Automobile corner module air-cooled heat dissipation driving brake integrated system assembly

Abstract

The application discloses a kind of automobile angle module air-cooled heat dissipation drive brake integrated system assembly, it is related to new energy vehicle chassis line control technical field;The assembly includes angle module shell, the centrifugal negative pressure impeller being arranged to the outer side of angle module shell, internal isolation baffle and the annular air inlet groove structure of inside;Isolation baffle divides internal space into the inner chamber of encapsulating motor and the outer chamber of encapsulating brake;When vehicle travels, wheel drives negative pressure impeller rotation to produce suction effect, external air is separated into inner chamber after physical gas-liquid separation by annular air inlet groove, absorbs motor heat to become warm air, then enters outer chamber cooling brake system, finally dust is extracted outside the vehicle;The present application ingeniously utilizes wheel rotation kinetic energy, realizes the passive heat management of zero additional energy consumption, and simultaneously solves the inherent contradiction between high-level waterproof dustproof and high-power continuous heat dissipation of angle module.

Description

Technical Field

[0001] This invention relates to the fields of chassis drive-by-wire technology and vehicle thermal management technology for new energy vehicles, specifically to an integrated system assembly for an automotive corner module air-cooled heat dissipation drive and braking system. Background Technology

[0002] With the rapid development of new energy vehicles and intelligent chassis technology, distributed drive and drive-by-wire chassis are gradually becoming industry trends. Among them, the vehicle corner module, as a highly integrated chassis execution unit, typically integrates the drive motor, drive-by-wire mechanism, and mechanical braking system within a small and enclosed wheel hub space.

[0003] However, existing highly integrated corner modules face an extremely serious engineering dilemma: the conflict between high-level sealing protection and high-power heat dissipation.

[0004] Heat buildup problem: The drive motor generates a lot of heat during continuous operation. If the temperature is too high, it can cause irreversible demagnetization of the permanent magnet. At the same time, the mechanical braking system generates extreme high temperatures and a large amount of metal dust during frequent braking. If a fully enclosed physical seal is used, the heat from the motor and brake will create a "stuffed-in effect," leading to a sharp drop in motor efficiency and brake thermal fade.

[0005] Environmental intrusion issues: The vehicle wheels are located in the harshest working environment of the entire vehicle. If a ventilation design with openings is used for heat dissipation, mud, de-icing agents, and gravel kicked up by the wheels can quickly intrude into the corner module, short-circuiting and destroying the delicate MCU control board, or jamming the drive-by-wire actuator.

[0006] Unsprung mass limitation: If the traditional liquid cooling circulation system of new energy vehicles is introduced to solve the thermal management problem, it will not only require the addition of complex electronic water pumps, cooling pipes and sealing joints, but also significantly increase the weight of the corner module, which will seriously deteriorate the vehicle's handling smoothness and response speed.

[0007] Therefore, how to cleverly resolve the inherent contradiction between waterproofing and dustproofing and efficient heat dissipation inside the corner module without significantly increasing unsprung mass and additional energy consumption is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0008] The main objective of this invention is to provide an integrated system assembly for an automotive corner module air-cooled heat dissipation drive and braking system, which solves the problems in the prior art where corner modules are difficult to balance high-level sealing and efficient heat dissipation, and where traditional liquid cooling solutions result in excessive unsprung mass.

[0009] To achieve the above objectives, the present invention provides an integrated automotive corner module air-cooled heat dissipation drive and braking system assembly, comprising: The corner module housing has two independently connected inner and outer chambers. The inner chamber is a temperature-sensitive clean area, which encapsulates one or more of the following: a drive motor stator, a steering mechanism by wire, and an MCU control board. The outer chamber is a high-heat contamination area, which encapsulates the brake caliper and brake disc. Airflow absorbs heat in the inner chamber to form warm air, which then enters the higher-temperature outer chamber to continue cooling the brake caliper and brake disc. The centrifugal negative pressure assembly includes a centrifugal impeller mounted on the outer shell of the corner module and communicating with the outer chamber, and a tortuous air intake channel mounted on the outer shell of the corner module and communicating with the inner chamber. The centrifugal impeller is connected to an external wheel, so that when the wheel rotates in the forward direction, external air is drawn in through the air intake channel, flows through the inner chamber and then through the outer chamber, finally forming a positive pressure dustproof air curtain on the outside of the centrifugal impeller. When the wheel is rotating, the suction effect generated by the centrifugal negative pressure impeller assembly ensures that the air pressure in the outer chamber is always lower than that in the inner chamber, thereby ensuring unidirectional airflow from the inside to the outside and forming a positive pressure air curtain dustproof effect inside the corner module that repels impurities outward.

