Bridge drive heat dissipation system of distributed electric drive chassis and control method

Abstract

The invention provides an axle heat dissipation system of a distributed electric drive chassis and a control method, and belongs to the technical field of heavy new energy automobiles. The number of the heat dissipation modules corresponds to that of the drive axles, and each heat dissipation module comprises a heat dissipation device, a heat dissipation fan, an electronic water pump, a temperature sensor and a heat dissipation controller; each heat dissipation module is independently arranged on the outer side, close to the corresponding drive axle, of the frame, and the air outlet direction of each heat dissipation module is the side direction of the frame; a water outlet of the radiator, the electronic water pump, a cooling flow channel of the motor controller, a cooling flow channel of the driving motor and a water inlet of the radiator are sequentially communicated in series through a connecting pipeline to form an independent cooling circulation loop; the heat dissipation controller of each heat dissipation module is connected with the temperature sensor and the heat dissipation fan and used for adjusting the rotating speed of the heat dissipation fan according to temperature signals collected by the temperature sensor. The distributed heat dissipation modules are adopted and independently serve all the drive axles, and space arrangement is optimized.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of heavy new energy vehicles, and particularly relates to a bridge drive heat dissipation system of a distributed electric drive chassis and a control method. BACKGROUND

[0002] For a new energy vehicle, a motor and a motor controller are core power components, and a large amount of heat is generated during operation. High temperature will cause demagnetization of motor magnetic materials, aging of winding insulation, and overheating breakdown of controller power devices, which seriously affects the performance, safety and reliability of the vehicle. Therefore, an efficient heat dissipation system is crucial for a new energy vehicle.

[0003] The existing heavy new energy vehicles mostly adopt central drive or electric drive axle forms, and the heat dissipation system thereof usually arranges a radiator in the front part of a vehicle frame, and cools all the motors and controllers of the drive units in series through a long pipeline. This centralized mode has certain applicability when facing a traditional single axle or double axle drive chassis. However, for a special multi-axle electric drive chassis adopting distributed drive, the power is derived from multiple wheel edge or hub motors, and the number of drive axles can reach five axles or more. If the above-mentioned heat dissipation schemes are adopted, the cooling pipeline needs to be laid from the front end of the vehicle to the drive axle at the end, resulting in a long pipeline, a significant increase in flow resistance and heat loss. At the same time, in order to meet the heat dissipation requirements of multiple axles, the volume of the radiator, the power of the fan and the water pump have to be greatly increased, which seriously occupies the layout space of the chassis, restricts the vehicle height and passability, and makes it extremely difficult to flexibly expand the chassis structure.

[0004] Related patents disclose heat dissipation of distributed electric drive vehicles, but due to the software logic of the central controller, the rapid expansion of the number of chassis axles cannot be realized, and the communication wire harness needs to be adaptively changed. Another related patent discloses cooling of distributed drive, which adjusts the flow of cooling liquid of different motors through multiple flow valves, but the heat dissipation of multiple hub motors still uses the same radiator, which cannot meet the use requirements of decoupling and independent control of each axle of the multi-axle chassis, and the problems of radiator volume and layout limitation still exist.

[0005] Therefore, there is an urgent need for a new heat dissipation mode that can adapt to the characteristics of a multi-axle distributed special chassis to solve the problems of high heat dissipation energy consumption, limited layout and poor expandability. SUMMARY

[0006] In a first aspect, an embodiment of the present application provides a bridge drive heat dissipation system of a distributed electric drive chassis, wherein a plurality of drive axles are arranged on the distributed electric drive chassis. The system comprises a plurality of heat dissipation modules, and the number of heat dissipation modules corresponds to the number of drive axles. Each heat dissipation module is independently arranged outside the vehicle frame at the corresponding drive axle. Each heat dissipation module comprises a heat sink, a heat dissipation fan, an electronic water pump, a temperature sensor, a heat dissipation controller and a connecting pipeline; the heat sink is provided with a water outlet and a water inlet; Each heat dissipation module is connected to the motor controller and the drive motor on the corresponding drive axle through the connecting pipeline to establish a heat exchange connection, so that the heat sink, the electronic water pump, the motor controller and the drive motor of the heat dissipation module are connected in series through the connecting pipeline to form an independent cooling circulation loop; The power input end of each heat dissipation module is connected to a low-voltage distribution box at the corresponding drive axle, and the power supply interfaces of the heat dissipation fan, the heat dissipation controller and the electronic water pump are connected to the power input end; The heat dissipation controller is connected to the temperature sensor and the heat dissipation fan, and is used to adjust the rotating speed of the heat dissipation fan according to the temperature signal collected by the temperature sensor.

[0007] Further, each heat dissipation module further comprises an expansion tank and a mounting bracket; The expansion tank is arranged in close contact with the heat sink and above the heat sink; The mounting bracket is arranged on one side of the heat sink and is used to fix the heat dissipation module to a preset mounting hole position on the outside of the vehicle frame.

[0008] Further, the drive motor is a water-cooled wheel-side motor; The heat exchange connection is a direct cooling connection, and the serial connection order of the corresponding cooling circulation loop is: The heat sink water outlet, the electronic water pump, the cooling flow channel of the motor controller, the cooling flow channel of the water-cooled wheel-side motor and the heat sink water inlet.

[0009] Further, the drive motor is an oil-cooled wheel-hub motor; The heat exchange connection comprises a direct cooling connection to the motor controller and an indirect cooling connection to the oil-cooled wheel-hub motor; The serial connection order of the corresponding cooling circulation loop is: The heat dissipation module water outlet, the electronic water pump, the cooling flow channel of the motor controller, the cooling liquid side pipeline of the motor oil-cooled heat exchanger and the heat dissipation module water inlet; The oil side pipeline of the motor oil-cooled heat exchanger is in communication with the internal oil circuit of the oil-cooled wheel-hub motor.

