Water-cooled high-voltage electronic fan
Through centralized cooling design and multi-layer water channel optimization, the problem of difficult control of high-voltage electronic fan coolant flow is solved, efficient heat dissipation and stable motor temperature are achieved, and the burden and production cost of the entire vehicle are reduced.
Patent Information
- Application Number
- CN202511068694.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-31
- Publication Date
- 2025-09-19
AI Technical Summary
The existing high-voltage electronic fan's cooling water circuit design is simple, resulting in limited heat dissipation and difficulty in controlling the coolant flow, which affects the fan's performance and lifespan and places a burden on the vehicle's water system.
A centralized cooling method is adopted, and the high-voltage motor and controller are designed as one. The coolant flows from the water inlet into the high-heat area of the motor controller, flows into the cooling channel of the high-voltage motor through the transition water outlet, and finally flows out from the water outlet. A multi-layer water channel and guide belt design is used to optimize the coolant flow rate and retention area, realizing simultaneous cooling of the motor and controller.
It improves heat dissipation efficiency, reduces coolant consumption, reduces water channel design cost and motor volume, stabilizes motor operating temperature, extends fan life, and adapts to the heat dissipation needs of different motor capacities.
Smart Images
Figure CN120667418A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to an engine cooling system, in particular to a water-cooled high-voltage electronic fan. Background Art
[0002] At present, the new energy commercial vehicle market is booming. In the field of commercial vehicle cooling, high-voltage electronic fans are gradually replacing traditional low-pressure fans due to their high power and high efficiency. Compared with low-voltage electronic fans, high-voltage electronic fans have large heat dissipation requirements. Mainstream air-cooling can no longer meet the heat dissipation requirements. Additional coolant needs to be introduced through the water channel inside the motor to exchange heat with the metal outer wall of the heat-generating components to remove excess heat and ensure reliable operation of the motor. The heat-generating parts of the high-voltage fan are mainly concentrated in: the stator coil part in the high-voltage motor and the circuit of the drive motor in the controller. The heat dissipation of the above two parts needs to be given priority in the water channel design.
[0003] Currently, high-pressure fans are still in the pre-research stage, and there are no mature products on the market. Most motor manufacturers have little research and design concept for the cooling water circuit inside the motor. As a result, the cooling water circuit of the motor is mostly copied from the cooling water circuit design inside the radiator product. That is, the coolant can circulate through a straight water circuit, flowing in from the water inlet, passing through the high-temperature area and dissipating heat, and finally flowing out from the water outlet. This water circuit design is relatively simple and the heat dissipation effect is limited: that is, the effect depends entirely on the temperature of the coolant at the water inlet and the coolant flow rate. When the heat dissipation requirement is high, the only way to cool is to increase the coolant flow rate or reduce the coolant inlet temperature. This water circuit design often requires a large amount of coolant to flow into the high-pressure fan, which will place a heavy burden on the vehicle's water system. Due to the large coolant flow rate, the coolant flow rate is relatively difficult to control. If the flow rate is not properly controlled, the high-pressure fan product will fluctuate between hot and cold, thus affecting the fan's performance and working efficiency. The rapid fluctuation of the coolant flow rate will also cause a significant impact on the aluminum tube in the motor water circuit, which can at least reduce the life and reliability of the high-pressure fan, and in severe cases, directly affect the fan's performance. Summary of the Invention
[0004] To solve the above problems, the present invention provides a water-cooled high-voltage electronic fan, which adopts a centralized cooling method to cool the motor and controller in the high-voltage fan at the same time, avoiding the traditional dual-water-path cooling design, that is, two water paths dissipate heat for the motor and controller respectively, reducing the design cost of multiple water paths and reducing the motor manufacturing cost.
[0005] The technical solution adopted by the present invention is: a water-cooled high-voltage electronic fan, including a high-voltage motor and a motor controller, characterized in that: the motor controller includes a high-heating area and a low-heating area, a first cooling channel is provided in the high-heating area, and a second cooling channel is provided in the high-voltage motor; the coolant flows from the water inlet into the first cooling channel in the high-heating area of the motor controller, then passes through the transition water outlet and flows into the second cooling channel in the high-voltage motor, and finally flows out from the water outlet to dissipate heat for the high-voltage motor and the motor controller. The high-voltage motor and the motor controller adopt an integrated design, and the cooling water path also centrally cools the motor and the controller, that is, the coolant flows from the water inlet into the controller, passes through the transition water outlet and flows into the motor, and finally flows out of the high-voltage fan from the water outlet, realizing centralized circulation cooling.
[0006] Preferably, the first cooling channel is provided with four guide strips, namely the first, second, third, and fourth guide strips. Strip-shaped guide strips are arranged at bends and slow-flowing areas of the cooling water channel to accelerate the flow of the coolant and increase the flow rate of the coolant per unit time. Fine metal bosses are arranged near components with high heat dissipation requirements to form retention zones, allowing the coolant to remain near the metal bosses, extending the cooling time within the retention zones and improving local heat dissipation.
