Cooling pipeline integrated structure of extended-range electric vehicle and vehicle

Abstract

The invention belongs to the technical field of automobile manufacturing, and discloses a cooling pipeline integrated structure of an extended-range electric automobile and the vehicle, and the cooling pipeline integrated structure comprises a water side heat management module, a cooling pipeline integrated assembly, an integrated brake controller assembly and an air conditioner pipeline. The cooling pipeline integrated assembly is characterized in that the cooling pipeline integrated assembly fixes a plurality of groups of cooling pipelines into an integral module in an up-and-down layering mode through a pipeline integrated support, and the cooling pipeline integrated assembly is kept consistent in structure and trend in left-rudder and right-rudder vehicle models. Through integrated and modularized pipeline layout, a plurality of groups of cooling pipelines with different functions are integrated into an integral module which is compact in structure and regular in trend, so that the occupied space of disordered pipelines is reduced; when the engine room cooling system is applied to a right-rudder vehicle model, only the positions of a few parts related to a driving position need to be adjusted, and the problems that in the prior art, engine room cooling pipelines are disordered in arrangement and large in occupied space, and development cost is high due to the fact that the left-rudder vehicle model and the right-rudder vehicle model cannot be used universally are effectively solved.

Description

Technical Field

[0001] This invention belongs to the field of automotive manufacturing technology, and specifically relates to an integrated structure for cooling pipes in a range-extended electric vehicle and the vehicle thereof. Background Technology

[0002] With the rapid development and widespread adoption of electric vehicle technology, the complexity of vehicle thermal management systems is increasing, especially in plug-in hybrid electric vehicles and range-extended electric vehicles. Because these vehicles integrate multiple thermal management circuits for the engine, drive motor, and battery, the number of cooling pipes required has significantly increased, and the pipe layout has become increasingly complex. Against this backdrop, the adoption of integrated thermal management modules (especially water-side thermal management modules) has become a mainstream industry trend. By modularly integrating core components such as water pumps, valve bodies, and heat exchangers, the system architecture has been simplified and assembly efficiency improved to some extent.

[0003] Although the application of thermal management integrated modules has achieved initial success, those skilled in the art have found in practice that existing technical solutions still have many prominent problems that urgently need to be solved, mainly in the following aspects: On the one hand, existing solutions mostly focus on the integration of thermal management components themselves, while lacking systematic optimization of the routing and integrated layout of cooling pipes after they are connected from the integrated module. This results in irregular and intertwined routing of cooling pipes in the engine compartment, which not only occupies a lot of engine compartment space, but also easily causes motion interference or thermal damage risks with surrounding components (such as the engine exhaust system), seriously restricting the optimization of the overall vehicle layout and the improvement of reliability.

[0004] On the other hand, when facing different global markets (especially those requiring right-hand drive vehicles), the existing piping design does not fully consider its universality. When the positions of components related to the driver's seat, such as the integrated brake controller, change due to the left-hand or right-hand drive configuration, the original cooling piping layout is usually not suitable. A completely new piping system must be planned, designed, and developed for right-hand drive vehicles, which leads to a longer development cycle and increases the cost and complexity of platform development.

[0005] Therefore, there is an urgent need in this field for an innovative integrated cooling pipe solution suitable for range-extended electric vehicles that can fundamentally optimize the pipe space layout to achieve an efficient, platform-based, and universal design. Summary of the Invention

[0006] To address the lack of systematic optimization in the routing and integrated layout of existing cooling pipes, which leads to low engine compartment space utilization efficiency, difficult layout, and inability to meet the universal requirements of left-hand and right-hand drive vehicles, ultimately resulting in a series of technical problems such as high development costs and long development cycles, this invention provides an integrated cooling pipe structure and vehicle for range-extended electric vehicles.