[0010] Further, the low-voltage distribution box is internally provided with a heat dissipation relay; The control end of the heat dissipation relay is configured to receive a control instruction issued synchronously with an enable signal of the corresponding motor controller to control the power supply on-off of the heat dissipation module.

[0011] In a second aspect, the embodiments of the present application also provide a bridge drive heat dissipation control method of a distributed electric drive chassis, applied to the heat dissipation system of the first aspect, comprising the following steps: S1. In response to the motor controller on any drive axle being enabled, generate and send a first control instruction to turn on the power supply for the corresponding cooling module configured for the corresponding drive axle, start the electronic water pump and the cooling controller of the corresponding cooling module; S2. The cooling controller after starting, real-time acquires the temperature signal collected by the temperature sensor in the corresponding cooling module, and generates the corresponding speed control signal based on the temperature signal, and then sends the speed control signal to the cooling fan of the cooling module to adjust the speed of the cooling fan; S3. In response to the motor controller on any drive axle being disabled, generate and send a second control instruction to turn off the power supply for the corresponding cooling module configured for the corresponding drive axle, so that the electronic water pump, cooling fan and cooling controller of the corresponding cooling module stop working.

[0012] Further, the specific steps of step S1 are as follows: S11. The vehicle controller or the local controller of the corresponding drive axle generates a relay closing instruction synchronized with the motor controller enable signal; S12. Send the relay closing instruction to the cooling relay in the low-voltage distribution box at the corresponding drive axle to control the closing of the cooling relay to power the corresponding cooling module.

[0013] Further, the specific steps of generating the corresponding speed control signal based on the temperature signal in step S2 are as follows: Compare the real-time acquired temperature signal With the preset target temperature To get the temperature deviation : ; Using proportional-integral-derivative control algorithm, according to the temperature deviation Calculate the target fan speed :

[0014] Where, 、 、 Is a preset control parameter; The target fan speed As a speed control signal output to the cooling fan.

[0015] Further, the specific steps of generating the corresponding speed control signal based on the temperature signal in step S2 are as follows: According to the real-time acquired temperature signal T, query the preset temperature-fan speed mapping table; Get the target fan speed Corresponding to the temperature signal T from the mapping table; target fan rotating speed as a rotating speed control signal to the cooling fan.

[0016] Further, the method further comprises the following steps: When a new drive axle and a corresponding cooling module are added to the distributed electric drive chassis, the newly added cooling module is independently controlled, including: In response to the enable or disable state of the motor controller on the newly added drive axle, steps S1 and S3 are independently executed to control the power supply of the corresponding cooling module, and step S2 is independently executed by the cooling controller of the cooling module to adjust the rotating speed of the corresponding cooling fan.

[0017] From the above technical solutions, the present application has the following advantages: In the bridge drive cooling system and control method of the distributed electric drive chassis provided by the present application, through the design of the distributed cooling module, each cooling module independently serves the corresponding drive axle, avoiding the flow resistance and heat loss problems caused by long pipelines in traditional centralized cooling systems, improving the cooling efficiency, and reducing the cooling energy consumption; the cooling module is independently arranged outside the vehicle frame, reducing the occupation of the internal space of the vehicle frame, avoiding the influence of the oversized radiator on the vehicle height and passability, improving the flexible expansion of the chassis structure, and facilitating the adaptation to multi-axle distributed special chassis; each cooling module works independently and does not interfere with each other, the cooling controller adjusts the fan rotating speed in real time according to the temperature sensor signal, ensuring the cooling effect, reducing the risk of failure of the entire cooling system caused by a single component failure, and improving the reliability and stability of the system; the independent cooling module makes maintenance and replacement more convenient, and when a new drive axle and a cooling module are added, independent control can be quickly realized without the need for large-scale adjustment of the existing system, simplifying the vehicle layout and expansion work. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the present application, the following will briefly introduce the drawings needed to be used in the description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0019] Figure 1 FIG. 1 is a schematic diagram of the cooling module of the bridge drive cooling system of the distributed electric drive chassis of the present application.

[0020] Figure 2 FIG. 2 is a schematic diagram of the cooling pipeline of the bridge drive cooling system of the distributed electric drive chassis of the water-cooled wheel-side motor of the present application.

[0021] Figure 3The schematic diagram of the heat dissipation pipeline structure of the bridge drive heat dissipation system of the distributed electric drive chassis of the water-cooled in-wheel motor.

[0022] Figure 4 The layout side view of the bridge drive heat dissipation system of the distributed electric drive chassis of the water-cooled in-wheel motor.

[0023] Figure 5 The layout top view of the bridge drive heat dissipation system of the distributed electric drive chassis of the water-cooled in-wheel motor.

[0024] Figure 6 The schematic diagram of the heat dissipation pipeline of the bridge drive heat dissipation system of the distributed electric drive chassis of the in-wheel motor.

[0025] Figure 7 The schematic diagram of the heat dissipation pipeline structure of the bridge drive heat dissipation system of the distributed electric drive chassis of the in-wheel motor.

[0026] Figure 8 The layout side view of the bridge drive heat dissipation system of the distributed electric drive chassis of the in-wheel motor.

[0027] Figure 9 The layout top view of the bridge drive heat dissipation system of the distributed electric drive chassis of the in-wheel motor.

[0028] Figure 10 The power supply schematic diagram of the bridge drive heat dissipation system of the distributed electric drive chassis.

[0029] Figure 11 The flowchart of the bridge drive heat dissipation control method of the distributed electric drive chassis.