[0007] Preferably, the first guide belt separates the first cooling channel into two water areas, namely a first water area and a second water area. The first water area connects the water inlet and the second water area, and the second water area connects the first water area and the transition water outlet.
[0008] Preferably, the second guide belt is arranged near the bend of the water channel in the first water area to avoid the irregular design of the bend slowing down the flow rate of the coolant and to increase the flow rate of the coolant entering the water channel.
[0009] Preferably, the third guide strip adopts an arc-shaped structure and is located at the transition bend between the first and second water areas, corresponding to the first guide strip. Numerous retention areas are arranged near the third guide strip, which also serve as bends in the waterway. Considering that retention areas and bends will double the slowdown of the coolant flow rate, the incoming coolant flow rate must be increased before it can pass through this section to reach the water area below. Furthermore, the bend angle divides the coolant into two parts, allowing the cooling water that does not need to pass through the retention area to pass quickly.
[0010] Preferably, the fourth guide belt is arranged in the second water area to increase the flow rate of the coolant flowing from the second water area to the transition water outlet, thereby ensuring the subsequent cooling effect.
[0011] Preferably, in the first water area, a plurality of bosses are provided between the second guide belt and the third guide belt to form a coolant retention area for reducing the flow rate of the coolant.
[0012] Preferably, a plurality of bosses are provided on a side of the third guide strip away from the first guide strip to form a coolant retention area for reducing the flow rate of the coolant.
[0013] Preferably, the second cooling channel adopts a double-layer water channel structure symmetrically arranged in an upper and lower manner, including a first cooling water channel and a second cooling water channel. The double-layer water channel can provide a cooling effect far higher than that of a single-layer water channel.
[0014] Preferably, the first cooling water channel is connected to the transition water inlet and the second cooling water channel, and the second cooling water channel is connected to the first cooling water channel and the water outlet.
[0015] The beneficial effects achieved by the present invention are: 1. The centralized cooling method can cool the motor and controller in the high-pressure fan at the same time, avoiding the traditional dual-water-path cooling design, that is, two water paths dissipate heat for the motor and controller respectively, reducing the design cost of multiple water paths and the cost of motor production; 2. The coolant can circulate in the motor and controller at the same time. One flow of coolant can complete the cooling of both the motor and the electronic control, reducing the coolant consumption of the high-pressure fan part and reducing the burden on the entire vehicle; 3. The water circuit adopts a multi-layer cooling method, which can perform layered composite cooling on the high-heating parts inside the motor (such as the stator), improving the heat dissipation effect per unit area. The multi-layer design allows the water circuit to be superimposed, reducing the water circuit layout space and effectively reducing the motor volume. The multi-layer design can extend the coolant circulation time in the water circuit, reduce the impact of the coolant flow fluctuation of the vehicle on the operating temperature of the motor, and keep the motor operating temperature stable within the appropriate range to ensure the life of the motor. According to the different motor capacity, the number of cooling layers can be flexibly increased to realize cross-platform electronic fan application. 4. Strip guide strips are arranged at the bends of the water channel to increase the flow rate of the coolant; independent metal bosses are arranged near the components with high heat dissipation requirements to form a retention area, so that the coolant is retained near the boss, increasing the cooling time and thus improving local heat dissipation; 5. The water channel can adjust the coolant flow rate, that is, the places that require high heat dissipation are detained and decelerated, and the places that need acceleration are accelerated using guide belts. This idea of accelerating and decelerating in the water channel can provide a way of thinking for other motor suppliers, because the current mainstream is to have a certain coolant flow rate in a water channel. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1-2 It is a structural schematic diagram of the high-voltage motor of the high-voltage fan of the present invention; Figure 3 A layout diagram of the first cooling channel of the motor controller of the present invention; Figure 4 Schematic diagram of the layout of the second cooling channel of the high-voltage motor of the present invention; Figure 5 This is the layout diagram of the overall cooling water circuit; In the figure: 1.1, water inlet; 1.2, water outlet; 1.3, high-voltage motor; 1.4, motor controller; 2.1, high-heating area; 2.2, low-heating area; 2.3, transition water inlet; 2.4, first cooling channel; 2.41, first water area; 2.42, second water area; 2.43, first guide belt; 2.44, second guide belt; 2.45, third guide belt; 2.46, fourth guide belt; 2.47, boss; 2.5, second cooling channel; 2.51, first cooling water channel; 2.52, second cooling water channel; 3.1, aluminum shell; 3.2, stator part. DETAILED DESCRIPTION
[0017] The present invention will be further described below with reference to the accompanying drawings.
