A brushless electronic fan and a new energy vehicle thermal management device

Abstract

The application discloses a brushless electronic fan and a new energy vehicle thermal management device, and belongs to the field of new energy vehicle thermal management. The brushless electronic fan comprises a fan blade unit and an air frame unit. The fan blade unit is used for efficiently dissipating heat of the new energy vehicle thermal management device. The air frame unit is arranged on the outer side of the fan blade unit, is used for guiding the air outlet direction of the fan blade unit, and provides fixed support for the fan blade unit. The brushless electronic fan is designed by matching the air frame and the fan blade, arranging the reverse curvature and the flow guide structure, optimizing the aerodynamic path to reduce the wind resistance, reducing the energy loss caused by airflow turbulence, improving the heat dissipation efficiency, and realizing energy saving and efficiency increase.

Description

Technical Field

[0001] This invention relates to the field of thermal management technology for new energy vehicles, and in particular to a brushless electronic fan. Background Technology

[0002] In the field of thermal management of new energy vehicles, especially in the high-voltage thermal management system of new energy commercial vehicles, the thermal management integrated box is the temperature control center of high-voltage components such as batteries and motor controllers. It needs to maintain a stable temperature range inside to ensure the performance and safety of the high-voltage system. As a key heat dissipation component of the integrated box, the electric fan plays the role of quickly dissipating the heat inside the integrated box. Electric fans are typically driven by brushless motors and are mainly mounted on the heat dissipation surface of thermal management integrated boxes. The high-speed rotation of the blades creates forced airflow, which washes over the heat dissipation fins on the surface of the integrated box or directly acts on the heat exchange medium channels inside the box, carrying away the heat generated by the high-voltage components and avoiding problems such as battery degradation and electric drive system failure due to excessive temperature. The design of the fan blades and the blade frame structure directly affect the airflow speed, direction and heat exchange efficiency. The existing electronic fans used in high-voltage thermal management integrated boxes for new energy commercial vehicles generally adopt conventional structural designs for their blades and blade frames. This makes it difficult to fully combine the high-power and concentrated heat generation characteristics of the high-voltage system in new energy commercial vehicles with airflow guidance and wind pressure enhancement designs. As a result, the airflow disturbance is large and the wind pressure is insufficient when the blades rotate, and some areas have heat dissipation dead zones, making it difficult to quickly remove the heat generated by high-voltage components such as batteries and motor controllers in the integrated box.

[0003] It should be noted that the information disclosed in this background section is only for understanding the background technology of this application concept, and therefore may include information that does not constitute prior art. Summary of the Invention

[0004] This invention provides a brushless electronic fan and a thermal management device for new energy vehicles, to solve the problem that existing high-voltage integrated box electronic fans in new energy commercial vehicles have conventional blade and frame structures, lack targeted optimization, and have poor airflow.

[0005] The present invention adopts the following technical solution: a brushless electronic fan, including a fan blade unit and a fan frame unit; the fan blade unit is used to efficiently dissipate heat from the thermal management device of a new energy vehicle, and the fan frame unit is sleeved on the outside of the fan blade unit to guide the airflow direction of the fan blade unit and to provide fixed support for the fan blade unit.

[0006] Furthermore, the wind frame unit includes a second wind frame, which has multiple sets of mounting ends 2 equidistantly arranged along the axial direction. The second wind frame integrates inclined reinforcing ribs 2, and arc-shaped guide ribs connect the multiple sets of reinforcing ribs 2. The side of the second wind frame is connected to the fan blade unit through a guide cover 1.

[0007] Furthermore, the fan blade unit includes a second blade frame, which is sleeved on the first guide cover. The second blade frame is connected to a hub through multiple sets of inclined blades. The inclination direction of the second blade is opposite to that of the second reinforcing rib, and the connection between the second blade and the second blade frame is provided with an extension angle.

[0008] Furthermore, the wind frame unit includes a wind frame one, the wind frame one is provided with multiple sets of mounting ends one at equal intervals along the axial direction, the wind frame one integrates an arc-shaped reinforcing rib one, the multiple sets of reinforcing ribs one are connected by arc-shaped guide ribs, and the side of the wind frame one is connected to the fan blade unit through a guide cover two.

[0009] Furthermore, the fan blade unit includes a blade frame 1, which is fitted onto a guide cover 2. The blade frame 1 is connected to a hub 2 via multiple sets of arc-shaped twisted blades with reinforced structures 1. The arc direction of the blades 1 and the reinforcing ribs 1 is designed in opposite directions.

[0010] Furthermore, a brushless motor is installed between the second wind frame and the first hub, and between the first wind frame and the second hub. The first hub is provided with multiple sets of triangular drainage holes and multiple sets of V-shaped heat dissipation holes along the axial direction. The second hub is provided with multiple sets of drainage grooves and multiple sets of circular heat dissipation holes along the axial direction.

[0011] Furthermore, the integrated box, mounting angle plate, and two sets of symmetrically arranged brushless electronic fans are included. The integrated box is used to carry the high-pressure thermal management components. The mounting angle plate is integrally fixed to the outer wall of the integrated box to fix the integrated box to the new energy vehicle body. Mounting end one or mounting end two are both mounted on the side of the integrated box. The two sets of brushless electronic fans are distributed horizontally on the heat dissipation side of the integrated box. Each set of brushless electronic fans includes a fan blade unit and a fan frame unit. The fan frame unit is detachably connected to the integrated box. The fan blade unit is assembled in the fan frame unit and is used to directionally deliver air to the high-pressure thermal management components in the integrated box for heat dissipation. The fan frame unit is used to limit the air outlet path of the fan blade unit.