[0007] To achieve the above objectives, the present invention provides the following technical solution: First, this invention provides an integrated cooling pipe structure for a range-extended electric vehicle, the integrated cooling pipe structure being adaptable to left-hand drive or right-hand drive vehicles, comprising: The water-side thermal management module is located on one side of the vehicle's engine compartment; An integrated brake controller assembly is fixed to a mounting surface on the vehicle body, the position of which corresponds to the left or right side of the vehicle depending on whether the vehicle model is left-hand drive or right-hand drive. Air conditioning pipes are arranged above the cooling pipe assembly; The cooling piping assembly is located on one side of the vehicle's engine compartment and includes multiple sets of cooling pipes and pipe integration brackets. Among them, multiple sets of cooling pipes are fixed and integrated on the pipe integration bracket by a spatial arrangement of upper and lower layers; The cooling pipe assembly has the same structure and layout on both left-hand drive and right-hand drive vehicles.

[0008] Preferably, in a right-hand drive vehicle, the integrated brake controller assembly is positioned above the cooling pipe assembly and below the air conditioning pipes.

[0009] Preferably, the multiple sets of cooling pipes include three sets of auxiliary heating system pipes and two sets of battery inlet and outlet water pipes; The spatial arrangement of the upper and lower layers includes: three auxiliary heating system pipes arranged on the upper layer of the pipe integrated bracket, and two sets of battery inlet and outlet water pipes arranged on the lower layer of the pipe integrated bracket.

[0010] Preferably, the pipeline integrated support is provided with an upper fixing structure, a lower fixing structure and fixing holes, wherein the two sets of battery inlet and outlet water pipes located in the lower layer are fixedly connected to the lower fixing structure by pipe clamps, and the two sets of auxiliary heating system pipelines located in the upper layer are fixedly connected to the upper fixing structure by pipe clamps.

[0011] Preferably, another set of auxiliary heating system pipes located on the upper layer is fixed in the fixing hole by pipe clamps.

[0012] Preferably, the upper fixing structure is a first fixing stud located above the pipeline integrated support.

[0013] Preferably, the lower fixing structure is a second fixing stud located below the pipeline integrated support.

[0014] Preferably, the water-side thermal management module is provided with multiple cooling water pipe interfaces below it for connecting to each group of cooling pipes in the cooling pipe integration assembly.

[0015] Preferably, the water-side thermal management module integrates a water pump, valve body, heat exchanger, and low-temperature expansion tank.

[0016] Secondly, the present invention provides a vehicle comprising an integrated cooling pipe structure for a range-extended electric vehicle as described above.

[0017] Compared with the prior art, the present invention has the following advantages: 1. This invention integrates multiple cooling pipes with different functions into a compact and well-organized module through an innovative pipe integration bracket and a layered arrangement scheme. This changes the messy and crisscrossing situation of cooling pipes in the engine compartment in the prior art, reduces the space occupied by pipes in the engine compartment, effectively solves the problem of limited engine compartment space caused by the complexity of the system in range-extended vehicles, and reserves valuable space for the arrangement of other components.

[0018] 2. The integrated cooling pipe assembly designed in this invention has the same structure and layout in both left-hand drive and right-hand drive models. When applied to right-hand drive models, only the positions of a few components related to the driver's seat, such as the integrated brake controller assembly, need to be adjusted. The integrated cooling pipe assembly itself can be perfectly adapted without any changes, successfully avoiding the huge cost of developing a new cooling pipe system for right-hand drive models. This significantly shortens the development cycle of international models and reduces the complexity and total cost of platform development.

[0019] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description, claims, and drawings. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 A schematic diagram of the installation of the integrated cooling pipe structure of the present invention in a left-hand drive vehicle is shown; Figure 2 A schematic diagram of the installation of the integrated cooling pipe structure of the present invention in a right-hand drive vehicle is shown; Figure 3 A schematic diagram of the integrated cooling pipe structure of the present invention is shown; Figure 4 A front view of the integrated cooling pipe structure of the present invention is shown; Figure 5 The overall structural diagram of the pipe integrated support of the present invention is shown; Figure 6 A front view of the pipe integration support of the present invention is shown.

[0022] In the diagram: 1. Cooling pipe integrated assembly; 11. Pipe integrated bracket; 111. First fixing stud; 112. Second fixing stud; 113. Fixing hole; 12. Battery inlet and outlet water pipes; 13. Auxiliary heating system pipes; 2. Water-side thermal management module; 3. Left-hand drive body assembly; 4. Air conditioning pipes; 5. Integrated brake controller assembly; 6. Right-hand drive body assembly. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] The embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0025] This invention provides an integrated structure for cooling pipes in range-extended electric vehicles.

