Multi-way rotary valve for vehicle thermal management system

Abstract

The invention discloses a multi-way rotary valve for a vehicle thermal management system, and belongs to the technical field of fluid control valves. The multi-way rotary valve comprises a valve body, a valve element, a driving unit and a sealing assembly. The valve body is provided with eight external connectors distributed in the circumferential direction. The valve element is rotatably arranged in the valve body, and an internal flow channel of a specific structure is pre-machined in the valve element. The driving unit is used for driving the valve element to rotate to different preset angle positions, so that different external connectors are selectively communicated through the internal flow channel, and at least four stable circulation channel states are formed. Through innovative valve element flow channel design and an angle positioning mechanism, multi-mode accurate control over a complex heat management loop through a single valve body is achieved, and the valve has the advantages of being high in integration degree, small in flow resistance, reliable in sealing and rapid in response.

Description

Technical Field

[0001] This invention relates to the field of fluid control valve technology, and more specifically to a multi-pass rotary valve for use in the thermal management system of electric or hybrid vehicles. Background Technology

[0002] With the development of new energy vehicle technology, vehicle thermal management systems are becoming increasingly complex, requiring precise temperature management of multiple components such as the battery, motor, electronic control system, and cabin. Traditional thermal management systems use multiple independent three-way valves, four-way valves, and complex piping for loop switching, resulting in complex system structure, large space occupation, high cost, and cumbersome control logic.

[0003] While some multi-way valves are used in existing technologies, they generally suffer from problems such as unreasonable flow channel design leading to high flow resistance, poor sealing reliability, limited operating states (usually less than four), and inaccurate angle positioning. These issues make it difficult to meet the requirements of modern intelligent thermal management systems for multi-mode operation, high efficiency, and high reliability.

[0004] Therefore, there is an urgent need for a multi-way rotary valve with high integration, flexible flow path switching, precise control, and strong reliability as the core control component of the next-generation integrated thermal management system. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a multi-way rotary valve with compact structure, low flow resistance, good sealing performance, multiple working states and precise control, so as to meet the needs of complex vehicle thermal management systems.

[0006] The technical solution of the present invention is achieved in the following ways: A multi-way rotary valve for a vehicle thermal management system includes a valve body, a valve core, a drive unit, and a sealing assembly. The valve body has eight circumferentially symmetrically distributed external interfaces. The valve core has a cylindrical structure with pre-machined internal flow channels, including U-shaped flow channels and axially penetrating flow channels. The drive unit (such as a stepper motor) can precisely drive the valve core to rotate within the valve body. By dividing the 360° rotation range of the valve core into four angular working states, each state corresponds to a predetermined flow path connection state, thus achieving four different working modes. A reliable seal is achieved between the valve core and the valve body through O-rings and end face seals. The system also integrates a Hall effect-based position feedback mechanism for real-time closed-loop control of the valve core angle.

[0007] The beneficial effects of this invention include: 1. High integration: A single valve body enables switching between at least four complex flow paths, replacing multiple traditional valves and simplifying system structure and control; 2. Low flow resistance and high efficiency: The internal flow channels are optimized with streamlined design, significantly reducing fluid pressure loss and improving the energy efficiency of the entire thermal management system; 3. Reliable sealing: Utilizing a combined dynamic and static sealing scheme, it effectively prevents cross-contamination between different flow paths and external leakage; 4. Precise Control: Utilizing stepper motor drive and Hall sensor feedback, precise control of the valve core angle and real-time position confirmation are achieved, ensuring the accuracy and reliability of flow path switching; 5. Multifunctionality: Four preset working modes perfectly cover the main typical working conditions of vehicle thermal management, such as conventional heat dissipation, waste heat recovery, and emergency cooling. Attached Figure Description

[0008] Figure 1 This is a three-dimensional assembly diagram of the multi-way rotary valve of the present invention.

[0009] Figure 2 This is an exploded view of the multi-way rotary valve of the present invention.

[0010] Figure 3 This is a three-dimensional structural diagram of the valve core, showing the internal flow channel layout.

[0011] Figure 4 , Figure 5 , Figure 6 , Figure 7 This diagram illustrates the correspondence between the internal flow channel of the valve core and the valve body interface under four operating conditions (a: State 1, b: State 2, c: State 3, d: State 4). Detailed Implementation

[0012] A preferred embodiment of the present invention will now be described in detail with reference to the accompanying drawings.

[0013] Reference Figure 1 and Figure 2 This multi-way rotary valve is mainly composed of valve body 1, valve core 2, drive unit 3, O-ring seal 4, end face seal 5, magnet 6 and Hall sensor 7.

[0014] The valve body 1 is made of die-cast aluminum alloy with a high-precision cylindrical cavity machined inside. Eight standard pipe thread interfaces, numbered 101 to 108, are evenly machined circumferentially on its sidewalls for connecting to external pipelines. The valve core 2 is precision-machined from engineering plastics (such as PEEK) or stainless steel, with its outer diameter fitting closely to the inner diameter of the cavity in the valve body 1. The valve core 2 has a complex pre-machined flow channel network inside, such as… Figure 3 As shown, it includes a first U-shaped flow channel 201, a second U-shaped flow channel 202, and two axially penetrating flow channels 203. The inlets and outlets of these flow channels are uniformly arranged at a circumferential angle of 45° on the outer surface of the valve core 2.

