A cooling module heat dissipation testing system

Abstract

The application relates to a heat dissipation test system of a cooling module, which comprises a mounting seat, a rotating main shaft and a main beam assembly, a driving mechanism drives the rotation of the main shaft, the two ends of the main beam are respectively provided with a cooling module and a movable mounting box, the cooling module is vertically arranged and the front part faces the rotating direction, the rotating radius of the cooling module is greater than that of the mounting box, a water supply tank and an air supply tank provided with a heater are arranged in the mounting box and are respectively connected with a radiator and an intercooler of the cooling module, temperature sensors and water pumps / air pumps are arranged in pipelines, the application simulates the laminar head wind of a vehicle during driving through rotation, avoids turbulence interference, can independently adjust the cooling liquid temperature, flow, air temperature, flow and rotating speed, truly simulates the heat dissipation performance under different working conditions, when different cooling modules are replaced, vibration sensors are used to monitor vibration and the position of the mounting box is moved to quickly realize system dynamic balance, the test safety and precision are ensured, and the heat dissipation test of various cooling modules is suitable.

Description

Technical Field

[0001] This invention relates to the field of cooling module technology, specifically to a cooling module heat dissipation testing system. Background Technology

[0002] Vehicle cooling modules typically consist of a radiator and an intercooler, used to control engine and intake air temperatures, and are key components ensuring normal vehicle operation. Before a new product is finalized, the heat dissipation capacity of the cooling module must be accurately tested to verify whether it meets the vehicle's operating requirements under different conditions.

[0003] Currently, common heat dissipation testing methods often employ direct fan blowing onto the cooling module, such as the multifunctional heat dissipation testing device and method disclosed in CN120992204A. However, this method has significant shortcomings: the airflow generated by the fan easily forms turbulence, failing to realistically simulate the laminar oncoming wind faced by the cooling module during vehicle operation; simultaneously, existing testing devices struggle to simultaneously and accurately simulate the actual operating conditions where multiple factors such as ambient temperature, driving speed, coolant flow rate, and airflow are coupled, leading to significant deviations between test results and real-world vehicle performance. Therefore, there is an urgent need for a cooling module heat dissipation testing system that can more realistically simulate vehicle driving conditions and flexibly adjust multiple parameters. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a system for testing the heat dissipation of a cooling module.

[0005] This invention is achieved through the following technical solution: a heat dissipation testing system for a cooling module, comprising a fixed mounting base, a rotating spindle vertically connected to the mounting base, and a main beam assembly horizontally fixed to the rotating spindle. The mounting base contains a drive mechanism for rotating the rotating spindle. A cooling module and a mounting housing are respectively mounted at both ends of the main beam assembly. The cooling module is vertically oriented with its front facing the direction of rotation. The distance from the cooling module to the rotating spindle is greater than the distance from the mounting housing to the rotating spindle. A water supply tank and an air supply tank are fixedly connected inside the mounting housing. A water heater and an air heater are respectively installed in the water supply tank and air supply tank. The water supply tank is connected to both ends of the radiator of the cooling module via water pipes, and a water temperature sensor is installed on each water pipe. At least one water pipe is equipped with a water pump. The air supply tank is connected to both ends of the intercooler of the cooling module via air pipes, and an air temperature sensor is installed on each air pipe. At least one air pipe is equipped with an air pump.

[0006] In this design, a rotating spindle drives the main beam assembly and cooling module in a circular motion. This ensures the cooling module always faces the direction of rotation, creating a stable relative airflow that simulates the laminar headwind experienced when a vehicle is traveling in a straight line. This avoids the turbulence interference of traditional fans, significantly improving the realism and accuracy of the test. By placing the cooling module and mounting housing on opposite sides of the rotating spindle, and using a larger rotation radius for the cooling module, a longer lever arm can be achieved. This allows for higher relative airflow at lower speeds, resulting in energy savings and ease of control. Simultaneously, the mounting housing acts as a counterweight, ensuring rotational balance and reducing vibration. Heaters are installed in the water and air supply tanks, and water / air pumps and temperature sensors are incorporated into the circulation pipeline. This allows for independent and precise adjustment of the coolant and air temperature and flow rate, simulating real heat exchange conditions under different engine loads and ambient temperatures.