[0012] Furthermore, it also includes an installation component for easy assembly and disassembly of the brushless electric fan. The installation component includes a guide unit for assisting in the assembly of the brushless electric fan frame, two sets of locking units for symmetrically fixing the brushless electric fan, and two sets of pressing units for applying pressure to the locking units. The two sets of pressing units are horizontally symmetrically distributed along the center line of the brushless electric fan. The guide unit includes a fixing ring integrally set on the side of the integrated box. The fixing ring has symmetrical notches and grooves, and an inner groove is formed on the fixing ring. The inner groove slides in conjunction with the mounting end. The locking unit includes two sets of right-angle brackets symmetrically arranged on the side of the integrated box and close to the notch slot. A T-shaped rod is vertically and movably inserted through the right-angle bracket. A return spring is sleeved on the T-shaped rod. The two ends of the return spring are respectively connected to one end of the T-shaped rod and the upper surface of the right-angle bracket. A spherical locking end is integrally fixed to one end of the T-shaped rod that passes through the right-angle bracket. The spherical locking end is adapted to fit and engage with the upper surface of the leaf frame. A guide shaft is fixed to the upper end of the right-angle bracket and is adapted to movably fit one end of the T-shaped rod.

[0013] Furthermore, the pressing unit includes a mounting box installed on the side of the integrated box. A rotating shaft is installed inside the mounting box through a bearing. Two sets of rotating groups are mounted on the rotating shaft, each acting on a corresponding set of brushless electric fans. Each rotating group includes a bevel gear one fixed on the rotating shaft. The bevel gear one meshes with a bevel gear two. The bevel gear two has a central shaft connected to a bearing on the inner side of the mounting box, and a cam is fixed on the central shaft. The two sets of cams respectively contact one end of the T-shaped rod of the corresponding brushless electric fan and are arranged symmetrically.

[0014] Furthermore, a linkage unit for integrating the synchronous movement of the two sets of pressing units is connected between the two sets of mounting boxes. The linkage unit includes a protective box connected between the two sets of mounting boxes. A drive shaft is installed in the protective box through a bearing. Both ends of the drive shaft are provided with bevel gear sets. The bevel gear set includes a bevel gear three fixed to one end of the drive shaft. The bevel gear three meshes with a bevel gear four fixedly sleeved on the rotating shaft. A rotating handle is fixed to one end of the rotating shaft, a pointer is fixed to the rotating handle, and an angle plate coaxially sleeved on the rotating handle is fixed to one end of the mounting box.

[0015] The above-mentioned at least one technical solution adopted in this invention can achieve the following beneficial effects: A brushless electronic fan, by setting up a blade unit and a frame unit, with the blade unit focusing on heat dissipation of the thermal management device in new energy vehicles, and the frame unit covering the outside of the blade unit to guide the airflow direction and provide fixed support, can effectively solve the problems of existing electronic fans in high-voltage thermal management integrated boxes of new energy commercial vehicles. Due to the conventional structural design of the blades and frame, they are difficult to adapt to the high-power and concentrated heat generation characteristics of high-voltage systems, resulting in large airflow disturbance, insufficient air pressure, and the existence of heat dissipation dead zones. It is difficult to quickly remove the concentrated heat generated by high-voltage components such as batteries and motor controllers in the integrated box. Through the combined effect of the frame unit guiding the airflow direction and the blade unit providing directional and efficient heat dissipation, airflow turbulence is reduced, air pressure and heat dissipation are improved, heat dissipation dead zones are eliminated, and the concentrated heat generated by high-voltage components is ensured to be quickly dissipated. Attached Figure Description

[0016] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this invention, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention.

[0017] In the attached diagram: Figure 1 This is an overall schematic diagram of a brushless electronic fan according to Embodiment 1 of this application; Figure 2 This is an overall schematic diagram of a brushless electronic fan according to Embodiment 2 of this application; Figure 3 for Figure 1 Exploded view of a brushless electronic fan; Figure 4 for Figure 2 Exploded view of a brushless electronic fan; Figure 5 This is a schematic diagram of a thermal management device for new energy vehicles. Figure 6 This is a schematic diagram of the brushless electronic fan assembled with a thermal management device for a new energy vehicle, as shown in Example 2. Figure 7 for Figure 6 Exploded view; Figure 8 for Figure 7 Enlarged view of point A; Figure 9 for Figure 5 Exploded view; Figure 10 for Figure 9 Enlarged view of point B; Figure 11 for Figure 6 A partial structural diagram; Figure 12 for Figure 11 Enlarged view of point C; Figure 13 for Figure 11 Enlarged view of point D; Figure label: 1. Integrated box; 11. Mounting angle plate; 2. Brushless electric fan one; 21. Fan frame one; 22. Mounting end one; 23. Blade frame one; 24. Blade one; 25. Heat dissipation hole one; 26. Drain groove; 27. Reinforcing rib one; 28. Guide cover two; 3. Brushless electric fan two; 33. Fan frame two; 34. Mounting end two; 35. Reinforcing rib two; 36. Guide cover one; 37. Hub; 38. Blade frame two; 39. Blade two; 391. Extension angle; 310. Drain hole two; 311. Heat dissipation hole two; 4. Mounting components ; 41. Retaining ring; 42. Notch; 43. Pressing unit; 431. Mounting box; 432. Rotating shaft; 433. Bevel gear one; 434. Bevel gear two; 435. Central shaft; 436. Cam; 44. Right angle bracket; 45. T-shaped rod; 46. Return spring; 47. Locking end; 411. Guide shaft; 48. Linkage unit; 481. Protective box; 482. Drive shaft; 483. Bevel gear three; 484. Bevel gear four; 49. Rotating handle; 491. Pointer; 410. Angle dial. Detailed Implementation