[0010] As a further improvement of the present invention, the corner module housing is hollow and provided with an annular isolation plate; the annular isolation plate is distributed with multiple sets of unidirectional flow guide holes.

[0011] As a further improvement of the present invention, the annular isolation plate is made of a heat-insulating alloy material and coated with a phase change heat-insulating coating on its surface to block heat conduction from the outer cavity to the inner cavity.

[0012] As a further improvement of the present invention, the centrifugal impeller includes an end shell connected to the outer shell of the corner module and guide vanes rotatably disposed within the end shell and arranged radially; the guide vanes are connected to an external wheel.

[0013] As a further improvement of the present invention, the corner module housing is provided with a water baffle plate, and multiple sets of water baffles are arranged at radial intervals along the water baffle plate; the water baffles are spaced apart to form an annular water baffle groove, which is used to achieve gas-liquid separation by physical impact when external air is drawn in.

[0014] As a further improvement of the present invention, the water baffle plate is provided with a water collection groove; the water baffle plate is provided with a drain hole communicating with the water collection groove, and the water baffle plate is provided with an air inlet communicating with the annular water baffle groove. The annular water baffle groove and the water baffle ring structure block the separated water and impurities, which are discharged through the drain hole under the action of gravity or centrifugal force.

[0015] As a further improvement of the present invention, a one-way gravity drain valve or a hydrophobic and breathable membrane structure is added to the air inlet and the drain hole to prevent external water flow from entering the inner cavity in reverse when the vehicle is in a low-speed wading or reversing condition, which weakens the negative pressure suction effect.

[0016] The beneficial effects of this invention are reflected in: 1. Achieving passive and efficient thermal management with zero additional energy consumption: This invention eliminates the complex electronic water pumps and pipelines of traditional liquid cooling systems, and cleverly uses the physical kinetic energy of the vehicle's own rotation as a "pneumatic pump". The faster the vehicle speed and the more frequent the braking, the stronger the negative pressure suction force generated by the centrifugal impeller and the greater the flow rate of the cold air drawn in, thus achieving adaptive matching between heat dissipation power and heat generation power.

[0017] 2. Skillfully resolve the engineering conflict between "protection and heat dissipation": Gas-liquid separation: By utilizing the mass difference between air and mud-water droplets through the annular air intake groove on the inner side of the chassis, a purely physical gas-liquid separation of "air in, water out" is achieved during the suction of air.

[0018] Positive pressure dust prevention: A strong unidirectional airflow from the inside out forms an "air curtain" effect on the outside of the corner module; the internal air pressure is greater than the external ambient air pressure, making it difficult for external fine sand, cement slurry and braking dust to flow back into the corner module, which greatly improves the reliability of the drive-by-wire mechanism.

[0019] 3. Stepped fluid heat utilization design: Through the cold and heat isolation dual-chamber design, fresh cold air first cools the temperature-sensitive and cleanliness-required motor and MCU, and becomes "warm air" after absorbing heat; since the working temperature of the brake disc is much higher than that of the warm air, the airflow can still effectively cool the braking system after entering the outer chamber, realizing the ultimate squeezing of air kinetic energy and heat absorption capacity.

[0020] 4. Significantly reduced unsprung mass: This invention highly integrates the centrifugal air duct, water-blocking structure and corner module shell, eliminating the bulky liquid cooling components and greatly reducing the weight of the corner module assembly, which is beneficial to improving the dynamic response and handling performance of the vehicle chassis. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of an automotive corner module air-cooled heat dissipation drive and braking integrated system assembly according to the present invention; Figure 2 This is a schematic diagram of the internal structure of the corner module housing of an automotive corner module air-cooled heat dissipation drive and braking integrated system assembly according to the present invention; Figure 3 This is a schematic diagram of the centrifugal impeller structure of an integrated automotive corner module air-cooled heat dissipation drive and braking system assembly according to the present invention; Figure 4 This is a schematic diagram of the annular water-retaining groove structure of an integrated drive and braking system assembly for an automotive corner module according to the present invention; Explanation of reference numerals in the attached figures: 1. Corner module housing; 2. Inner chamber; 3. Outer chamber; 4. Centrifugal impeller; 401. End shell; 402. Guide vane; 5. Air inlet channel; 6. Positive pressure dustproof curtain; 7. Motor stator; 8. Brake caliper; 9. Brake disc; 10. Annular isolation plate; 11. One-way guide hole; 12. Water baffle plate; 13. Water baffle; 14. Annular water baffle groove; 15. Water collection groove; 16. Drain hole; 17. Air inlet; 18. One-way gravity drain valve. Detailed Implementation To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the described embodiments are merely some, not all, of the embodiments of this invention. Unless otherwise specified, the embodiments and features described in this application can be combined with each other. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0022] In one embodiment, see Figure 1 , 2 The present invention provides an integrated system assembly for an automotive corner module air-cooled heat dissipation drive and braking system, comprising a corner module housing 1 and a centrifugal negative pressure component.