[0030] 1 - heat dissipation module; 1.1 - first heat dissipation module; 1.2 - second heat dissipation module; 1.3 - third heat dissipation module; 1.4 - fourth heat dissipation module; 1.(2N-1) - (2N-1)th heat dissipation module; 1.(2N) - 2Nth heat dissipation module; 2 - radiator; 3 - heat dissipation fan; 4 - electronic water pump; 5 - temperature sensor; 6 - heat dissipation controller; 7 - connecting pipeline; 8 - mounting bracket; 9 - power supply input; 10 - low-voltage wiring harness; 11 - heat dissipation module water inlet; 12 - heat dissipation module water outlet; 13 - water-cooled wheel rim motor; 14 - motor controller; 14.1 - first motor controller; 14.2 - second motor controller; 14.3 - third motor controller; 14.4 - fourth motor controller; 14.(2N-1) - (2N-1)th motor controller; 14.(2N) - 2Nth motor controller; 15 - oil-cooled hub motor; 16 - motor oil-cooled heat exchanger; 17 - oil pump; 18 - heat dissipation oil tank; 19.1 - first bridge drive controller; 19.2 - second bridge drive controller; 19.3 - third bridge drive controller; 19.4 - fourth bridge drive controller; 19.(2N-1) - (2N-1)th bridge drive controller; 19.(2N) - 2Nth bridge drive controller; 20.1 - first low-voltage distribution box; 20.2 - second low-voltage distribution box; 20.3 - third low-voltage distribution box; 20.4 - fourth low-voltage distribution box; 20.(2N-1) - (2N-1)th low-voltage distribution box; 20.(2N) - 2Nth low-voltage distribution box; 21 - expansion tank. DETAILED DESCRIPTION

[0031] Various embodiments of the present disclosure will be described in detail below with reference to the drawings. Various embodiments of the present disclosure can have various embodiments, and adjustments and changes can be made therein. However, it should be understood that there is no intention to limit various embodiments of the present disclosure to the specific embodiments disclosed herein, but the present disclosure should be understood to cover all adjustments, equivalents and / or alternatives falling within the spirit and scope of various embodiments of the present disclosure.

[0032] By way of example, in a new energy vehicle, the motor and motor controller as core power components will generate a large amount of heat when running. High temperature can cause demagnetization of motor magnetic material, aging of winding insulation, and overheating breakdown of controller power devices, seriously affecting the performance, safety and reliability of the vehicle. Therefore, an efficient heat dissipation system is crucial for a new energy vehicle.

[0033] Currently, heavy new energy vehicles mostly adopt central drive or electric drive axle form, and the radiator is usually arranged at the front of the frame to cool the motors and controllers of all drive units through long pipelines in series. This centralized cooling scheme is still applicable in single axle or double axle drive chassis, but for distributed drive special multi axle electric drive chassis (such as five axles or more), the power is derived from multiple wheel edge or hub motors. If the traditional cooling scheme is continued to be used, the cooling pipeline will extend from the front end of the frame to the end drive axle, resulting in long pipeline, increased flow resistance and increased heat loss. At the same time, in order to meet the cooling demand of multiple axles, the volume of the radiator, the power of the fan and the water pump need to be greatly improved, which not only occupies the chassis layout space, but also limits the overall height and passability, making it extremely difficult to flexibly expand the chassis structure.

[0034] In the existing related patents, although there are distributed electric drive vehicle cooling schemes, it is difficult to realize the rapid expansion of the chassis axle number due to the software logic of the central controller, and the communication wire harness needs to be adaptively changed. In some other patents, although multiple flow valves are used to regulate the cooling liquid flow of different motors, multiple hub motors still share the same radiator, which cannot meet the requirements of decoupling and independent control of each axle chassis, and the volume and layout of the radiator are still limited.

[0035] Therefore, there is an urgent need for a new cooling method to adapt to the characteristics of multi axle distributed special chassis and solve the problems of high cooling energy consumption, limited layout and poor expandability.

[0036] To solve the above problems, the embodiment provides a bridge drive cooling system of a distributed electric drive chassis, which independently arranges the cooling modules, optimizes the space, reduces the energy consumption, improves the cooling efficiency, enhances the system reliability, and is convenient for maintenance and expansion.

