high-power resistor that functions as an integral component of a continuous braking system for electrically operated brakes. This braking system with a high-power resistor is used to convert the kinetic energy, i.e., the motion energy of the vehicle, into electrical energy, and thus to brake or stop large commercial vehicles with a weight of more than 5.5 tons. The solution proposed here can also be used in commercial vehicles with a weight of more than nine tons. The high-power resistor is used to dissipate the electrical energy formed during continuous braking and thus to prevent the operating brakes from overheating.

[0007] According to the present invention, the high-power resistor is thus used to provide resistance in the circuit. In this way, the current in the braking circuit can be controlled, and thus precise adjustment or blending of the braking force can be achieved between the operating brakes and the continuous brakes. To prevent the high-power resistor from overheating here, the present invention provides for efficiently discharging the heat generated, in such a way that the high-power resistor is integrated into a radiator so that the heat generated is discharged by the driving wind.

[0008] The radiator housing is a component that encloses and protects the radiator (cooler) in the vehicle.

[0009] The solution according to the present invention includes integrating the high-power resistor into the front area of the vehicle, where the high-power resistor is integrated into a dedicated radiator. It can be stacked onto the radiator group of the components of the drive train similar to the condenser of an air-conditioning circuit. In this case, the high-power resistor integrated into the radiator is cooled by the driving wind, or for example, it can also be achieved by one or more electric fan impellers installed in the vehicle area in front of the other radiators.

[0010] In the context of the present invention, an insulating layer is a separating layer of material that is considered for, for example, preventing electrical conductivity.

[0011] In an advantageous embodiment of the highly integrated high-power resistor device proposed according to the present invention, the insulating layer at least partially, preferably completely, surrounds the high-power resistor for electrical insulation.

[0012] The protection of high-power resistors by an insulating layer plays an important role in continuous braking devices. The proposed insulating layer satisfies several important functions with respect to the proposed solution. The insulating layer serves, for example, as a heat conductor in such a way that the heat generated by the high-power resistor during the braking process is guided and discharged by the insulating layer. In addition, the insulating layer provides an electrical insulation structure that protects the high-power resistor against possible short circuits or leakage currents that can occur, for example, due to moisture or external influences. Furthermore, the insulating layer serves, for example, as a protection structure against mechanical damage, such as vibrations or shocks, which can have an adverse effect on the power of the high-power resistor.

[0013] In an advantageous embodiment of the highly integrated high-power resistor device proposed according to the invention, the insulating layer comprises a magnesium oxide-based material.

[0014] The insulating layer containing magnesium oxide has advantages such as chemical stability and mechanical strength for use as an insulating layer.

[0015] In an advantageous embodiment of the highly integrated high-power resistor device proposed according to the invention, the insulating layer comprises an oxide ceramic - alumina-based material.

[0016] In an advantageous embodiment of the highly integrated high-power resistor device proposed according to the invention, the insulating layer comprises a aluminum nitride - ceramic-based material.

[0017] In an advantageous embodiment of the highly integrated high-power resistor device proposed according to the invention, the high-power resistor is at least partially surrounded by a stainless steel jacket.

[0018] The stainless steel jacket of the high-power resistor brings specific advantages in the sense of the present invention. This stainless steel jacket extremely effectively improves the power capacity and lifespan of the high-power resistor. Here, the stainless steel jacket is mainly used to effectively discharge the generated heat from the high-power resistor. This helps, for example, to avoid overheating of the high-power resistor and to regulate the operating temperature of the high-power resistor, such that efficient power operation is ensured. In addition, the stainless steel jacket, for example, comprises a corrosion-resistant material that provides excellent protection against moisture and environmental influences that can have an adverse effect on the operation and lifespan of the high-power resistor.

[0019] In an advantageous embodiment of the highly integrated high-power resistor device proposed according to the invention, the high-power resistor can be stacked on the radiator group of the components of the drive train.

[0020] In an advantageous embodiment of the highly integrated high-power resistor device according to the invention, the high-power resistor is cooled passively. In the context of the present invention, passive cooling should be understood as the technique by which heat can be removed from the system without a coolant circulation.

[0021] According to the solution according to the invention, the passive cooling of the high-power resistor has various advantages over the more costly coolant cooling. Thus, passive cooling by the driving wind is notable for, for example, a simple and reliable method that requires neither moving parts nor auxiliary devices. This significantly reduces the maintenance cost, which results in cost savings. An additional advantage of passive cooling compared to the more complex coolant cooling is that the cooling is independent of the coolant, thereby minimizing potential hazards such as leaks or other defects.

[0022] In an advantageous embodiment of the highly integrated high-power resistor device according to the invention, the high-power resistor is integrated into the front region of a commercial vehicle, in particular into the radiator present there.