[0023] The corner module housing 1 has an independently connected inner chamber 2 and an outer chamber 3. The centrifugal negative pressure assembly includes a centrifugal impeller 4 installed on the corner module housing 1 and connected to the outer chamber 3, and a tortuous air intake channel 5 installed on the corner module housing 1 and connected to the inner chamber 2. The centrifugal impeller 4 is connected to an external wheel, so that when the wheel rotates in the forward direction, external air is drawn in from the air intake channel 5, flows through the inner chamber 2 and the outer chamber 3, and finally forms a positive pressure dustproof air curtain 6 on the outside of the centrifugal impeller 4.

[0024] In this embodiment, see Figure 1 The inner chamber 2 is set as a temperature-sensitive clean area (encapsulating the drive motor stator 7, the drive-by-wire steering mechanism, the MCU control board, etc.); the outer chamber 3 is set as a high-heat contamination area (encapsulating the brake caliper 8 and the brake disc 9); the airflow absorbs heat in the inner chamber 2 to form warm air, which enters the outer chamber 3, which has a higher temperature, to continue cooling the braking components; in order to make the airflow flow from the inner chamber 2 to the outer chamber 3, the corner module housing 1 is hollow inside and is provided with an annular isolation plate 10. The annular isolation plate 10 is distributed with multiple sets of unidirectional guide holes 11. The airflow enters the inner chamber 2 from the air intake channel 5 and then enters the outer chamber 3 through the guide holes, and finally flows out from the centrifugal impeller 4.

[0025] For details, see Figure 2The annular isolation plate 10 is made of heat-insulating alloy material and coated with a phase change heat-insulating coating on its surface to block heat conduction from the outer chamber 3 to the inner chamber 2.

[0026] In this embodiment, see Figure 1 , 3 The centrifugal impeller component 4 includes an end shell 401 connected to the corner module housing 1 and guide vanes 402 rotatably disposed inside the end shell 401 and arranged radially. The guide vanes 402 are connected to an external wheel. The end shell 401 and the guide vanes 402 form a centrifugal negative pressure impeller.

[0027] Specifically, the end shell 401 is integrally formed with the outermost metal shell of the corner module shell 1, or is mechanically connected by fastening bolts.

[0028] In this embodiment, see Figure 4 To prevent water droplets mixed in with the cold air drawn in through the air intake channel 5 from entering the inner chamber 2, multiple staggered annular water-blocking grooves 14 are provided at the air intake channel 5. These include a water-blocking plate 12 connected to the corner module housing 1, and multiple sets of water-blocking plates 13 arranged radially at intervals along the water-blocking plate 12. The water-blocking plates 13 are spaced apart to form annular water-blocking grooves 14. Water-collecting grooves 15 are provided on the water-blocking plates 13. Drainage holes 16 communicating with the water-collecting grooves 15 are provided on the water-blocking plate 12. Air inlets 14 communicating with the annular water-blocking grooves 14 are provided on the water-blocking plate 12. 7. External air enters through the air inlet 17 under negative pressure suction and moves in a spiral manner along the annular water baffle 14. Finally, it passes through the tortuous air intake channel 5 and enters the inner chamber 2. During the movement of the external air in the annular water baffle 14, the spiral movement of the external air generates centrifugal force. The water droplets mixed in the air collide with the inner wall of the baffle plate 13 to achieve gas-liquid separation. The water droplets move along the inner wall of the baffle plate 13 and enter the water collection tank 15 during the movement. Finally, they flow out from the drain hole 16 to prevent water droplets from entering the inner chamber 2.