[0018] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0019] The technical solutions provided by the various embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Example 1

[0020] Reference Figure 2 and Figure 4 , Figure 6 and Figures 7-8 As shown, the brushless electronic fan of this invention is mainly used for the stable installation, structural reinforcement, and airflow guidance of the brushless electronic fan. Preferably, the brushless electronic fan includes a second brushless electronic fan 3, and its frame unit includes a second frame 33. The second frame 33 is provided with multiple sets of mounting ends 34 at equal intervals along the circumference. The second frame 33 integrates inclined reinforcing ribs 35. The inclination angle of the reinforcing ribs 35 is adapted to the airflow direction, which not only enhances the deformation resistance of the second frame 33, but also helps to organize the airflow. The multiple sets of reinforcing ribs 35 are fixedly connected by arc-shaped guide ribs (not shown in the figure). The arc-shaped guide ribs and the second reinforcing ribs 35 enclose a smooth airflow channel, which effectively reduces wind resistance and avoids airflow turbulence. The side of the second frame 33 near the fan blade unit is connected to the first guide cover 36.

[0021] To further improve the air delivery efficiency and structural stability of the fan blade unit, the fan blade unit of the brushless electronic fan 3 adopts an integrated molding design, including a ring-shaped blade frame 38. The inner sidewall of the blade frame 38 is provided with a groove that fits the outer periphery of the guide cover 36. It is tightly fitted to the outer side of the large end of the guide cover 36 through an interference fit, so as to achieve precise coaxial positioning of the fan blade unit and the fan frame unit. The blade frame 38 is integrally connected to the central hub 37 through multiple sets of inclined blades 39 evenly distributed along the circumference. The blades 39 are inclined in the whole, and their inclination direction is opposite to that of the reinforcing ribs 35, forming a synergistic effect of pushing and guiding airflow, which not only improves the air volume capture efficiency, but also reduces airflow turbulence loss. Furthermore, the connection between the blade 2 39 and the blade frame 2 38 extends integrally to form an extension angle 391. This extension angle 391 smoothly transitions with the tangential direction of the blade frame 2 38, which not only increases the connection contact area between the blade and the blade frame and strengthens the root structure, but also guides the airflow to flow smoothly along the blade surface, further reducing wind resistance.

[0022] To achieve drainage and prevent water accumulation in the hub area and to assist in efficient heat dissipation of the brushless motor, a brushless motor is fixedly mounted between the second fan frame 33 and the first hub 37 via a bracket. The motor output shaft is coaxially and tightly connected to the first hub 37, driving the fan blade unit to rotate at high speed. The first hub 37 of the second brushless electronic fan 3 has multiple sets of triangular drainage holes 310 and multiple sets of V-shaped heat dissipation holes 311 circumferentially through it. The drainage holes 310 are evenly distributed circumferentially around the first hub 37. Its triangular structure combines structural strength and smooth drainage, which can quickly drain the infiltrated condensate or rainwater and prevent water accumulation from corroding the motor. The second heat dissipation hole 311 is set around the motor output shaft, with the V-shaped opening facing the direction of blade rotation. This creates negative pressure during rotation to guide airflow through the motor housing and carry away the motor's operating heat. The V-shaped structure also reduces airflow resistance and does not affect the overall rigidity of the hub, achieving triple optimization of drainage, heat dissipation, and structural stability.

[0023] Working principle: During use, the left and right sets of brushless electric fans 3 are embedded and securely connected to the side of the corresponding device through the mounting end 34 on the fan frame 33, ensuring close contact with the heat dissipation surface of the corresponding device and structural stability, reducing energy loss caused by operating gaps; when the high-voltage thermal management component of the new energy vehicle generates heat, the brushless motor starts as needed, and its output shaft drives the hub 37 and the integrated fan blade unit to rotate precisely. The blade frame 38 maintains coaxial rotation through the interference fit between the inner side wall slot and the guide cover 36, avoiding eccentric vibration caused by the brushless motor. Energy consumption and airflow waste; the blade 39 of the fan unit rotates in the opposite tilt direction to the reinforcing rib 35, and efficiently captures external airflow with the optimized aerodynamic angle and pushes it directionally to the heat dissipation surface of the corresponding device. The extension angle 391 of the connection between the blade 39 and the frame 38 guides the airflow to flow smoothly along the blade surface. At the same time, the reinforcing rib 35 on the frame 33 and the arc-shaped guide rib form a smooth airflow channel. The two work together to reduce wind resistance, reduce airflow eddies and turbulence, and improve the effective utilization rate of heat dissipation airflow, so as to achieve a stronger heat dissipation effect with less energy consumption. During this process, the V-shaped heat dissipation hole 311 on the hub 37 naturally forms a negative pressure as the hub rotates. Without additional power, it can guide the airflow through the brushless motor housing to remove the working heat. The triangular water leakage hole 310 quickly discharges the seeping liquid to prevent motor corrosion. This extends the service life of the equipment while reducing maintenance and replacement energy consumption. It ensures the long-term stable and reliable operation of the device while reducing the energy consumption burden of the whole vehicle. Example 2