[0037] The technical solutions in the embodiments of the present application will be described clearly and completely in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0038] Please refer to Figure 1 Fig. 1 is a schematic diagram of a bridge drive cooling system of a distributed electric drive chassis in a specific embodiment, and the distributed electric drive chassis is provided with a plurality of drive axles; The system comprises a plurality of cooling modules 1; the number of the cooling modules 1 corresponds to the number of the drive axles; Each cooling module 1 is independently arranged outside the frame at the corresponding drive axle; It should be noted that each heat dissipation module 1 independently serves the corresponding drive axle, avoids mutual interference of the heat dissipation system, can accurately dissipate heat according to the actual heat dissipation demand of each drive axle, improves the heat dissipation efficiency; the heat dissipation module 1 is independently arranged outside the vehicle frame, reduces the occupation of the internal space of the vehicle frame, optimizes the layout of the chassis space, and improves the passability and flexibility of the whole vehicle; Each heat dissipation module 1 comprises a radiator 2, a heat dissipation fan 3, an electronic water pump 4, a temperature sensor 5, a heat dissipation controller 6 and a connecting pipeline 7; the radiator 2 is provided with a water outlet and a water inlet; It should be noted that the radiator 2 absorbs heat through the circulation of cooling liquid and dissipates to the air, ensuring that the motor and the controller work stably under high temperature conditions; the radiator 2 and the electronic water pump 4 form a cooling cycle through the connecting pipeline 7, which is compact in structure and convenient for integration and arrangement; The heat dissipation fan 3 accelerates the air flow on the surface of the radiator by forced convection, improves the heat dissipation efficiency, and ensures that the radiator 2 can quickly dissipate heat to the environment; the speed of the heat dissipation fan 3 is dynamically adjusted by the heat dissipation controller according to the signal of the temperature sensor 5, realizing the balance between energy saving and high efficiency heat dissipation; The electronic water pump 4 provides power for the circulation of cooling liquid, ensures the efficient flow of cooling liquid between the radiator 2, the motor controller and the drive motor, and maintains stable heat dissipation effect; the electronic water pump 4 can dynamically adjust the speed according to the actual heat dissipation demand, reducing energy consumption; The temperature sensor 5 collects the temperature signal of the radiator 2 or the cooling liquid in real time, provides accurate temperature data for the heat dissipation controller 6, and ensures the accurate control of the heat dissipation system; by monitoring the temperature in real time through the temperature sensor 5, potential overheating risks are found in advance, improving the reliability and safety of the system; The heat dissipation controller 6 dynamically adjusts the speed of the heat dissipation fan 3 according to the signal of the temperature sensor 5, realizes intelligent management of the heat dissipation system, improves the heat dissipation efficiency and energy saving effect; the heat dissipation controllers 6 of each heat dissipation module 1 work independently and do not interfere with each other, reducing the risk of failure of the whole heat dissipation system due to failure of a single component; It should be noted that the connecting pipeline 7 connects the heat dissipation pipelines of the radiator 2, the electronic water pump 4, the motor controller and the drive motor in series to form an independent cooling circulation loop, ensuring efficient operation of the heat dissipation system; by optimizing the pipeline design, the flow resistance of the cooling liquid is reduced, the heat loss is reduced, and the system arrangement is simplified; Each heat dissipation module 1 is connected to the motor controller and the drive motor on the corresponding drive axle through the connecting pipeline 7 to form a heat exchange connection, so that the radiator 2, the electronic water pump 4, the motor controller and the drive motor of the heat dissipation module 1 are connected in series through the connecting pipeline to form an independent cooling circulation loop; The power input end 9 of each heat dissipation module 1 is connected to a low-voltage distribution box 20 at the corresponding drive axle, and the power supply interfaces of the heat dissipation fan 3, the heat dissipation controller 6 and the electronic water pump 4 are connected to the power input end 9; The low-voltage distribution box 20 provides stable power supply for the heat dissipation module 1, ensuring normal operation of the heat dissipation system; The heat dissipation controller 6 is connected to the temperature sensor 5 and the heat dissipation fan 3, and is used to adjust the rotating speed of the heat dissipation fan 3 according to the temperature signal collected by the temperature sensor 5.

[0039] The embodiment adopts a distributed heat dissipation module, independently serves each drive axle, optimizes spatial arrangement, reduces heat dissipation energy consumption, improves heat dissipation efficiency, enhances system reliability, is convenient for maintenance and expansion, and adapts to the demand of a multi-axle chassis.