[0007] As an optimization, the mounting box is slidably connected to the main beam assembly along its length. The main beam assembly is equipped with a position adjustment mechanism to adjust the position of the mounting box, and a vibration sensor is mounted on the mounting base. In this design, the mounting box is slidably connected along the length of the main beam assembly and equipped with a position adjustment mechanism, allowing for flexible changes in the distance between the mounting box and the rotating spindle, thereby adjusting the counterweight torque. Simultaneously, a vibration sensor is installed on the mounting base. When replacing cooling modules of different weights or sizes, the system drives the rotating spindle to rotate at low speed, monitors the vibration amplitude in real time through the vibration sensor, and moves the mounting box accordingly via the position adjustment mechanism until the vibration is minimized, thus achieving rapid and precise dynamic balance adjustment. This effectively solves the dynamic balance adaptation problem when testing different cooling modules, ensuring testing safety and data accuracy at high speeds.

[0008] As an optimization, the position adjustment mechanism includes an adjustment motor fixed to the end of the main beam assembly and a lead screw fixed to the shaft of the adjustment motor. A lead screw connecting plate is fixed to the side of the mounting box near the adjustment motor. The lead screw connecting plate is fixed to the mounting box via a longitudinal connecting plate, and the lead screw is threadedly connected to the lead screw connecting plate. This solution employs an adjustment mechanism where the adjustment motor drives the lead screw and the lead screw connecting plate, enabling automatic, precise, and continuous adjustment of the mounting box position. It can also be linked with a vibration sensor to form a closed-loop control, offering convenient operation and high repeatability.

[0009] As an optimization, the main beam assembly includes two main beams arranged side by side and multiple connecting beams connecting the two main beams. Fixed discs are fixed to the ends of the two main beams. An adjusting disc is axially connected to the side of the fixed disc away from the main beam along a horizontal axis. The adjusting disc and the fixed disc are connected by multiple bolts, and the bolt holes on the fixed disc are arc-shaped elongated holes. A module mounting bracket is fixed to the adjusting disc, and the cooling module is detachably fixed to the module mounting bracket. In this design, the axial connection structure between the fixed disc and the adjusting disc, and the use of arc-shaped elongated holes and bolts to achieve angle locking, allows for convenient adjustment of the cooling module's windward angle, expanding the coverage of test conditions.

[0010] As an optimization, the module mounting frame includes two vertically arranged support beams, with two vertical support beams fixed between them. Support plates are fixed to the support beams, and the left and right ends of the cooling module are connected to the two support plates via bolts. In this design, the module mounting frame adopts a combined structure of support beams, support beams, and support plates, resulting in a stable structure. Furthermore, the cooling module is detachably connected to the support plates via bolts, facilitating quick replacement of different models of cooling modules and improving testing efficiency.

[0011] As an optimization, two vertical front mounting beams are fixed between the two supporting crossbeams. Insect screens and / or air intake grilles located in front of the cooling module are detachably fixed to these front mounting beams. The detachable insect screens and / or air intake grilles on the front mounting beams in this design can simulate the impact of front-end air intake resistance and protective structures on heat dissipation performance in a real vehicle, making the test conditions closer to actual vehicle conditions.

[0012] As an optimization, a slide rail is fixedly connected to one side of the two main beams that are close to each other, and sliders adapted to the slide rail are fixedly connected to both sides of the mounting box. This design employs a sliding guide structure with slide rails and sliders, ensuring smooth and unobstructed movement of the mounting box, strong load-bearing capacity, and high long-term operational reliability.

[0013] As an optimization, the adjusting disc and the fixed disc are fitted together, and a central shaft is fixedly connected to the center of the adjusting disc, which is then connected to the fixed disc. In this design, the adjusting disc is connected to the fixed disc via the central shaft, resulting in a simple structure, flexible rotation, and the mating surface can be equipped with friction damping for easy angle fixing.