[0018] like Figure 1-2 As shown, the high-voltage electronic fan includes a high-voltage motor 1.3, a motor controller 1.4 and nylon fan blades; the high-voltage electronic fan has four interfaces with the entire vehicle, namely a low-voltage interface, a high-voltage interface, a water inlet 1.1 and a water outlet 1.2.
[0019] like Figure 3 As shown, the motor controller 1.4 includes a high-heating area 2.1 and a low-heating area 2.2. The high-heating area 2.1 is equipped with an IGBT or SIC chip that drives the high-voltage motor and related high-voltage driving parts; the low-heating area 2.2 is mainly equipped with various low-voltage power supply chips, MCU chips, capacitors, resistors and other low-power consumption components.
[0020] Combine Figure 4-5As shown, the water-cooled high-voltage electronic fan of the present invention includes a high-voltage motor 1.3 and a motor controller 1.4. The motor controller 1.4 includes a high-heating area 2.1 and a low-heating area 2.2. A first cooling channel 2.4 is provided in the high-heating area 2.1, and a second cooling channel 2.5 is provided in the high-voltage motor 1.3. The present invention adopts a centralized heat dissipation mode, that is, the coolant will flow from the water inlet 1.1 into the first cooling channel 2.4 in the high-heating area 2.1 of the motor controller 1.4, and then through the transition water port 2.3, flow into the second cooling channel 2.5 in the high-voltage motor 1.3, and finally flow out from the water outlet 1.2. It can be seen that the coolant can dissipate heat for the high-voltage motor 1.3 and the motor controller 1.4 together. This is a centralized heat dissipation mode. Considering the compact requirements and low-cost design requirements of future vehicle layouts, the electronic fan of the present invention will become the trend of future high-voltage electronic fans. The high-voltage motor 1.3 and the motor controller 1.4 are integrated into a design. Compared with distributed high-voltage motors, this saves wiring between the high-voltage motor 1.3 and the motor controller 1.4. At the same time, the motor layout is more compact, saving layout space.
[0021] The core of motor controller 1.4 is the PCBA. In this example, the motor board is circular in design, with an external aluminum shell. There's a gap between the aluminum shell and the PCBA, allowing the PCBA to exchange heat with the outside world through the aluminum shell. When coolant flows through the external aluminum shell in high-heat zone 2.1, it cools the corresponding PCBA area through heat exchange. There's no water path for low-heat zone 2.2, as the return air from the fan blades provides sufficient cooling.
[0022] In this embodiment, four guide strips are provided within the first cooling channel 2.4: a first guide strip 2.43, a second guide strip 2.44, a third guide strip 2.45, and a fourth guide strip 2.46. Strips are placed at bends and slow-flowing areas of the cooling channel to accelerate the coolant flow rate and increase the amount of coolant delivered per unit time. Finely divided metal bosses are placed near high-dissipation components to create retention zones, allowing the coolant to remain near the metal bosses, extending the cooling time within the retention zones and improving local heat dissipation.
[0023] The first guide strip 2.43 is the longest guide strip, which divides the first cooling channel 2.4 into two water areas, namely the first water area 2.41 and the second water area 2.42. The first water area 2.41 connects to the water inlet 1.1 and the second water area 2.42, and the second water area 2.42 connects to the first water area 2.41 and the transition water outlet 2.3.
[0024] The second guide strip 2.44 is arranged near the bend of the water channel in the first water area 2.41 to prevent the irregular design of the bend from slowing down the flow rate of the coolant and to increase the flow rate of the coolant entering the water channel.
[0025] The third guide strip 2.45, an arc-shaped structure, is located at the transition bend between the first water area 2.41 and the second water area 2.42, corresponding to the end of the first guide strip 2.43. Numerous retention zones, also known as bends in the waterway, are arranged near the third guide strip 2.45. Considering that retention zones and bends double-decelerate the flow of coolant, the incoming coolant must first be accelerated to pass through these sections and reach the water area below. Furthermore, the bend angle effectively divides the coolant into two sections, allowing for faster passage of coolant that does not require stagnation.
[0026] The fourth guide strip 2.46 is provided in the second water area 2.42 to increase the flow rate of the coolant flowing from the second water area 2.42 to the transition water outlet 2.3, thereby ensuring the subsequent cooling effect.
[0027] In the first water area 2.41, a plurality of bosses 2.47 are provided between the second guide strip 2.44 and the third guide strip 2.45 to form a coolant retention area for reducing the flow rate of the coolant.
[0028] A plurality of bosses 2.47 are provided on a side of the third guide strip 2.45 away from the first guide strip 2.43 to form a coolant retention area for reducing the flow rate of the coolant.