[0026] Example 1: like Figure 1 The diagram shows the installation of the integrated cooling pipe structure of a range-extended electric vehicle in a left-hand drive vehicle. The integrated cooling pipe structure includes a cooling pipe assembly 1, a water-side thermal management module 2, an air conditioning pipe 4, and an integrated brake controller assembly 5. The water-side thermal management module 2 and the integrated cooling pipe assembly 1 are arranged adjacent to each other on one side of the vehicle's engine compartment. The integrated brake controller assembly 5 is fixed to the mounting surface of the vehicle body. The position of the mounting surface corresponds to the left or right side of the vehicle depending on whether the vehicle is left-hand drive or right-hand drive. The air conditioning pipe 4 is located above the integrated cooling pipe assembly 1. In this embodiment, the main perspective is the direction the vehicle faces. The left side of the direction the vehicle faces is the left side of the vehicle. In the left-hand drive body assembly 3, the integrated brake controller assembly 5 is arranged on the left side of the vehicle. The water-side thermal management module 2 is located in front of the shock absorber tower on the right side of the vehicle's engine compartment. The cooling pipe integrated assembly 1 is arranged on the right side of the vehicle's engine compartment and fixed to the front bulkhead of the vehicle body. The air conditioning pipe 4 is a dedicated pipe for transporting refrigerant in the vehicle's air conditioning system. When the air conditioning is turned on, the refrigerant circulates in the air conditioning pipe 4 to achieve cooling or provide a cold source for battery cooling. The air conditioning pipe 4 is located above the integrated brake controller assembly 5, making full use of vertical space, avoiding interference between pipes and wiring harnesses, and making the layout more regular.

[0027] like Figure 3 As shown, the cooling pipe integration assembly 1 includes multiple sets of cooling pipes and pipe integration bracket 11. The water-side thermal management module 2 integrates a water pump, valve body, heat exchanger and low temperature expansion tank. The bottom of the water-side thermal management module 2 is provided with multiple cooling water pipe interfaces, all of which are standardized interfaces, for connecting the various sets of cooling pipes in the cooling pipe integration assembly 1. In this embodiment, the water-side thermal management module 2 is the heat exchange and distribution center of the vehicle thermal management system. The cooling water pipe interface of the water-side thermal management module 2 is used to connect the complex flow channels integrated inside the module to the cooling pipe network of the cooling pipe integration assembly 1 in the simplest and most reliable way, so as to ensure that each system of the vehicle operates in the optimal temperature range.

[0028] like Figure 4 As shown, the multiple cooling pipes include three sets of auxiliary heating system pipes 13 and two sets of battery inlet and outlet water pipes 12, which are fixed and integrated on the pipe integration bracket 11 in a layered spatial arrangement. The layered spatial arrangement includes: the three auxiliary heating system pipes 13 are arranged on the upper layer of the pipe integration bracket 11, and the two sets of battery inlet and outlet water pipes 12 are arranged on the lower layer of the pipe integration bracket 11. In this embodiment, the pipe integration bracket 11 serves as the mechanical carrier and structural foundation of the cooling pipe integration assembly 1. It is fixed to the front bulkhead of the vehicle body with two bolts, providing a pre-designed and precise installation position, fixing point, and routing channel for the cooling pipes. Furthermore, through the layered spatial arrangement, multiple sets of cooling pipes can be arranged in an orderly manner in a compact three-dimensional space, significantly reducing the projected area (XY plane) occupied by the cooling pipe assembly in the front bulkhead area. The traditionally dispersed and circuitous pipes are designed into a compact integrated module, freeing up installation space for other components in the engine compartment, such as the integrated brake controller assembly 5, steering shaft, and air conditioning pipes 4. In this embodiment, the auxiliary heating system pipeline 13 is part of the high-temperature cooling circuit and is used to provide rapid heating for the battery pack and cabin in low-temperature environments to ensure battery activity and passenger comfort; the battery inlet and outlet water pipe 12 is the core circulation channel of the battery thermal management system, which is directly connected to the battery pack and the water-side thermal management module 2 and is used to remove the heat generated by the battery pack, and its temperature control accuracy requirements are higher. In this embodiment, the cooling pipes are pre-assembled into an assembly module on the pipe integration bracket 11. On the vehicle production line, workers only need to install the entire module onto the front bulkhead of the vehicle body in one go through the pipe integration bracket 11. This replaces the complicated operation of installing, fixing and connecting multiple scattered pipes one by one in the traditional process, which greatly improves assembly efficiency, reduces labor costs and reduces the risk of assembly errors caused by numerous operation steps.