[0014] As an optimization, the rotating spindle is vertically inserted into the mounting base, with bearings installed at both the upper and lower ends of the mounting base. The drive mechanism includes a drive motor fixed within the mounting base and a driven gear fixed to the rotating spindle. A driving gear, meshing with the driven gear, is fixed to the shaft of the drive motor. In this design, the rotating spindle is supported by upper and lower bearings, and the drive motor is driven by a gear pair, resulting in smooth transmission, high speed control precision, and the ability to simulate various driving speeds from low to high.

[0015] As an optimization, a battery is fixedly connected to the main beam assembly above the rotating spindle. This design, with the battery rotating with the main beam assembly, provides a stable power supply for equipment such as water pumps, air pumps, and sensors during rotation, eliminating the need for complex conductive structures like slip rings and reducing system cost and failure rate.

[0016] The beneficial effects of this invention are as follows: By driving the rotating spindle to rotate the main beam assembly and cooling module in a circular motion, the front of the cooling module always faces the direction of rotation, forming a stable laminar oncoming airflow. This realistically simulates the airflow state during vehicle operation, avoiding the turbulence interference caused by traditional fans and significantly improving the accuracy of heat dissipation testing. Simultaneously, the cooling module and mounting housing are positioned on opposite sides of the spindle, with the cooling module having a larger rotation radius. This allows for higher relative airflow at lower speeds, and the system's dynamic balance can be quickly and accurately adjusted after replacing different cooling modules by moving the mounting housing and utilizing real-time feedback from vibration sensors, ensuring testing safety and data reliability at high speeds. Furthermore, the system can independently adjust coolant temperature and flow rate, as well as air temperature and flow rate, simulating different engine loads and ambient temperatures. The angle of attack of the cooling module can be changed by adjusting the disc, and insect screens or air intake grilles can be detached and installed to simulate the intake resistance of a real vehicle. The module mounting bracket supports quick replacement of different models of cooling modules, thus comprehensively covering various actual operating conditions and providing an efficient, accurate, and safe testing method for the design verification of cooling modules. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a structural schematic diagram of the present invention from another angle; Figure 3 This is a front view of the present invention; Figure 4 This is a top view of the present invention; Figure 5 This is a structural schematic diagram of the installation location of the cooling module of the present invention; Figure 6 This is a schematic diagram of the installation position of the cooling module of the present invention from another angle; Figure 7 This is a structural diagram showing the installation position of the mounting box of the present invention; Figure 8 For the present invention Figure 3 Sectional view of plane AA; As shown in the figure: 1. Main beam, 2. Connecting beam, 3. Fixed disc, 4. Adjusting disc, 5. Central shaft, 6. Arc-shaped elongated hole, 7. Supporting crossbeam, 8. Supporting longitudinal beam, 9. Support plate, 10. Cooling module, 11. Front mounting longitudinal beam, 12. Battery, 13. Mounting housing, 14. Water supply tank, 15. Air supply tank, 16. Adjusting motor, 17. Lead screw, 18. Slide rail, 19. Lead screw connecting plate, 20. Longitudinal connecting plate, 21. Mounting base, 22. Rotating spindle, 23. Vibration sensor, 24. Bearing, 25. Drive motor, 26. Driving gear, 27. Driven gear. Detailed Implementation

[0018] To clearly illustrate the technical features of this solution, the following detailed implementation method will be used to explain the solution.

[0019] like Figures 1-8 As shown, a heat dissipation testing system for a cooling module according to the present invention includes a fixed mounting base 21. The mounting base 21 is hollow and contains a drive mechanism. A rotating spindle 22 is vertically inserted into the mounting base 21 and rotatably connected to the mounting base 21 via upper and lower bearings 24. The drive mechanism includes a drive motor 25 fixedly mounted on the inner wall of the mounting base 21 and a driven gear 27 fixedly connected to the rotating spindle 22. A driving gear 26, which meshes with the driven gear 27, is fixedly connected to the rotating shaft of the drive motor 25. When the drive motor 25 is working, it drives the driven gear 27 to rotate through the driving gear 26, thereby causing the rotating spindle 22 to rotate smoothly within the mounting base 21.