[0040] Further, as a refinement and expansion of the specific implementation manner of the above embodiment, in order to completely describe the specific implementation process in the embodiment, another bridge drive heat dissipation system of a distributed electric drive chassis is provided, and a plurality of drive axles are arranged on the distributed electric drive chassis; The system comprises a plurality of heat dissipation modules 1; the number of the heat dissipation modules 1 corresponds to the number of the drive axles; Each heat dissipation module 1 is independently arranged outside a vehicle frame at the corresponding drive axle; Each heat dissipation module 1 comprises a radiator 2, a heat dissipation fan 3, an electronic water pump 4, a temperature sensor 5, a heat dissipation controller 6 and a connecting pipeline 7; the radiator 2 is provided with a water outlet and a water inlet; Each heat dissipation module 1 is connected to a motor controller and a drive motor on the corresponding drive axle through the connecting pipeline 7 to form a heat exchange connection, so that the radiator 2, the electronic water pump 4, the motor controller and the drive motor of the heat dissipation module 1 are connected in series through the connecting pipeline 7 to form an independent cooling circulation loop; It should be noted that the heat dissipation module water inlet 11 and the heat dissipation module water outlet 12 are used to be connected to the external motor controller and drive motor through the connecting pipeline 7 to form a cooling circulation loop and realize independent connection; The power input end 9 of each heat dissipation module 1 is connected to a low-voltage distribution box 20 at the corresponding drive axle, and the power supply interfaces of the heat dissipation fan 3, the heat dissipation controller 6 and the electronic water pump 4 are connected to the power input end 9 through a low-voltage wire harness 10; As Figure 10As shown, each drive axle of the chassis is equipped with an independent low-voltage distribution box 20. The power input terminal 9 of each heat dissipation module 1 is connected to the rear end of the heat dissipation relay of the corresponding drive axle's low-voltage distribution box 20. The control terminal of the heat dissipation relay communicates with the axle drive controller or vehicle controller of the corresponding drive axle and receives relay closing / opening commands synchronized with the motor controller enable signal. When the motor controller 14 of a certain drive axle is enabled, the heat dissipation relay of the corresponding low-voltage distribution box 20 closes, supplying power to the electronic water pump 4, cooling fan 3, and heat dissipation controller 6 of the heat dissipation module 1 of that drive. When the motor controller 14 is disabled, the power supply is simultaneously cut off. This power supply architecture realizes the linkage start and stop of the heat dissipation module 1 and the drive axle power system, which not only avoids the ineffective energy consumption and noise in the standby state, but also simplifies the layout of the chassis power supply harness. Each axle power supply circuit is independent and there is no power supply interference, which further improves the reliability and energy efficiency of the multi-axle chassis heat dissipation system. The heat dissipation controller 6 is connected to the temperature sensor 5 and the cooling fan 3, and is used to adjust the speed of the cooling fan 3 according to the temperature signal collected by the temperature sensor 5. Each heat dissipation module 1 also includes an expansion tank 21 and a mounting bracket 8; The expansion tank 21 is fitted to the radiator 2 and positioned above the radiator 2; Mounting bracket 8 is located on one side of radiator 2 and is used to fix heat dissipation module 1 to the preset mounting hole on the outside of the frame; like Figure 2 and Figure 3 As shown, the drive motor is a water-cooled wheel-side motor 13; The heat exchange connection is a direct cooling connection, and the corresponding series sequence of the cooling circulation loop is as follows: The radiator 2 outlet, the electronic water pump 4, the cooling channel of the motor controller 14, the cooling channel of the water-cooled wheel-side motor 13, and the radiator 2 inlet; The low-voltage distribution box is equipped with a heat dissipation relay; The control terminal of the heat dissipation relay is configured to receive control commands that are synchronously sent with the enable signal of the corresponding motor controller 14, so as to control the power supply to the heat dissipation module 1. like Figure 4 and Figure 5As shown, the first heat dissipation module 1.1, the second heat dissipation module 1.2, the third heat dissipation module 1.3, the fourth heat dissipation module 1.4, …, the (2N-1)th heat dissipation module 1.(2N-1), and the 2Nth heat dissipation module 1.(2N) are independently installed at the preset mounting hole positions on the same side of the frame outside the corresponding drive axle, and the overall state is uniformly distributed along the longitudinal direction of the frame; the air outlet direction of each heat dissipation module is lateral to the frame, which avoids airflow interference with other components (such as suspension and tires) of the chassis, and does not occupy the power assembly and pipeline arrangement space on the inner side of the frame; the installation height of each heat dissipation module matches the pipeline interface height of the motor controller 14 and the water-cooled wheel motor 13 of the corresponding drive axle, which can greatly shorten the length of the cooling pipeline, reduce the pipeline flow resistance and heat loss, and the structural size of each heat dissipation module 1 is uniform, which ensures the regularity and consistency of the chassis side layout, and improves the passability and space utilization of the vehicle; each drive axle of the chassis is provided with an independent heat dissipation module and a motor controller, the left and right water-cooled wheel motors are connected in parallel to the cooling circulation loop of the corresponding drive axle, and then connected in series with the motor controller cooling flow passage of the corresponding drive axle and connected to the same side heat dissipation module; the cooling pipeline of each heat dissipation module only covers the power components of the corresponding drive axle, and the pipeline is arranged in a near-by manner along the lateral direction of the frame without crossing the bridge long pipeline; as can be seen from the top view, all heat dissipation modules are externally arranged on both sides of the frame, and there is no large area occupation of the centralized heat sink on the inner side of the frame, which reserves sufficient space for the arrangement of other components such as the chassis battery and gas cylinder, and the bridge heat dissipation system is completely decoupled, and the working state of any bridge heat dissipation module does not affect the heat dissipation effect of other drive axles, realizing independent controllability and flexible expansion of multi-axle chassis heat dissipation; Unlike the above embodiments, as shown in Figure 6 and Figure 7 the drive motor is an oil-cooled wheel motor 15; the heat exchange connection includes a direct cooling connection to the motor controller 14 and an indirect cooling connection to the oil-cooled wheel motor 15; the series connection order of the corresponding cooling circulation loop is: the water outlet of the radiator 2, the electronic water pump 4, the cooling flow passage of the motor controller 14, the cooling liquid side pipeline of the motor oil-cooled heat exchanger 16, and the water inlet of the radiator 2; the oil side pipeline of the motor oil-cooled heat exchanger 16 is in communication with the internal oil circuit of the oil-cooled wheel motor, and the internal oil circuit is provided with an oil pump 17 and a heat dissipation oil tank 18; as shown in Figure 8 and Figure 9As shown, the first heat dissipation module 1.1, the second heat dissipation module 1.2, the third heat dissipation module 1.3, the fourth heat dissipation module 1.4, …, the (2N-1)th heat dissipation module 1.(2N-1), and the 2Nth heat dissipation module 1.(2N) still maintain the frame-outer-side installation form corresponding to the drive axle, the height and angle of the mounting bracket are optimized to adapt to the position of the pipeline interface of the oil-cooled heat exchanger 16; due to the addition of auxiliary heat dissipation components such as the motor oil-cooled heat exchanger 16 and the oil pump 17 to the oil-cooled hub motor 15, the longitudinal arrangement spacing of the heat dissipation module 1 matches the installation space of the oil-cooled components of the corresponding drive axle, ensuring that the cooling pipeline (including the cooling liquid pipeline and the lubricating oil pipeline) is simple and free of bending; the side air outlet design of the heat dissipation module 1 can simultaneously consider the heat dissipation of the radiator 2 and the environmental heat dissipation of the oil-cooled heat exchanger 16, improving the efficiency of the overall heat dissipation link, and the modular arrangement form does not change the side profile of the chassis, ensuring the passability of the vehicle and reserving sufficient operation space for the maintenance of the oil-cooled system; the motor controller 14 of each drive axle is directly connected to the corresponding heat dissipation module through the cooling liquid pipeline, while the left and right oil-cooled hub motors are indirectly cooled through the motor oil-cooled heat exchanger 16, that is, the cooling liquid side pipeline of the oil-cooled heat exchanger is connected in series to the cooling circulation loop of the drive axle, and the oil side pipeline forms an independent oil circulation loop with the internal oil circuit of the hub motor, the oil pump 17, and the heat dissipation oil tank 18; as can be seen from the top view, the cooling liquid pipeline and the lubricating oil pipeline of each drive axle are independently formed into a network and are connected to the heat dissipation module on the same side without crossing the bridge pipeline; all the heat dissipation modules 1 are symmetrically distributed on both sides of the frame, and the auxiliary components (the oil pump 17 and the heat dissipation oil tank 18) of the oil-cooled system are arranged on the inner side of the frame corresponding to the drive axle to form a side-in complementary layout with the heat dissipation module 1, which not only ensures the compactness of the heat dissipation link but also realizes decoupling control of the heat dissipation of the multi-axle oil-cooled hub motor, meeting the dual requirements of expandability and reliability of the heat dissipation system of the special multi-axle chassis.