[0029] like Figure 5 As shown, the pipeline integrated support 11 is provided with an upper fixing structure, a lower fixing structure and fixing holes 113, wherein the upper fixing structure is a first fixing stud 111 located above the pipeline integrated support 11; In this embodiment, the two sets of auxiliary heating system pipes 13 located on the upper layer are fixedly connected to the upper fixing structure (first fixing stud 111) by pipe clamps. The other set of auxiliary heating system pipes 13 located on the upper layer is fixed in the fixing hole 113 by pipe clamps. The auxiliary heating system pipes 13 are connected to the first fixing stud 111 or the fixing hole 113 by pipe clamps and are installed on the upper layer of the pipe integrated bracket 11 to avoid unnecessary thermal impact on the battery inlet and outlet water pipes 12 below, which are more sensitive to temperature and have more stringent requirements.

[0030] like Figure 6 As shown, the lower fixing structure is the second fixing stud 112 located below the pipeline integrated support 11; In this embodiment, the two sets of battery inlet and outlet water pipes 12 located on the lower layer are fixedly connected to the lower fixing structure (second fixing stud 112) by pipe clamps and installed on the lower layer of the pipeline integrated bracket 11 to avoid heat radiation from the high-temperature pipeline above, ensuring a more stable and less disturbed environment. At the same time, the lower layer arrangement of the battery inlet and outlet water pipes 12 also facilitates a shorter and more direct connection with the battery pack that is usually located at the bottom of the vehicle.

[0031] Example 2: like Figure 2 The diagram shows the installation of the integrated cooling pipe structure of a range-extended electric vehicle in a right-hand drive vehicle. The integrated cooling pipe structure includes a cooling pipe assembly 1, a water-side thermal management module 2, an air conditioning pipe 4, and an integrated brake controller assembly 5. In this embodiment, the main perspective is the direction the front of the vehicle is facing, and the right side of the direction the front of the vehicle is the right side of the vehicle. Compared with the cooling pipe integration structure in the left-hand drive body assembly 3 of Embodiment 1, the cooling pipe integration assembly 1 has the same structure and layout on both the left-hand drive body assembly 3 and the right-hand drive body assembly 6. The positions of the water-side thermal management module 2 and the air conditioning pipe 4 are fixed. As an integrated module, the cooling pipe integration assembly 1 also has a fixed pipe layout, bending angle, and connection point position.

[0032] It should be noted that in the design of the left-hand drive body assembly 3 in Embodiment 1, the cooling pipe integration assembly 1 is not arranged close to the air conditioning pipe 4 above it, but a reserved space is left above the cooling pipe integration assembly 1. Unlike Embodiment 1, in the right-hand drive body assembly 6 of Embodiment 2, the integrated brake controller assembly 5 is arranged on the right side of the vehicle in the right-hand drive body assembly 6. In this embodiment, the reserved space above the cooling pipe assembly 1 is occupied by the relocated integrated brake controller assembly 5. In terms of layout, since the positions of the cooling pipe assembly 1 and the air conditioning pipe 4 are fixed, the air conditioning pipe 4 is located above the integrated brake controller assembly 5, and the cooling pipe assembly 1 is located below the integrated brake controller assembly 5, in order to avoid the integrated brake controller assembly 5.

[0033] Secondly, a vehicle comprising an integrated cooling pipe structure for a range-extended electric vehicle as described above.