[0020] The upper end of the rotating spindle 22 extends out of the mounting base 21 and is horizontally fixedly connected to the main beam assembly. The main beam assembly consists of two main beams 1 arranged side by side and multiple connecting beams 2 connecting the two main beams 1, forming a stable frame structure. A storage battery 12 is fixedly connected to the middle of the main beam assembly (i.e., directly above the rotating spindle 22). The storage battery 12 rotates with the main beam assembly, providing a stable power supply to the various electrical devices in the system without the need for slip rings.

[0021] A cooling module 10 is installed at the left end of the main beam assembly, and a mounting box 13 is installed at the right end. The cooling module 10 is vertically positioned, with its front (windward side) facing the direction of rotation (i.e., the tangential direction of the circular motion). The distance from the cooling module 10 to the rotating spindle 22 is greater than the distance from the mounting box 13 to the rotating spindle 22. This allows the cooling module 10 to achieve a higher linear velocity during rotation to simulate travel speed, while the mounting box 13 serves as a counterweight.

[0022] like Figure 5 , Figure 6As shown, the specific installation structure of the cooling module 10 is as follows: A fixed disc 3 is fixedly connected to the left end of the two main beams 1. An adjusting disc 4 is rotatably connected to the left side of the fixed disc 3 via a central shaft 5, and the adjusting disc 4 fits against the fixed disc 3. The fixed disc 3 has multiple arc-shaped elongated holes 6, and the adjusting disc 4 is connected to the fixed disc 3 by bolts passing through the arc-shaped elongated holes 6. Loosening the bolts allows the adjusting disc 4 to be rotated, thereby changing the windward angle of the cooling module 10, simulating the installation state of the heat dissipation module on different vehicle models. Tightening the bolts fixes the angle. A module mounting bracket is fixedly connected to the adjusting disc 4. The module mounting bracket includes two vertically arranged support beams 7, and two vertical support longitudinal beams 8 are fixedly connected between the two support beams 7. A support plate 9 is fixedly connected to each support longitudinal beam 8. The left and right ends of the cooling module 10 are detachably connected to the two support plates 9 by bolts. Two vertical front mounting beams 11 are also fixedly connected between the two supporting crossbeams 7. Insect screens and / or air intake grilles are detachably mounted on the front mounting beams 11 to simulate the air intake resistance and airflow conditions at the front of the real vehicle.

[0023] like Figure 7 As shown, a slide rail 18 is fixedly connected to one side of the two main beams 1 that are close to each other. Slider blocks adapted to the slide rail 18 are fixedly connected to both sides of the mounting box 13, allowing the mounting box 13 to slide smoothly along the length of the main beam 1. An adjusting motor 16 is fixedly connected to the right end of the main beam assembly, and a lead screw 17 is fixedly connected to the shaft of the adjusting motor 16. A lead screw connecting plate 19 is fixedly connected to the side of the mounting box 13 closest to the adjusting motor 16 via a longitudinal connecting plate 20, and the lead screw 17 is threadedly connected to the lead screw connecting plate 19. When the adjusting motor 16 drives the lead screw 17 to rotate, the lead screw connecting plate 19 causes the mounting box 13 to move left and right along the slide rail 18, thereby changing the distance between the mounting box 13 and the rotating main shaft 22 and adjusting the counterweight torque.

[0024] A vibration sensor 23 is fixedly mounted on the mounting base 21. The vibration sensor 23 is used to monitor the vibration amplitude of the system after replacing different cooling modules, providing real-time feedback for dynamic balance adjustment.

[0025] The housing 13 houses a water supply tank 14 and an air supply tank 15. The water supply tank 14 contains a water heater to heat the coolant to a set temperature. The water supply tank 14 is connected to the inlet and outlet of the radiator in the cooling module 10 via two water pipes. Water temperature sensors are installed on the water pipes, and at least one of the pipes is equipped with a water pump to drive coolant circulation. The air supply tank 15 contains an air heater to heat the air to a set temperature. The air supply tank 15 is connected to the inlet and outlet of the intercooler in the cooling module 10 via two air pipes. Air temperature sensors are installed on the air pipes, and at least one of the air pipes is equipped with an air pump to drive air circulation.