[0029] In this embodiment, the second cooling channel 2.5 utilizes a double-layered annular waterway structure, arranged symmetrically from top to bottom, comprising a first cooling channel 2.51 and a second cooling channel 2.52. This double-layered structure provides significantly greater cooling efficiency than a single-layered channel. The first cooling channel 2.51 connects to the transition water port 2.3 and the second cooling channel 2.52, while the second cooling channel 2.52 connects to the first cooling channel 2.51 and the water outlet 1.2. When the coolant flows through the transition water port 2.3 into the second cooling channel 2.5 within the high-voltage motor 1.3, it dissipates heat from the aluminum shell 3.1 at the rotating portion 3.2 of the motor.
[0030] In the present embodiment, the coils within the stator of a synchronous motor flow current and rotate in a magnetic field, generating a large amount of heat. Therefore, the second cooling channel 2.5 is used to dissipate heat from the stator. Of course, the second cooling channel 2.5 is not limited to a two-layer design. When the motor's heat dissipation requirements are greater, a three- or four-layer water channel design can also be used.
[0031] In this example, the part of high-voltage motor 1.3 that generates heat during rotation is stator 3.2, which is surrounded by an aluminum shell 3.1. When coolant dissipates heat through aluminum shell 3.1, it indirectly dissipates heat from stator 3.2. Because stator 3.2 is cylindrical, the second cooling channel 2.5 within the motor is an annular design that wraps around the stator. In this example, the motor capacity is only 10 kW, so a double-layer water channel design is sufficient for dissipating heat. For larger capacity motors, a multi-layer design can be used to meet higher heat dissipation requirements. Thermal simulation confirms that heat generation is relatively uniform across the stator, so the water channel design uses a symmetrical structure.
[0032] The above illustrates and describes the basic principles and main structural features of the present invention. The present invention is not limited to the above examples. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.
Claims
1. A water-cooled high-voltage electronic fan, comprising a high-voltage motor (1.3) and a motor controller (1.4), characterized in that: The motor controller (1.4) comprises a high-heating zone (2.1) and a low-heating zone (2.2); a first cooling channel (2.4) is provided in the high-heating zone (2.1); and a second cooling channel (2.5) is provided in the high-voltage motor (1.3); coolant flows from the water inlet (1.1) into the first cooling channel (2.4) in the high-heating zone (2.1) of the motor controller (1.4), then flows through the transition water outlet (2.3) into the second cooling channel (2.5) in the high-voltage motor (1.3), and finally flows out from the water outlet (1.2), dissipating heat for both the high-voltage motor (1.3) and the motor controller (1.4).
2. The water-cooled high-voltage electronic fan according to claim 1, characterized in that: Four guide strips are provided in the first cooling flow channel (2.4), namely a first guide strip (2.43), a second guide strip (2.44), a third guide strip (2.45) and a fourth guide strip (2.46).
3. The water-cooled high-voltage electronic fan according to claim 2, characterized in that: The first guide strip (2.43) separates the first cooling channel (2.4) into two water areas, namely a first water area (2.41) and a second water area (2.42); the first water area (2.41) is connected to the water inlet (1.1) and the second water area (2.42); and the second water area (2.42) is connected to the first water area (2.41) and the transition water outlet (2.3).
4. The water-cooled high-voltage electronic fan according to claim 2, characterized in that: The second guide strip (2.44) is arranged near the bend of the water channel in the first water area (2.41), so as to avoid the irregular design of the bend slowing down the flow rate of the coolant and increase the flow rate of the coolant entering the water channel.
5. The water-cooled high-voltage electronic fan according to claim 2, characterized in that: The third guide belt (2.45) adopts an arc-shaped structure and is arranged at the transition bend between the first water area (2.41) and the second water area (2.42), corresponding to the first guide belt (2.43).
6. The water-cooled high-voltage electronic fan according to claim 2, characterized in that: The fourth guide strip (2.46) is arranged in the second water area (2.42) to increase the flow rate of the coolant flowing from the second water area (2.42) to the transition water outlet (2.3).
7. The water-cooled high-voltage electronic fan according to claim 2, characterized in that: In the first water area (2.41), a plurality of bosses (2.47) are provided between the second guide strip (2.44) and the third guide strip (2.45) for reducing the flow rate of the coolant.
8. The water-cooled high-voltage electronic fan according to claim 2, characterized in that: A plurality of bosses (2.47) are provided on a side of the third guide strip (2.45) away from the first guide strip (2.43) for reducing the flow rate of the coolant.
9. The water-cooled high-voltage electronic fan according to claim 1, characterized in that: The second cooling channel (2.5) adopts a double-layer water channel structure that is symmetrically arranged up and down, and comprises a first cooling water channel (2.51) and a second cooling water channel (2.52).
10. The water-cooled high-voltage electronic fan according to claim 9, characterized in that: The first cooling water channel (2.51) is connected to the transition water inlet (2.3) and the second cooling water channel (2.52), and the second cooling water channel (2.52) is connected to the first cooling water channel (2.51) and the water outlet (1.2).