[0024] Reference Figure 1 and Figure 3 , Figure 5 and Figures 9-10 As shown, the brushless electronic fan in this embodiment is mainly used for the stable installation, structural reinforcement, and airflow guidance of the brushless electronic fan. Preferably, the brushless electronic fan also includes a brushless electronic fan 2, whose frame unit includes an integrally formed frame 21. The frame 21 is provided with multiple sets of mounting ends 22 with threaded holes at equal intervals along the circumference. These are fastened by bolts to the corresponding device's side mounting holes, ensuring the sealing and structural stability of the connection between the frame 21 and the corresponding device. The inner circumferential wall of the frame 21 is integrally integrated with arc-shaped reinforcing ribs 27 evenly distributed along the circumference. The arc curvature of the reinforcing ribs 27 conforms to the airflow trajectory, which not only improves the deformation resistance and overall rigidity of the frame 21, but also helps guide the orderly flow of airflow. Multiple sets of reinforcing ribs 27 are fixedly connected by arc-shaped guide ribs (not shown in the figure). The arc-shaped guide ribs and reinforcing ribs 27 enclose a smooth air guiding channel, which effectively reduces airflow resistance and avoids the generation of eddies. The wind frame 21 is connected to the fan blade unit through the guide cover 28. The guide cover 28 has a trumpet-shaped structure and provides a positioning base for the fan blade unit.

[0025] To further improve the air delivery efficiency and structural stability of the fan blade unit, the fan blade unit of the brushless electronic fan 2 adopts an integrated injection molding design, including a ring-shaped blade frame 23. The inner sidewall of the blade frame 23 is provided with a groove that fits the outer periphery of the guide cover 2. It is tightly fitted to the outer side of the large end of the guide cover 2 through an interference fit, realizing the coaxial positioning of the fan blade unit and the fan frame unit, and avoiding eccentric shaking during operation. The blade frame 23 is integrally connected to the central hub 2 through multiple sets of blades 24 evenly distributed along the circumference. The blades 24 are generally arc-shaped and twisted with a reinforced structure. The middle of the blade surface is raised to form a longitudinal reinforcing ridge, which enhances the fatigue strength and deformation resistance of the blades. Moreover, the arc direction of the blades 24 is designed in the opposite direction to the reinforcing ribs 27, forming a synergistic effect of pushing and guiding airflow, which not only improves the efficiency of airflow capture and pushing, but also reduces the energy loss caused by airflow turbulence.

[0026] To achieve drainage and prevent water accumulation in the hub area and to assist in efficient heat dissipation of the brushless motor, a brushless motor is fixedly mounted between the fan frame 21 and the hub 2 via a bracket. The motor output shaft is coaxially and tightly connected to the hub 2, providing stable driving force for the fan blade unit. The hub 2 of the brushless electronic fan 2 has multiple sets of drainage grooves 26 and multiple sets of circular heat dissipation holes 25 circumferentially through it. The drainage grooves 26 are evenly distributed around the hub 2, with a long strip structure and openings facing the edge of the hub, combining structural strength and smooth drainage. They can quickly drain infiltrated condensate, rainwater, or cleaning fluid, preventing water accumulation in the hub area from corroding the motor. The circular heat dissipation holes 25 are evenly arranged around the motor output shaft, with the hole diameter adapted to the airflow requirements. They not only create negative pressure when the hub rotates, guiding airflow through the motor housing to efficiently remove the motor's operating heat, but also, due to the uniform stress of the circular structure, do not affect the overall rigidity of the hub, achieving triple optimization of drainage, heat dissipation, and structural stability.

[0027] Working principle: During use, the brushless electric fan 2 is fastened to the pre-set mounting holes on the side of the corresponding device via the threaded mounting end 22 on the fan frame 21, achieving an embedded and sealed installation. The flared guide cover 2 on the side of the fan frame 21 near the fan blade unit is detachably connected by a snap-fit, providing a precise assembly base for the fan blade unit. When the high-pressure thermal management components of the new energy vehicle generate heat, the brushless motor starts as needed, and the output shaft drives the hub 2 and the integrated injection-molded fan blade unit to rotate efficiently. The blade frame 23 is connected to the guide cover 2 via the inner wall groove. The interference fit maintains coaxial rotation, avoiding energy waste caused by eccentric vibration; the blades of the fan unit 24 have an arc-shaped twisted structure with longitudinal reinforcing ribs, rotating along the arc direction opposite to that of the reinforcing rib 27. This can efficiently capture external airflow and push it directionally to the heat dissipation surface of the corresponding device. The optimized aerodynamic structure also reduces rotational resistance. The arc-shaped reinforcing rib 27 and the arc-shaped guide rib on the fan frame 21 form a smooth airflow channel. The two work together to sort the airflow, reduce eddies and wind resistance, further reduce energy loss and improve heat dissipation efficiency. Meanwhile, the circular heat dissipation holes 25 on the wheel hub generate negative pressure as the wheel hub rotates, which can guide airflow through the motor housing to remove working heat without additional power. The water drain 26 quickly drains the seeping liquid to prevent motor corrosion, extending the service life of the equipment while reducing maintenance energy consumption. It also ensures the long-term stable operation of the brushless electric fan 2 while reducing the overall vehicle energy consumption. Example 3