[0026] The specific usage method and dynamic balance adjustment process of this invention are as follows: Step 1: Install the cooling module. Secure the cooling module 10 to be tested to the left and right support plates 9 with bolts. Depending on the testing requirements, an insect screen or air intake grille can be installed on the front mounting beam 11. To simulate different windward angles, loosen the bolts between the fixing disc 3 and the adjusting disc 4, rotate the adjusting disc 4 to the desired angle, and then tighten the bolts.

[0027] Step 2: Perform dynamic balancing. Due to the different weights and center of gravity positions of the various cooling modules, the original dynamic balance of the system is disrupted after installation. At this point, the drive motor 25 is started via the controller, causing the main beam assembly to rotate at a low speed (e.g., 20 to 40 revolutions per minute). The vibration sensor 23 detects the vibration amplitude of the mounting base 21 in real time and transmits the signal to the controller. After reading the vibration data, the controller starts the adjustment motor 16, which drives the lead screw 17 to rotate, moving the mounting box 13 to the left or right along the slide rail 18. During the movement, the vibration amplitude will change. The controller continuously monitors the vibration amplitude, and when the vibration amplitude reaches its minimum value, it stops the adjustment motor 16, at which point the system reaches its optimal dynamic balance. This process can be completed automatically by the controller in a closed loop, or the operator can manually control the adjustment motor 16 based on the displayed values ​​of the vibration sensor 23. After the dynamic balancing is completed, the drive motor 25 can be turned off or preparations can be made for formal testing.

[0028] Step 3: Set test parameters. Start the water heater in water tank 14 and the air heater in air tank 15 to heat the coolant and air to the target temperatures, respectively. Start the water pump and adjust the coolant flow rate to the set value; start the air pump and adjust the air flow rate to the set value. Monitor and adjust the temperature and flow rate in real time using water temperature and air temperature sensors to maintain stability.

[0029] Step 4: Conduct heat dissipation testing. Restart the drive motor 25 to increase the rotational speed of the main beam assembly to the target test speed (corresponding to the simulated vehicle speed). The cooling module 10 moves in a circular motion in the air, forming a stable relative airflow in front of it. Record the data from each temperature sensor, flow sensor, and the calorimeter or heat flow sensor additionally installed on the cooling module. Calculate the heat dissipation of the radiator and intercooler respectively according to the heat calculation formula (e.g., Q = mass flow rate × specific heat capacity × temperature difference). Multi-condition testing can be conducted by changing parameters such as rotational speed, water temperature, air temperature, water flow rate, and air flow rate.

[0030] Step 5: Replace the cooling module. When testing a different type of cooling module, first stop the drive motor 25, remove the original cooling module, and install the new cooling module. Then repeat steps 2 to 4 above to perform dynamic balancing and testing again. Vibration sensor 23 is used to guide the position adjustment of the mounting housing 13 after each module replacement to ensure that the system always operates in the optimal dynamic balance state. During normal testing, vibration sensor 23 can also continuously monitor. If the vibration increases abnormally due to loose bolts or other reasons, the system can issue an alarm signal or automatically shut down to ensure safety.

[0031] Through the above steps, this invention can realistically simulate the laminar airflow when a vehicle is in motion, independently adjust multiple thermal parameters, and quickly adapt to the dynamic balance requirements of different cooling modules, thereby achieving accurate, efficient, and safe heat dissipation testing.

[0032] Of course, the above description is not limited to the examples above. Technical features not described in this invention can be implemented by or using existing technology, and will not be repeated here. The above embodiments and drawings are only used to illustrate the technical solutions of this invention and are not intended to limit this invention. This invention has been described in detail with reference to preferred embodiments. Those skilled in the art should understand that any changes, modifications, additions or substitutions made by those skilled in the art within the scope of this invention do not depart from the spirit of this invention and should also fall within the scope of protection of the claims of this invention.