[0041] As shown in the drawings, Figure 11 The following is an embodiment of a bridge drive heat dissipation control method of a distributed electric drive chassis provided by the embodiment of the present disclosure. The method belongs to the same inventive concept as the above-mentioned embodiments of the bridge drive heat dissipation system of the distributed electric drive chassis. Details not described in the embodiment of the bridge drive heat dissipation control method of the distributed electric drive chassis can be referred to the above-mentioned embodiments of the bridge drive heat dissipation system of the distributed electric drive chassis.

[0042] The method comprises the following steps: S1. In response to the motor controller on any drive axle being enabled, a first control instruction is generated and sent to turn on the power supply of the heat dissipation module configured for the corresponding drive axle, and start the electronic water pump and the heat dissipation controller of the corresponding heat dissipation module; It should be noted that the automatic on-off of the power supply of the heat dissipation module is realized by responding to the enable signal of the motor controller, which reduces the energy consumption and heat dissipation noise in the standby state and improves the energy-saving effect of the system. S2. The started heat dissipation controller obtains the temperature signal collected by the temperature sensor in the corresponding heat dissipation module in real time, generates a corresponding speed control signal based on the temperature signal, and sends the speed control signal to the heat dissipation fan of the heat dissipation module to adjust the speed of the heat dissipation fan; It should be noted that the heat dissipation controller obtains the temperature signal in real time and adjusts the speed of the heat dissipation fan, which ensures the heat dissipation effect while reducing the heat dissipation energy consumption, improves the dynamic adaptability and reliability; S3. In response to the motor controller on any drive axle being disabled, a second control instruction is generated and sent to disconnect the power supply of the heat dissipation module configured for the corresponding drive axle, so that the electronic water pump, heat dissipation fan and heat dissipation controller of the corresponding heat dissipation module stop working; It should be noted that in response to the disabled state of the motor controller, the power supply of the heat dissipation module is quickly disconnected, so that the heat dissipation module stops working, which improves the response speed of the system and reduces unnecessary energy consumption.

[0043] The heat dissipation module of the embodiment is independently arranged outside the vehicle frame, which optimizes the space occupation and reduces the heat dissipation energy consumption; through real-time temperature monitoring and intelligent control, the speed of the heat dissipation fan is dynamically adjusted to improve the heat dissipation efficiency and enhance the reliability; the heat dissipation module is independently controlled, which is convenient for maintenance and expansion, and is suitable for multi-axle distributed chassis and different drive motor heat dissipation requirements, and improves the performance and reliability of the whole vehicle Further, as a refinement and expansion of the specific implementation manner of the above embodiment, in order to completely describe the specific implementation process in the embodiment, another bridge drive heat dissipation control method of a distributed electric drive chassis is provided, which includes the following steps: S1. In response to the motor controller on any drive axle being enabled, a first control instruction is generated and sent to connect the power supply of the heat dissipation module configured for the corresponding drive axle, and the electronic water pump and heat dissipation controller of the corresponding heat dissipation module are started; the specific steps of step S1 are as follows: S11. The vehicle controller or the local controller of the corresponding drive axle generates a relay closing instruction synchronized with the motor controller enable signal; S12. The relay closing instruction is sent to the heat dissipation relay in the low-voltage distribution box located at the corresponding drive axle to control the closing of the heat dissipation relay and power the corresponding heat dissipation module; S2. The started heat dissipation controller obtains the temperature signal collected by the temperature sensor in the corresponding heat dissipation module in real time, generates a corresponding speed control signal based on the temperature signal, and sends the speed control signal to the heat dissipation fan of the heat dissipation module to adjust the speed of the heat dissipation fan; The specific steps of generating a corresponding speed control signal based on the temperature signal in step S2 are as follows: The temperature signal obtained in real time is compared with the preset target temperature By comparison, the temperature deviation is obtained. : ; A proportional-integral-derivative control algorithm is adopted, based on the temperature deviation. Calculate the target fan speed :

[0044] in, , , These are preset control parameters; Target fan speed The speed control signal is output to the cooling fan; S3. In response to the motor controller on any drive axle being disabled, generate and send a second control command to disconnect the power supply to the heat dissipation module configured for the corresponding drive axle, so that the electric water pump, cooling fan and heat dissipation controller of the corresponding heat dissipation module stop working.

[0045] Unlike the above embodiments, the specific steps for generating the corresponding speed control signal based on the temperature signal in step S2 are as follows: Based on the real-time acquired temperature signal T, query the preset temperature-fan speed mapping table; Obtain the target fan speed corresponding to the temperature signal T from the mapping table. ; Target fan speed The speed control signal is output to the cooling fan.