[0028] Reference Figure 5 one Figure 13 As shown, in order to facilitate precise guidance and assembly, symmetrical and stable locking, and efficient and convenient disassembly and assembly of the two sets of brushless electronic fans in the above embodiments, and to improve the convenience and efficiency of maintenance, this invention provides a thermal management device for new energy vehicles, including an integrated box 1, a mounting angle plate 11, and two sets of symmetrically arranged brushless electronic fans; the integrated box 1 is used to support the high-pressure thermal management components, and the mounting angle plate 11 is integrally fixed to the outer side wall of the integrated box to fix the integrated box to the body of the new energy vehicle; either mounting end 1 22 or mounting end 2 34 is mounted on the side of the integrated box 1, and the two sets of brushless electronic fans are distributed horizontally on the heat dissipation side of the integrated box. Each set of brushless electronic fans includes a fan blade unit and a frame unit. The frame unit is detachably connected to the integrated box 1, and the fan blade unit is assembled in the frame unit to direct airflow for heat dissipation to the high-pressure thermal management components in the integrated box. The frame unit is used to limit the air outlet path of the fan blade unit.

[0029] The integrated box 1 is provided with an integrated installation component 4 corresponding to the installation position of the brushless electronic fan; the installation component 4 includes a guide unit adapted to the wind frame of the brushless electronic fan, two sets of locking units located on the side of the integrated box 1 and symmetrically distributed along the center line, and two sets of pressing units 43 also located on the side of the integrated box 1 and corresponding to the locking units. The two sets of pressing units 43 are arranged horizontally and symmetrically along the center line of the brushless electronic fan. The guide unit is designed to assist the brushless fan frame in quick and accurate alignment. Its structure is adapted to the outer contour of the frame, guiding the frame to smoothly fit the heat dissipation surface of the integrated box 1 along a preset trajectory, avoiding poor sealing or structural interference caused by assembly deviations. Two locking units are set for the left and right brushless fans respectively, which can symmetrically clamp and fix the frame from both sides, ensuring balanced force during operation and preventing vibration and loosening. Two pressing units 43 apply pressing pressure to the locking units through synchronous or independent actions, which can quickly switch between locked and unlocked states. The brushless fan can be disassembled and assembled without additional tools, reducing the time cost and operation difficulty of maintenance. At the same time, it can adapt to the disassembly and assembly needs of single or two brushless fans, improving the flexibility of use.

[0030] To achieve precise guidance, positioning, stable locking, and unlocking / resetting of the brushless electric fan, the guiding unit includes a fixing ring 41 integrally formed on the side of the integrated box 1. The inner diameter of the fixing ring 41 is precisely matched with the outer circumference of the brushless electric fan frame, and it has symmetrical notches 42. The width of the notches 42 is adapted to the structure of the mounting end of the fan frame, facilitating quick alignment of the mounting end along the notches 42. An annular inner groove (not shown in the figure) is formed on the inner side wall of the fixing ring 41. The width and depth of the inner groove match the mounting end of the brushless electric fan. During installation, the mounting end of the fan frame can be inserted into the inner groove along the notches 42. Through sliding engagement, the brushless electric fan is smoothly locked into the fixing ring 41, achieving dual positioning in both radial and axial directions and avoiding assembly misalignment.

[0031] The locking unit includes two sets of right-angle brackets 44 symmetrically fixed to the side of the integrated box 1 and adjacent to the notch 42. The two sets of right-angle brackets 44 are respectively set on both sides of the air frame mounting end to form a symmetrical clamping structure. The vertical plate of the right-angle bracket 44 is provided with a through hole. The T-shaped rod 45 moves vertically through the right-angle bracket 44 through the through hole. The horizontal rod at the upper end is used to bear the pressing force, and the lower end extends to the top of the air frame. A return spring 46 is sleeved on the T-shaped rod 45. The return spring 46 is in a compressed state in its natural state, and its two ends are in close contact with the lower end face of the horizontal rod of the T-shaped rod 45 and the upper end face of the right-angle frame 44, respectively, providing a continuous downward preload for the T-shaped rod 45. The lower end of the T-shaped rod 45, which passes through the right-angle frame 44, is integrally fixed with a spherical locking end 47. The spherical structure of the spherical locking end 47 facilitates engagement and disengagement. The upper end face of the blade frame is provided with an arc-shaped groove that matches the spherical locking end 47. Under the action of the return spring 46, the spherical locking end 47 is embedded in the arc-shaped groove to achieve a stable lock of the brushless electronic fan. The upper end of the right-angle bracket 44 is fixed with a guide shaft 411 that is adapted to the vertical rod of the T-shaped rod 45. The guide shaft 411 is coaxially arranged with the T-shaped rod 45 and is movably connected, which can limit the movement trajectory of the T-shaped rod 45, prevent it from deviating or getting stuck when sliding up and down, and ensure the smoothness of locking and unlocking actions.