Claims

1. A system for testing the heat dissipation of a cooling module, characterized in that: The system includes a fixed mounting base (21), a rotating spindle (22) vertically mounted on the mounting base (21), and a main beam assembly horizontally fixed to the rotating spindle (22). The mounting base (21) contains a drive mechanism for rotating the rotating spindle (22). A cooling module (10) and a mounting housing (13) are respectively mounted at both ends of the main beam assembly. The cooling module (10) is vertically positioned with its front facing the direction of rotation. The distance from the cooling module (10) to the rotating spindle (22) is greater than the distance from the mounting housing (13) to the rotating spindle (22). The distance is such that a water supply tank (14) and an air supply tank (15) are fixedly connected inside the mounting box (13). The water supply tank (14) and the air supply tank (15) are respectively equipped with a water heater and an air heater. The water supply tank (14) is connected to both ends of the radiator of the cooling module (10) through water pipes and a water temperature sensor is installed on the water pipes. At least one water pipe is equipped with a water pump. The air supply tank (15) is connected to both ends of the intercooler of the cooling module (10) through air pipes and a temperature sensor is installed on the air pipes. At least one air pipe is equipped with an air pump.

2. The heat dissipation testing system for a cooling module according to claim 1, characterized in that: The mounting box (13) is slidably attached to the main beam assembly along its length. The main beam assembly is equipped with a position adjustment mechanism for adjusting the position of the mounting box (13), and a vibration sensor (23) is mounted on the mounting base (21).

3. The heat dissipation testing system for a cooling module according to claim 2, characterized in that: The position adjustment mechanism includes an adjustment motor (16) fixed to the end of the main beam assembly and a lead screw (17) fixed to the shaft of the adjustment motor (16). A lead screw connecting plate (19) is fixed to the side of the mounting box (13) near the adjustment motor (16). The lead screw connecting plate (19) is fixed to the mounting box (13) through a longitudinal connecting plate (20). The lead screw (17) is threadedly connected to the lead screw connecting plate (19).

4. The heat dissipation testing system for a cooling module according to claim 1, characterized in that: The main beam assembly includes two main beams (1) arranged side by side and multiple connecting beams (2) connecting the two main beams (1). Fixed discs (3) are fixed to the ends of the two main beams (1). An adjusting disc (4) is axially connected to the side of the fixed disc (3) away from the main beams (1) along the horizontal axis. The adjusting disc (4) and the fixed disc (3) are connected by multiple bolts and the bolt holes on the fixed disc (3) are arc-shaped long holes. A module mounting bracket is fixed to the adjusting disc (4). The cooling module (10) is detachably fixed to the module mounting bracket.

5. The heat dissipation testing system for a cooling module according to claim 4, characterized in that: The module mounting frame includes two supporting crossbeams (7) arranged vertically, and two vertical supporting longitudinal beams (8) are fixed between the two supporting crossbeams (7). Support plates (9) are fixed on the supporting longitudinal beams (8). The left and right ends of the cooling module (10) are respectively connected to the two supporting plates (9) by bolts.

6. The heat dissipation testing system for a cooling module according to claim 5, characterized in that: Two vertical front mounting beams (11) are fixed between the two support beams (7), and an insect screen and / or air intake grille located in front of the cooling module (10) are detachably fixed on the front mounting beams (11).

7. The heat dissipation testing system for a cooling module according to claim 4, characterized in that: The two main beams (1) are fixed to a slide rail (18) on one side that is close to each other, and the mounting box (13) is fixed to two sides with sliders that are adapted to the slide rail (18).

8. The heat dissipation testing system for a cooling module according to claim 4, characterized in that: The adjusting disc (4) and the fixed disc (3) are attached together, and a central shaft (5) is fixedly connected to the center of the adjusting disc (4). The central shaft (5) is axially connected to the fixed disc (3).

9. The heat dissipation testing system for a cooling module according to claim 1, characterized in that: The rotating spindle (22) is vertically inserted into the mounting base (21). The upper and lower ends of the mounting base (21) are equipped with bearings (24). The driving mechanism includes a drive motor (25) fixed in the mounting base (21) and a driven gear (27) fixed on the rotating spindle (22). The drive motor (25) has a drive gear (26) fixed on its shaft that meshes with the driven gear (27).

10. A heat dissipation testing system for a cooling module according to any one of claims 1-9, characterized in that: A battery (12) is fixedly connected to the main beam assembly above the rotating main shaft (22).

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