[0046] In some embodiments of the present invention, the following steps are also included: When a new drive axle and corresponding cooling module are added to a distributed electric drive chassis, the newly added cooling module is independently controlled, including: In response to the enabled or disabled state of the motor controller on the newly added drive axle, steps S1 and S3 are executed independently to control the power supply to the corresponding heat dissipation module, and step S2 is executed independently by the heat dissipation controller of the heat dissipation module itself to adjust the speed of the corresponding cooling fan.

[0047] For example, the control method is explained using a typical operating condition of a three-axis distributed electric drive chassis (equipped with a water-cooled wheel-side motor): A heavy-duty special three-axis distributed electric drive chassis, with each drive axle equipped with an independent heat dissipation module. The motor controller has a preset enable temperature threshold of 60℃, the target coolant temperature for the heat dissipation module is 75℃, and the PID control parameters are set as follows: =5、 =0.2、 =0.1, while the preset temperature-fan speed mapping table is shown in Table 1 below: Table 1

[0048] Working condition 1: chassis starting stage When the driver starts the vehicle, the vehicle controller sends an enable instruction to the motor controllers of the three drive axles, and simultaneously sends a cooling relay closing instruction to the low-voltage distribution boxes of each axle; The low-voltage distribution boxes of the first, second and third axles close the cooling relays in turn, and the corresponding electronic water pumps and cooling controllers of the cooling modules are started, and the coolant starts to circulate; During the starting stage, the motor load is low, and the initial temperature of the coolant is 55℃. After the temperature sensor collects the signal, the cooling controller calculates the temperature deviation by PID algorithm =75-55=20℃, the target fan speed is 800rpm; At the same time, query the mapping table, 55℃ corresponds to the speed of 800rpm, the results of the two ways are consistent, the cooling fan runs at 800rpm low speed, realizes low energy consumption cooling; If the driver temporarily stops and engages the neutral gear after starting, the vehicle controller disables the second axle motor controller and simultaneously sends a cooling relay opening instruction, the electronic water pump, fan and controller of the second axle cooling module stop working, only the first and third axle cooling modules remain running, reducing standby energy consumption.

[0049] Working condition 2: chassis heavy load climbing stage When the chassis is heavy load climbing, the motor controllers of the three drive axles remain enabled, and all cooling modules are powered and running continuously; Due to the sudden increase of motor load, the coolant temperature rises to 78℃ after 10min, and the temperature deviation =75-78=-3℃, the target fan speed is calculated to be 2200rpm by PID algorithm; Query the mapping table, 78℃ corresponds to the speed of 2200rpm, the cooling fan automatically increases to 2200rpm to quickly remove heat; After 3min, the coolant temperature drops to 74℃, and the fan speed decreases to 1600rpm, maintaining temperature stability; After climbing, the vehicle enters flat road cruising, the motor load decreases, if the first axle motor controller is disabled due to chassis power distribution strategy, the first axle cooling module is also powered off and stops working, only the second and third axle cooling modules dynamically adjust the fan speed according to the temperature.

[0050] Exemplarily, taking the typical working condition of a four-axle distributed electric drive chassis (equipped with oil-cooled hub motors) as an example, the control method is described: A certain four-axle distributed electric drive chassis carries oil-cooled wheel hub motors, and each axle cooling module needs to cool the motor controller (direct cooling) and the wheel hub motor (indirect cooling through an oil-cooled heat exchanger). The cooling relay is independently controlled by the axle drive controller, and the fan speed is controlled by a temperature-speed mapping table. The mapping table is shown in Table 2. Table 2

[0051] Working condition 1: chassis low-speed operation stage When the chassis is performing low-speed engineering operation, the four-axle motor controllers are enabled, the axle drive controllers synchronously close the cooling relays of the corresponding low-voltage distribution boxes, and the four sets of cooling modules are all started. The electronic water pump drives the cooling liquid to flow through the motor controller and the oil-cooled heat exchanger, and the oil pump synchronously drives the wheel hub motor lubricating oil circulation heat exchange. During the operation stage, the motor continuously operates at a low speed and a high torque, the cooling liquid temperature rises to 68°C, and the fan speed is increased to 1000 rpm after querying the mapping table. The oil-cooled heat exchanger cooling efficiency is improved, and the wheel hub motor lubricating oil temperature is stabilized at 85°C (within the safety threshold). After the operation is completed, only the first and second axle motor controllers are enabled, the third and fourth axle motor controllers are disabled, the corresponding cooling modules are synchronously powered off, the oil pump and the oil-cooled heat exchanger stop working, and the invalid energy consumption is reduced.

[0052] Working condition 2: cooling control after expanding the number of chassis axles The chassis adds a fifth axle and the corresponding cooling module due to operation requirements. The new module is consistent with the original module in specification, and the control logic does not need to be changed. When the fifth axle motor controller is enabled, the fifth axle low-voltage distribution box cooling relay is synchronously closed, and the new cooling module is automatically started. The electronic water pump and the controller start working. The temperature sensor of the new cooling module collects the cooling liquid temperature, independently queries the mapping table to adjust the fan speed, for example, when the cooling liquid temperature is 72°C, the fan automatically operates at 1500 rpm, and there is no control interference with the original cooling module. When the fifth axle motor controller is disabled, its cooling module is synchronously powered off and stops working, realizing seamless compatibility after expanding the number of axles.

[0053] It should be understood that the size of the serial number of each step in the above embodiment does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiment of the present application.