[0032] To achieve synchronous pressing control of the two sets of brushless electric fan locking units, switching between locked and unlocked states, and improving the uniformity and convenience of operation, the pressing unit 43 includes a mounting box 431 fastened to the side of the integrated box 1 by bolts. The mounting box 431 adopts a closed structure, which not only provides protection for the internal transmission components but also ensures structural stability. The two side walls of the mounting box 431 are horizontally connected by bearings with rotating shafts 432. The rotating shafts 432 can rotate smoothly around their own axis, and one end extends to the outside of the mounting box 431. Two sets of symmetrically distributed rotating groups are coaxially mounted on the section of the rotating shaft 432 located inside the mounting box 431. The two sets of rotating groups correspond one-to-one with the locking units of the left and right sets of brushless electric fans, ensuring precise power transmission.

[0033] The rotating assembly includes a first bevel gear 433 fixed to the rotating shaft 432 by a flat key. The first bevel gear 433 meshes perpendicularly with a second bevel gear 434 set horizontally, realizing a 90° turning transmission of power, which is compatible with the spatial layout of the pressing unit 43 and the locking unit. The second bevel gear 434 has an integrally formed central shaft 435 at its center. The two ends of the central shaft 435 are rotatably connected to the inner side of the mounting box 431 through bearings, ensuring smooth transmission of the second bevel gear 434. A cam 436 is coaxially fixed at the end of the central shaft 435 away from the bevel gear 434. The cam 436 adopts an eccentric structure design, and its contour edge is rounded. The two sets of cams 436 respectively abut against the upper end face of the T-shaped rods 45 of the left and right brushless electronic fans, and are arranged in a mirror symmetrical manner. When the rotating shaft 432 rotates, the two sets of cams 436 can be synchronously driven to rotate through the bevel gear set. The eccentricity of the cam 436 applies a precise pressing force to the T-shaped rod 45, pushing the T-shaped rod 45 to move downward against the elastic force of the return spring 46, thereby locking the locking end 47. Conversely, when the cam 436 rotates to the non-pressing position, the T-shaped rod 45 is reset under the action of the return spring 46, completing the unlocking. The entire transmission process is precise and stable, ensuring reliable switching between the locked and unlocked states.

[0034] To enable individual or synchronous disassembly and assembly of the brushless electric fan, improving the flexibility, precision, and efficiency of maintenance, a linkage unit 48 is connected between the two sets of mounting boxes 431 to integrate and synchronize the movement of the two sets of pressing units 43. The linkage unit 48 includes a protective box 481 sealed and connected between the two sets of mounting boxes 431. The protective box 481 can protect the internal transmission components from dust and interference. Inside, a drive shaft 482 is horizontally mounted via bearings. Both ends of the drive shaft 482 are provided with a set of bevel gears for power steering and transmission. The bevel gear set includes a bevel gear 3 483 fixed to the end of the drive shaft 482 by a flat key. The bevel gear 3 483 meshes perpendicularly with a bevel gear 484 fixedly sleeved on the rotating shaft 432 inside the mounting box 431, ensuring that the rotation of the drive shaft 482 can be accurately and synchronously transmitted to the rotating shafts 432 of the upper and lower sets of pressing units 43, realizing the linkage action.

[0035] One end of the rotating shaft 432 inside the mounting box 431 extends to the outside of the mounting box 431 and is fixed with a rotating handle 49 for easy manual operation. A pointer 491 is vertically fixed on the outer wall of the rotating handle 49. An angle disc 410, coaxially sleeved on the rotating handle 49, is fixed to the end face of the mounting box 431 corresponding to the rotating handle 49. The angle disc 410 is clearly marked with angle graduations, and the pointer 491 precisely corresponds to the angle graduations, enabling visual and accurate measurement of the rotation angle and avoiding operational errors. Figure 11 Based on the initial state, the two sets of cams 436 are in close contact with the upper end face of the T-shaped rod 45 of the corresponding brushless electric fan. Under the pressing action of the cams 436, the T-shaped rod 45 overcomes the elastic force of the return spring 46 and moves downward. The spherical locking end 47 is embedded in the arc-shaped slot on the upper end face of the blade frame, realizing the synchronous locking of the two sets of brushless electric fans. When the rotating shaft 432 inside the upper mounting box 431 is rotated until the pointer 491 points to the 45-degree mark, the power is transmitted through the bevel gear 3 483, bevel gear 484 and transmission shaft 482 to the rotating shaft 432 inside the lower mounting box 431, causing the upper and lower sets of pressing units 43 to rotate synchronously. At this time, after the left cam 436 rotates 45 degrees, its eccentric end moves away from the T-shaped rod 45. Under the elastic reset action of the return spring 46, the left T-shaped rod 45 moves upward, and the ball locking end 47 disengages from the blade frame slot, canceling the lock on the left brushless electric fan. After the right cam 436 rotates 45 degrees, it still maintains the pressing state on the right T-shaped rod 45, and the ball locking end 47 continues to engage with the blade frame. At this time, the left brushless electric fan can be disassembled separately. If the shaft 432 is rotated 90 degrees in the opposite direction, the pointer 491 will be reset to the initial 45-degree reverse mark. The upper and lower pressing units 43 will move in sync. After the left cam 436 rotates 90 degrees, it will return to the initial pressing position, and the ball locking end 47 will re-lock the leaf frame. After the right cam 436 rotates 90 degrees, it will move away from the right T-shaped rod 45, and the ball locking end 47 will be unlocked. At this time, the right brushless electric fan can be disassembled separately. If the rotating shaft 432 is rotated 45 degrees in the opposite direction again, the pointer 491 returns to the initial zero mark position, and the upper and lower pressing units 43 move synchronously. The left cam 436 and the right cam 436 both rotate 45 degrees and move away from the corresponding T-shaped rod 45. Both T-shaped rods 45 are reset under the action of the reset spring 46, and the ball locking end 47 is completely disengaged from the blade frame slot. At this time, the brushless electronic fans on the left and right sides can be disassembled simultaneously to achieve flexible operation of graded disassembly and assembly.