[0023] By integrating the highly integrated high-power resistor device into the cooler in the front region of a commercial vehicle, especially a vehicle over 5.5 tons, the heat of the high-power resistor is advantageously dissipated by the driving wind. For example, the driving wind flows around the high-power resistor during driving, and in the proposed solution of integrating the high-power resistor in the front region of the commercial vehicle, the driving wind effectively dissipates the heat of the high-power resistor. In this way, the driving wind is used as a natural cooling mechanism that maintains the thermal state of the high-power resistor to such an extent that efficient operation of the continuous braking equipment can be achieved. The proposed solution of the highly integrated high-power resistor is advantageously achieved without additional cooling equipment or energy source and ensures a long life of the component.

[0024] In an advantageous embodiment of the highly integrated high-power resistor device according to the invention, the high-power resistor module is coupled to the radiator by mechanical connection and thermal coupling to ensure an effective heat exchange surface.

[0025] According to the present invention, thermal coupling should be understood, for example, as the mutual interaction between components connected to each other, such as the mutual interaction between a radiator network and a high-power resistor, which results in efficient heat exchange or heat transfer between the components. Therefore, thermal coupling is an important part of the high-power resistor and its heat dissipation. Optimal thermal coupling enables efficient heat dissipation of the high-power resistor to the surrounding environment, thereby maintaining a stable temperature level and avoiding overheating. The thermal coupling of components, especially with respect to the heat exchange surface, can be achieved, for example, by connecting the high-power resistor to the radiator network over a large area in a manner similar to the connection of the cooling water pipes of a conventional water-air radiator to the radiator network, so as to increase the heat exchange surface.

[0026] In the solution according to the present invention, the convective heat transfer achieved by means of the driving wind usually has a less favorable heat transfer coefficient between metal and air than the heat transfer coefficient between metal and coolant. In order to be able to transfer the same heat power, it is necessary to increase the heat exchange surface participating in the heat exchange. According to the present invention, this can be advantageously achieved by the mechanical connection (such as by brazing connection) and thermal coupling of the high-power resistor module and the radiator network, wherein the high-power resistor of the high-power resistor module has high efficient conduction ability and electrical insulation through a magnesium oxide insulating layer and a stainless steel jacket. The radiator network describes the entirety of all the sheets of the radiator, for example, similar to a water-air heat exchanger ("radiator").

[0027] In an advantageous embodiment of the highly integrated high-power resistor device proposed according to the present invention, the mechanical connection is designed as a material-locking connection, especially designed as a brazing connection.

[0028] As an alternative to the brazing connection, the mechanical connection can be achieved, for example, by screw connection, riveting, fusion welding connection, bonding or plugging, wherein the type of the mechanical connection varies according to different factors, such as the type of the materials to be connected, the type of the load and other specific requirements.

[0029] Furthermore, the present invention relates to the use of a highly integrated high-power resistor device in a commercial vehicle having an allowable gross mass of more than nine tons, wherein, however, commercial vehicles of all weight classes are included here.

[0030] Advantages of the present invention:

[0031] The solution according to the present invention is remarkable in that the cooling of the high-power resistor is achieved by convective cooling by means of the driving wind by integrating the high-power resistor into the radiator and eliminating the cooling medium. This advantageously allows the omission of a plurality of components necessary for cooling according to the prior art. The omitted components include components such as water pumps, hoses and additional pumps. In addition, by omitting the components, the demand for electrical energy is advantageously omitted, for example, the electrical energy demand generated by the pumps.

[0032] In an advantageous manner, the highly integrated high-power resistor device according to the invention can be integrated into the front region of a vehicle, where the high-power resistors can, for example, be stacked on a radiator, thereby further efficiently saving structural space.

[0033] Furthermore, the solution according to the invention is distinguished in that, compared to the prior art mentioned above, the highly integrated high-power resistor device does not require liquid cooling and can be positioned almost freely.

[0034] Furthermore, the advantageous solution according to the invention is distinguished in that the highly integrated high-power resistor device is provided in a continuous braking device for commercial vehicles having an authorized gross mass of more than nine tons. Description of the Drawings

[0035] Embodiments of the invention will be explained in detail with reference to the drawings and the following description. Among them:

[0036] Figure 1 A schematic view of a highly integrated high-power resistor device is shown. Detailed Embodiments

[0037] In the following description of the embodiments of the invention, the same reference numerals are used for the same or similar elements, and in some cases, the repeated description of these elements is omitted. The drawings only schematically represent the subject matter of the invention.