[0015] The drive unit 3 is fixed to the end cover of the valve body 1 with screws, and its output shaft is connected to the valve core 2 via a coupling. In this embodiment, the drive unit 3 uses a 42-step motor, combined with a 1 / 16 micro-step drive, which can achieve a resolution of 1.8° per step, which is sufficient to accurately control the valve core to stay in four working angle states.

[0016] For sealing, two annular grooves are machined on the outer wall of the valve core 2, and fluororubber O-rings 4 are installed in the grooves to ensure dynamic sealing between the valve core and the valve body 1 when the valve core rotates. A polytetrafluoroethylene end face seal 5 is provided between the axial end face of the valve core 2 and the valve body end cover to prevent axial leakage.

[0017] The position feedback mechanism consists of a neodymium iron boron magnet 6 embedded in the end of the valve core 2 and a Hall sensor 7 mounted on the valve body end cover. Based on the voltage signal output by the Hall sensor 7, the control system can accurately calculate the absolute angle of the valve core 2 and compare it with the target angle to form a closed-loop control, ensuring precise flow path switching.

[0018] Work process: When the thermal management system controller issues a command to switch to "State 1" (e.g., the PCM heat storage mode corresponding to insufficient low-temperature radiator capacity), the controller sends a pulse signal to the drive unit 3, driving the valve core 2 to rotate to a 45° angle. At this time, as... Figure 4 As shown, the first U-shaped flow channel 201 inside the valve core connects interfaces 101 and 104 on the valve body, the axially penetrating flow channel 203 connects interfaces 105 and 106, and the second U-shaped flow channel 202 connects interfaces 107 and 108, thereby realizing the switching and connection of the heat flow path and the cooling path, achieving the connection state required by the thermal management system. The Hall sensor 7 verifies in real time that the valve core has reached the target position. Similarly, by rotating to 0°, -45°, and -90° angles, states two, three, and four (fully shut off) can be achieved, respectively.

[0019] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A multi-way rotary valve for a vehicle thermal management system, characterized in that, include: The valve body (1) has a cylindrical cavity inside, and the first to eighth external interfaces are symmetrically and evenly arranged on the side wall of the valve body (1) along the circumference. The valve core (2) is a cylindrical structure and is rotatably housed in the cylindrical cavity of the valve body (1); The drive unit (3) has its output shaft connected to the valve core (2) and is used to drive the valve core (2) to rotate around its axis inside the valve body (1); The valve core (2) has multiple non-penetrating internal flow channels pre-processed inside. By controlling the valve core (2) to rotate to N different preset angle positions, the internal flow channels can stably form N different interface connection combinations, where N≥4, thereby realizing the dynamic reconstruction of the flow path of the thermal management system.

2. The multi-way rotary valve according to claim 1, characterized in that, The drive unit (3) is a stepper motor or a servo motor. The rotation angle of the valve core (2) is divided into four preset working angles. Each working angle corresponds to the valve body (1) to form a stable interface connection combination.

3. The multi-way rotary valve according to claim 2, characterized in that, The four working angles are 45°, 0°, -45°, and -90°, respectively; the corresponding four interface connection combinations are as follows: State 1 (45° position): Connect the first interface (101) to the fourth interface (104), the fifth interface (105) to the sixth interface (106), and the seventh interface (107) to the eighth interface (108). State 2 (0° position): Connect the first interface (101) to the third interface (103), the second interface (102) to the fourth interface (104), the fifth interface (105) to the sixth interface (106), and the seventh interface (107) to the eighth interface (108). State 3 (-45° position): Connect the second interface (102) to the fourth interface (104), the fifth interface (105) to the sixth interface (106), and the third interface (103) to the seventh interface (107). State 4 (-90° position): All external interfaces are isolated from each other.

4. The multi-way rotary valve according to claim 1, characterized in that, The internal flow channel of the valve core (2) includes: The first U-shaped flow channel (201) is used to connect two adjacent interfaces in the same quadrant; The second U-shaped flow channel (202) is arranged in a spatially symmetrical manner with the first U-shaped flow channel (201) and is used to connect two other adjacent interfaces in the same quadrant; At least one through-flow channel (203) is arranged axially along the valve core for connecting two oppositely arranged interfaces.

5. The multi-way rotary valve according to claim 4, characterized in that, The bending radius of the first U-shaped flow channel (201) and the second U-shaped flow channel (202) is optimized by streamline design, and their inner wall surfaces are smoothly transitioned to reduce local resistance loss and vortex generation when the fluid passes through; the first U-shaped flow channel (201) and the second U-shaped flow channel (202) are arranged circumferentially at a fixed included angle on the outer surface of the valve core 2.

6. The multi-way rotary valve according to claim 1, characterized in that, A sealing assembly is provided between the valve core (2) and the valve body (1). The sealing assembly includes: at least two O-rings (4), which are embedded in the annular groove on the outer wall of the valve core (2) to achieve dynamic sealing between the valve core (2) and the valve body (1); and an end face seal (5), which is provided between the end of the valve core (2) and the valve body (1) to prevent axial leakage.

7. The multi-way rotary valve according to claim 1, characterized in that, It also includes a position feedback mechanism, which includes: a magnet (6) fixed to the end of the valve core (2); a Hall sensor (7) fixed to the valve body (1) and electrically connected to the control system of the drive unit (3); through the cooperation of the magnet (6) and the Hall sensor (7), the absolute rotation angle of the valve core (2) is detected and fed back in real time to realize closed-loop control.

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