[0054] The foregoing description of the disclosed embodiments enables a person skilled in the art to make or use the application. Modifications of these embodiments will occur to persons of skill in the art, and that the appended claims are intended to cover all such modifications that do not depart from the true spirit and scope of the application. Therefore, the application is not limited to the embodiments shown but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A bridge drive heat dissipation system of a distributed electric drive chassis, characterized in that, The distributed electric drive chassis is provided with a plurality of drive axles; The system comprises a plurality of heat dissipation modules; the number of the heat dissipation modules corresponds to the number of the drive axles; Each heat dissipation module is independently arranged outside the frame at the corresponding drive axle; Each heat dissipation module comprises a radiator, a heat dissipation fan, an electronic water pump, a temperature sensor, a heat dissipation controller and a connecting pipeline; the radiator is provided with a water outlet and a water inlet; Each heat dissipation module is connected to the motor controller and the drive motor on the corresponding drive axle through the connecting pipeline to form an independent cooling circulation loop in series through the radiator, the electronic water pump, the motor controller and the drive motor; The power input end of each heat dissipation module is connected to the low-voltage distribution box at the corresponding drive axle; the power supply interfaces of the heat dissipation fan, the heat dissipation controller and the electronic water pump are connected to the power input end; The heat dissipation controller is connected to the temperature sensor and the heat dissipation fan, and is used for adjusting the rotating speed of the heat dissipation fan according to the temperature signal collected by the temperature sensor.

2. The bridge drive heat dissipation system of the distributed electric drive chassis according to claim 1, wherein, Each heat dissipation module further comprises an expansion tank and a mounting bracket; The expansion tank is arranged in close contact with the radiator and above the radiator; The mounting bracket is arranged on one side of the radiator and is used for fixing the heat dissipation module to a preset mounting hole position outside the frame.

3. The bridge drive heat dissipation system of the distributed electric drive chassis of claim 1, wherein, The drive motor is a water-cooled wheel-side motor; The heat exchange connection is a direct cooling connection, and the series connection order of the corresponding cooling circulation loop is as follows: the water outlet of the radiator, the electronic water pump, the cooling flow channel of the motor controller, the cooling flow channel of the water-cooled wheel-side motor and the water inlet of the radiator.

4. The bridge drive heat dissipation system of the distributed electric drive chassis of claim 1, wherein, The drive motor is an oil-cooled hub motor; The heat exchange connection comprises a direct cooling connection to the motor controller and an indirect cooling connection to the oil-cooled hub motor; The series connection order of the corresponding cooling circulation loop is as follows: the water outlet of the radiator, the electronic water pump, the cooling flow channel of the motor controller, the cooling liquid side pipeline of the motor oil-cooled heat exchanger and the water inlet of the radiator; The oil side pipeline of the motor oil-cooled heat exchanger is in communication with the internal oil circuit of the oil-cooled hub motor.

5. The bridge drive heat dissipation system of the distributed electric drive chassis of claim 1, wherein, The low-voltage distribution box is internally provided with a heat dissipation relay; The control end of the heat dissipation relay is configured to receive a control instruction issued synchronously with an enable signal of the corresponding motor controller to control the power supply on / off of the heat dissipation module.

6. A bridge drive heat dissipation control method of a distributed electric drive chassis, applied to the heat dissipation system of any one of claims 1-5, characterized in that, The method comprises the following steps: S1. In response to the motor controller on any drive axle being enabled, a first control instruction is generated and sent to turn on the power supply of the heat dissipation module configured for the corresponding drive axle, and the electronic water pump and the heat dissipation controller of the corresponding heat dissipation module are started; S2. The started heat dissipation controller acquires the temperature signal collected by the temperature sensor in the corresponding heat dissipation module in real time, generates a corresponding rotating speed control signal based on the temperature signal, and sends the rotating speed control signal to the heat dissipation fan of the heat dissipation module to adjust the rotating speed of the heat dissipation fan; S3. In response to the motor controller on any drive axle being disabled, a second control instruction is generated and sent to turn off the power supply of the heat dissipation module configured for the corresponding drive axle, so that the electronic water pump, the heat dissipation fan and the heat dissipation controller of the corresponding heat dissipation module stop working.

7. The bridge drive heat dissipation control method of the distributed electric drive chassis according to claim 6, characterized in that, The specific steps of step S1 are as follows: S11. Generate a relay closing instruction synchronized with the motor controller enable signal by the vehicle controller or the local controller of the corresponding drive axle; S12. Send the relay closing instruction to the heat dissipation relay in the low-voltage distribution box at the corresponding drive axle, control the closing of the heat dissipation relay, and power the corresponding heat dissipation module.

8. The bridge drive heat dissipation control method of the distributed electric drive chassis according to claim 6, wherein, The specific steps of generating the corresponding speed control signal based on the temperature signal in step S2 are as follows: The temperature signal acquired in real time is compared with a preset target temperature to obtain a temperature deviation. :​​ ； using a proportional-integral-derivative control algorithm, based on the temperature deviation calculating a target fan speed : wherein, , , are preset control parameters; The target fan rotation speed is output as a rotation speed control signal to the cooling fan.

9. The bridge drive heat dissipation control method of the distributed electric drive chassis according to claim 6, wherein, The specific steps of generating the corresponding speed control signal based on the temperature signal in step S2 are as follows: According to the real-time acquired temperature signal T, query the preset temperature-fan speed mapping table; obtaining a target fan speed corresponding to the temperature signal T from the mapping table ; The target fan rotation speed is output as a rotation speed control signal to the cooling fan.

10. The bridge drive heat dissipation control method of the distributed electric drive chassis according to claim 6, wherein, Further comprising the following steps: When a new drive axle and the corresponding heat dissipation module are added to the distributed electric drive chassis, the newly added heat dissipation module is independently controlled, including: In response to the enable or disable state of the motor controller on the newly added drive axle, steps S1 and S3 are independently executed to control the power on-off of the corresponding heat dissipation module, and step S2 is independently executed by the heat dissipation controller of the heat dissipation module to adjust the speed of the corresponding heat dissipation fan.

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