[0036] Working Principle: During use, the entire device is first securely mounted on the designated position of the new energy vehicle using the mounting angle plate 11 of the integrated box 1, followed by the installation of the brushless electric fan. During installation, the fan frame mounting end of the brushless electric fan is aligned with the fixing ring 41 of the mounting component 4 on the side of the integrated box 1. The fan is then inserted into the annular groove of the fixing ring 41 along the symmetrical notch 42. Through sliding engagement, the fan frame and fixing ring 41 are positioned radially and axially, ensuring precise contact between the brushless electric fan and the heat dissipation surface of the integrated box 1, avoiding assembly deviations. At this time, the spherical locking end 47 at the lower end of the T-shaped rod 45 in the locking unit automatically engages in the arc-shaped slot on the upper surface of the blade frame under the continuous preload of the return spring 46. Simultaneously, the guide shaft 411 at the upper end of the right-angle bracket 44 restricts the movement trajectory of the T-shaped rod 45, ensuring a smooth and non-offset locking process. The two sets of locking units symmetrically clamp the fan from both sides, securing the brushless electric fan and preventing loosening due to vibration during operation.

[0037] When the high-voltage thermal management components of the new energy vehicle generate heat, the brushless motor of the brushless electric fan starts, driving the fan blade unit to rotate at high speed. The fan blades, through an arc design or arc-shaped twisted structure opposite to the fan frame reinforcing ribs, efficiently capture external airflow and direct it towards the heat dissipation surface of the integrated housing 1. The reinforcing ribs on the fan frame and the arc-shaped guide ribs form a smooth airflow channel, streamlining the airflow, reducing wind resistance, minimizing airflow turbulence losses, and improving the effective utilization rate of the cooling airflow. Simultaneously, the heat dissipation holes on the hub create negative pressure as the hub rotates, guiding airflow through the motor housing to carry away the operating heat. The drainage holes in the drainage groove 26 quickly drain any seeping condensate and rainwater, preventing water accumulation and corrosion of the motor. This achieves synergistic optimization of heat dissipation, drainage, and structural stability, ensuring the long-term stable operation of the brushless electric fan.

[0038] When maintenance is required, the brushless electric fan can be disassembled and reassembled in stages via the pressing unit 43 and the linkage unit 48 of the mounting component 4. Rotating the handle 49 outside the upper mounting box 431 causes the pointer 491 to rotate synchronously with the handle 49. Combined with the scale on the angle dial 410, the rotation angle can be precisely controlled. When the pointer 491 points to 45 degrees, power is transmitted through the bevel gear set and drive shaft 482 of the linkage unit 48 to the upper and lower pressing units 43, causing the left cam 436 to move away from the T-shaped rod 45, locking and unlocking the left side, allowing for the separate disassembly of the left brushless electric fan. Rotating 90 degrees in the opposite direction causes the right cam 436 to move away from the T-shaped rod 45, locking and unlocking the right side, allowing for the separate disassembly of the right brushless electric fan. Rotating 45 degrees in the opposite direction again causes both cams 436 to move away from the T-shaped rod 45, simultaneously locking and unlocking both sides, allowing for the simultaneous disassembly of both brushless electric fans. The entire disassembly and assembly process requires no additional tools, improving the flexibility and efficiency of maintenance.