[0034] In traditional designs, cooling pipes require two different pipe routes and supports to be designed and developed for left-hand and right-hand rudders, which doubles the development, verification, and mold costs. In this invention, through integrated, modular, and forward-looking spatial planning, the cooling pipe integrated assembly 1, the water-side thermal management module 2, and the air conditioning pipe 4 do not require any modifications. Only by adjusting the position of an integrated brake controller assembly 5, it can be perfectly adapted to left-hand drive and right-hand drive models. The integrated cooling pipe structure ensures that the cooling pipes in the vehicle's engine compartment are consistent in left-hand drive and right-hand drive models, saving pipes and avoiding structural changes to surrounding parts due to left-hand drive and right-hand drive adjustments, thus saving huge development costs and mold investment costs.

[0035] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An integrated cooling pipe structure for a range-extended electric vehicle, characterized in that, The integrated cooling pipe structure is adaptable to both left-hand drive and right-hand drive vehicles, including: The water-side thermal management module (2) is located on one side of the vehicle's engine compartment; An integrated brake controller assembly (5) is fixed to a mounting surface on the vehicle body, the position of which corresponds to the left or right side of the vehicle depending on whether the vehicle model is left-hand drive or right-hand drive. A cooling pipe assembly (1) is located on one side of the vehicle's engine compartment and includes multiple sets of cooling pipes and pipe integration brackets (11). Air conditioning pipes (4) are arranged above the cooling pipe assembly (1); Among them, multiple sets of cooling pipes are fixed and integrated on the pipe integration bracket (11) by a spatial arrangement of upper and lower layers; The cooling pipe assembly (1) has the same structure and layout on both the left-hand drive and right-hand drive vehicles.

2. The integrated cooling pipe structure for a range-extended electric vehicle according to claim 1, characterized in that, In a right-hand drive vehicle, the integrated brake controller assembly (5) is located above the cooling pipe assembly (1) and below the air conditioning pipe (4).

3. The integrated cooling pipe structure for a range-extended electric vehicle according to claim 1, characterized in that, The cooling pipelines include three sets of auxiliary heating system pipelines (13) and two sets of battery inlet and outlet water pipes (12). The spatial arrangement of the upper and lower layers includes: three auxiliary heating system pipes (13) arranged on the upper layer of the pipe integrated bracket (11), and two sets of battery inlet and outlet water pipes (12) arranged on the lower layer of the pipe integrated bracket (11).

4. The integrated cooling pipe structure for a range-extended electric vehicle according to claim 3, characterized in that, The pipeline integrated bracket (11) is provided with an upper fixing structure, a lower fixing structure and fixing holes (113). The two sets of battery inlet and outlet water pipes (12) located in the lower layer are fixedly connected to the lower fixing structure through pipe clamps, and the two sets of auxiliary heating system pipelines (13) located in the upper layer are fixedly connected to the upper fixing structure through pipe clamps.

5. The integrated cooling pipe structure for a range-extended electric vehicle according to claim 4, characterized in that, Another set of auxiliary heating system pipes (13) located on the upper layer is fixed in the fixing hole (113) by pipe clamps.

6. The integrated cooling pipe structure for a range-extended electric vehicle according to claim 4, characterized in that, The upper fixing structure is the first fixing stud (111) located above the pipeline integrated support (11).

7. The integrated cooling pipe structure for a range-extended electric vehicle according to claim 4, characterized in that, The lower fixing structure is a second fixing stud (112) located below the pipeline integrated support (11).

8. The integrated cooling pipe structure for a range-extended electric vehicle according to claim 1, characterized in that, The water-side thermal management module (2) is provided with multiple cooling water pipe interfaces below it, which are used to connect the cooling pipes in the cooling pipe assembly (1).

9. The integrated cooling pipe structure for a range-extended electric vehicle according to claim 8, characterized in that, The water-side thermal management module (2) integrates a water pump, valve body, heat exchanger and expansion tank.

10. A vehicle, characterized in that, It includes an integrated cooling pipe structure for a range-extended electric vehicle as described in any one of claims 1-9.

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