[0038] Figure 1 A schematic view of a highly integrated high-power resistor device 100 is shown, which includes a high-power resistor integrated into a radiator, the high-power resistor being configured to efficiently dissipate heat generated during a continuous braking process, wherein the high-power resistor 108 is fastened to the radiator housing 102.

[0039] From Figure 1 it is known that the high-power resistor 108 has a high-power resistor module 112 assembled from a plurality of components. According to Figure 1 , the high-power resistor module 112 has a high-power resistor 108, which is at least partially surrounded by an insulating layer 106. In addition, the high-power resistor 108 surrounded by the insulating layer 106 has an additional layer as a stainless steel jacket 104. Furthermore, from Figure 1 it can be seen that the high-power resistor 108 has a first high-voltage electrical connection 110.1 and a second high-voltage electrical connection 110.2.

[0040] This is achieved by at least partially surrounding the high-power resistor 108 with an insulating layer 106, preferably an insulating layer 106 made of magnesium oxide, and a stainless-steel jacket 104, such that the high-power resistor 108 has efficient conduction capabilities and is nevertheless advantageously electrically insulated.

[0041] By means of the highly integrated high-power resistor device 100 according to the invention, which is integrated into a radiator, overheating of the continuous braking device can be advantageously prevented, wherein the highly integrated high-power resistor device 100 is installed in the front region of the vehicle and is cooled by a driving wind cooling scheme while avoiding cooling by means of a coolant, in order to prevent overheating.

[0042] For example, cooling of the high-power resistor 108 can be achieved by the driving wind or, alternatively, by means of an electric fan impeller which is installed in the front region of the vehicle for a further radiator.

[0043] The highly integrated high-power resistor device 100 according to the invention, having at least one high-power resistor 108, is used for efficiently discharging the heat generated during the continuous braking of the continuous braking device, wherein the high-power resistor 108 is integrated into a radiator, as they are preferably used in commercial vehicles with an approved gross vehicle weight of more than nine tons, wherein all weight classes of commercial vehicles are included here.

[0044] The invention is not limited to the embodiments described herein and the aspects emphasized herein. Rather, various variants within the scope defined by the claims can be achieved which are within the capabilities of a person skilled in the art.

Claims

1. A highly integrated high-power resistor device (100), comprising: A high-power resistor (108) integrated into a heat sink, wherein the high-power resistor (108) is constructed to efficiently dissipate heat generated during a continuous braking process of a continuous braking device; it has a heat sink housing (102); a stainless steel sheath (104); an insulating layer (106) and at least a first high-voltage electrical connection (110.1) and a second high-voltage electrical connection (110.2), wherein at least the high-power resistor (108), the stainless steel sheath (104) and the insulating layer (106) form a high-power resistor module (112).

2. The highly integrated high-power resistor device (100) according to claim 1, wherein: The insulating layer (106) at least partially, preferably completely surrounds the high-power resistor (108) for electrical insulation.

3. The highly integrated high-power resistor device (100) according to claim 1 or 2, wherein: The insulating layer (106) includes a magnesium oxide based material.

4. The highly integrated high power resistor device (100) according to any one of the preceding claims, wherein: The insulating layer (106) includes an oxide ceramic-aluminum oxide based material.

5. The highly integrated high power resistor device (100) according to any one of the preceding claims, wherein: The insulating layer (106) includes an aluminum nitride-ceramic based material.

6. The highly integrated high power resistor device (100) according to any one of the preceding claims, wherein: The high power resistor (108) is at least partially surrounded by the stainless steel jacket (104).

7. The highly integrated high power resistor device (100) according to any one of the preceding claims, wherein: The high power resistor (108) can be stacked on a heat sink group of a component of a drive train.

8. The highly integrated high power resistor device (100) according to any one of the preceding claims, wherein: The high power resistor (108) is passively cooled.

9. The highly integrated high power resistor device (100) according to any one of the preceding claims, wherein: The high-power resistor (108) is integrated into the front region of the commercial vehicle, in particular into the radiator.

10. The highly integrated high power resistor device (100) according to any one of the preceding claims, wherein: The high-power resistor module (112) is coupled to the heat sink through mechanical connection and thermal coupling to ensure an effective heat exchange surface.

11. The highly integrated high power resistor device (100) according to claim 10, wherein: The mechanical connection is designed as a material-locking connection, in particular a soldered connection.

12. Use of a highly integrated high-power resistor device (100) according to any one of the preceding claims, wherein: The highly integrated high-power resistor device (100) has at least one high-power resistor (108) for efficiently dissipating heat generated during the continuous braking process of the continuous braking device, and the high-power resistor is integrated into a heat sink. The highly integrated high-power resistor device is arranged in a commercial vehicle with an allowable total mass of more than nine tons, which includes commercial vehicles of all weight classes.

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