[0039] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A thermal management device for new energy vehicles, characterized in that: The system includes an integrated box (1), a mounting angle plate (11), and two sets of symmetrically arranged brushless electronic fans. The integrated box (1) is used to carry the high-pressure thermal management components. The mounting angle plate (11) is integrally fixed to the outer wall of the integrated box to fix the integrated box to the body of the new energy vehicle. Mounting end one (22) or mounting end two (34) is mounted on the side of the integrated box (1). The two sets of brushless electronic fans are distributed horizontally on the heat dissipation side of the integrated box. Each set of brushless electronic fans includes a fan blade unit and a fan frame unit. The fan blade unit is used to efficiently dissipate heat from the thermal management device of the new energy vehicle. The fan frame unit is sleeved on the outside of the fan blade unit to guide the air outlet direction of the fan blade unit and provide fixed support for the fan blade unit. The air frame unit is detachably connected to the integrated box (1). The fan blade unit is assembled in the air frame unit and is used to directionally supply air to the high-pressure thermal management component in the integrated box for heat dissipation. The air frame unit is used to limit the air outlet path of the fan blade unit. It also includes an installation component (4) for easy assembly and disassembly of the brushless electric fan. The installation component (4) includes a guide unit for assisting in the assembly of the brushless electric fan frame, two sets of locking units for symmetrically fixing the brushless electric fan, and two sets of pressing units (43) for applying pressure to the locking units. The two sets of pressing units (43) are horizontally symmetrically distributed along the center line of the brushless electric fan. The guide unit includes a fixing ring (41) integrally set on the side of the integrated box (1). The fixing ring (41) has symmetrical notches (42) on the top and bottom. The fixing ring (41) has an inner groove, which slides with the mounting end. The locking unit includes two sets of right-angle brackets (44) symmetrically arranged on the side of the integrated box (1) and close to the notch (42). The right-angle brackets (44) are vertically movably connected by a T-shaped rod (45). A return spring (46) is sleeved on the T-shaped rod (45). The two ends of the return spring (46) are respectively connected to one end of the T-shaped rod (45) and the upper end face of the right-angle bracket (44). A spherical locking end (47) is integrally fixed at one end of the T-shaped rod (45) that passes through the right-angle bracket (44). The spherical locking end (47) is adapted to be fitted and engaged with the upper end face of the leaf frame. A guide shaft (411) is fixed at the upper end of the right-angle bracket (44) and is adapted to be movably sleeved with one end of the T-shaped rod (45). The pressing unit (43) includes a mounting box (431) installed on the side of the integrated box (1). A rotating shaft (432) is installed inside the mounting box (431) through a bearing. Two sets of rotating groups are mounted on the rotating shaft (432) respectively acting on two sets of brushless electric fans. The rotating group includes a bevel gear one (433) fixed on the rotating shaft (432). The bevel gear one (433) meshes with a bevel gear two (434). The bevel gear two (434) has a central shaft (435) connected to the bearing on the inner side of the mounting box (431). A cam (436) is fixed on the central shaft (435). The two sets of cams (436) respectively contact one end of the T-shaped rod (45) of the corresponding brushless electric fan and are arranged symmetrically. A linkage unit (48) for integrating the synchronous movement of two sets of pressing units (43) is connected between the two sets of mounting boxes (431). The linkage unit (48) includes a protective box (481) connected between the two sets of mounting boxes (431). A drive shaft (482) is installed in the protective box (481) through a bearing. Both ends of the drive shaft (482) are provided with bevel gear sets. The bevel gear set includes a bevel gear three (483) fixed at one end of the drive shaft (482). The bevel gear three (483) meshes with a bevel gear four (484) fixedly sleeved on the rotating shaft (432). One end of the rotating shaft (432) is fixed with a rotating handle (49), and a pointer (491) is fixed on the rotating handle (49). One end of the mounting box (431) is fixed with an angle plate (410) coaxially sleeved on the rotating handle (49).

2. The thermal management device for a new energy vehicle according to claim 1, characterized in that: The wind frame unit includes a second wind frame (33), which has multiple sets of mounting ends (34) equidistantly arranged along the circumference. The second wind frame (33) integrates inclined reinforcing ribs (35), and the multiple sets of reinforcing ribs (35) are connected by arc-shaped guide ribs. The side of the second wind frame (33) is connected to the fan blade unit through a guide cover (36).

3. The thermal management device for a new energy vehicle according to claim 2, characterized in that: The fan blade unit includes a second blade frame (38), which is sleeved on a first guide cover (36). The second blade frame (38) is connected to a hub (37) through multiple sets of inclined blades (39). The inclination direction of the blades (39) is opposite to that of the reinforcing ribs (35), and the connection between the blades (39) and the second blade frame (38) is provided with an extension angle (391).

4. A thermal management device for a new energy vehicle according to claim 3, characterized in that: The wind frame unit includes a wind frame (21), which has multiple sets of mounting ends (22) equidistantly arranged along the circumference. The wind frame (21) integrates an arc-shaped reinforcing rib (27), and the multiple sets of reinforcing ribs (27) are connected by arc-shaped guide ribs. The side of the wind frame (21) is connected to the fan blade unit through a guide cover (28).

5. A thermal management device for a new energy vehicle according to claim 4, characterized in that: The fan blade unit includes a blade frame (23), which is fitted onto a guide cover. The blade frame (23) is connected to a hub through multiple sets of arc-shaped twisted blades (24) with reinforced structures. The arc direction of the blades (24) and the reinforcing ribs (27) is designed in opposite directions.

6. A thermal management device for a new energy vehicle according to claim 5, characterized in that: A brushless motor is installed between the second wind frame (33) and the first hub (37), and between the first wind frame (21) and the second hub. The first hub (37) is provided with multiple sets of triangular drainage holes (310) and multiple sets of V-shaped heat dissipation holes (311) along the circumference. The second hub is provided with multiple sets of drainage grooves (26) and multiple sets of circular heat dissipation holes (25) along the circumference.

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