[0029] Specifically, a one-way gravity drain valve 18 or a hydrophobic and breathable membrane structure is added to the air inlet 17 and the drain hole 16 to prevent water from flowing backward into the inner cavity 2 due to the weakening of negative pressure when the vehicle is wading through water at low speed or reversing.

[0030] In the above configuration, the corner module housing 1 serves as the overall support structure. The centrifugal negative pressure impeller is installed on the vertical surface of the corner module housing 1 near the outer side of the wheel by bolt fastening. The centrifugal negative pressure impeller includes a set of radially arranged guide vanes 402. When the wheel rotates, the impeller rotates synchronously. According to Bernoulli's principle of fluid mechanics, the central air is thrown out to all sides, forming a significant negative pressure center inside the assembly.

[0031] Inside the corner module housing 1, there is an annular isolation partition made of high silicon aluminum alloy, the surface of which is coated with a phase change heat insulation coating. The annular isolation partition strictly divides the internal space into an inner chamber 2 and an outer chamber 3. The inner chamber 2 is a temperature-sensitive clean area, which encapsulates the drive motor stator 7 and the MCU control board. The outer chamber 3 is a high-heat contamination area, which encapsulates the brake caliper 8 and the brake disc 9. Several one-way flow guide holes 11 are opened on the annular isolation partition, which only allow airflow from the inner chamber 2 to the outer chamber 3.

[0032] To ensure air intake safety, a tortuous air intake channel 5 is provided on the inner side of the chassis, and multiple intersecting annular water baffles 14 are provided on the outer side of the air intake channel 5. When air containing water droplets is drawn in, the water droplets impact the wall of the annular water baffles 14 due to inertia and are discharged along the preset gravity drain hole 16, allowing only dry air to enter.

[0033] The dynamic working principle is as follows: Medium-high speed / frequent braking conditions: At this time, the heat generation increases dramatically; the wheel drives the centrifugal negative pressure impeller to rotate at high speed, the outer chamber 3 forms a strong negative pressure P1, the inner chamber 2 forms a secondary negative pressure P2, and the external atmospheric pressure P0>P2>P1; the relatively clean cold air on the chassis side is forcibly drawn into the inner chamber 2, sweeps over the motor cooling fins and takes away the heat; the heated airflow passes through the one-way guide hole 11 and enters the outer chamber 3, directly blowing onto the brake disc 9 which is in an extremely high temperature state for secondary cooling; finally, the airflow mixed with brake dust and waste heat is directly drawn out of the vehicle by the centrifugal impeller.

[0034] Low-speed / water wading conditions: At this time, the heat generated by the motor and brake is minimal, and no forced cooling is required. The wheel speed is low, and the negative pressure suction effect is weak or disappears. The annular water baffle 14 plays a purely static blocking role. The bottom of the air inlet 17 is equipped with a one-way gravity valve. When the external water pressure is greater than the internal air pressure, the valve automatically closes, completely cutting off the water intrusion path and protecting the internal electronic components.

[0035] The above description is merely a preferred embodiment of the invention and is not intended to limit the invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the protection scope of the invention.

Claims

1. A car corner module air-cooled heat dissipation drive and braking integrated system assembly, characterized in that, include: The corner module shell (1) has an internal cavity (2) and an external cavity (3) that are independently connected to each other. The centrifugal negative pressure assembly includes a centrifugal impeller (4) disposed on the corner module housing (1) and connected to the outer chamber (3), and a tortuous air intake channel (5) disposed on the corner module housing (1) and connected to the inner chamber (2); the centrifugal impeller (4) is connected to the external wheel, and when the wheel rotates in the forward direction, it draws in external air from the air intake channel (5), and flows through the inner chamber (2) and the outer chamber (3) to finally form a positive pressure dustproof air curtain (6) on the outside of the centrifugal impeller (4).

2. The automotive corner module air-cooled heat dissipation drive braking integrated system assembly according to claim 1, characterized in that: The corner module housing (1) is hollow inside and has an annular isolation plate (10); the annular isolation plate (10) has multiple sets of unidirectional flow guide holes (11).

3. The automotive corner module air-cooled heat dissipation drive braking integrated system assembly according to claim 2, characterized in that: The annular isolation plate (10) is made of heat-insulating alloy material and coated with a phase change heat-insulating coating on its surface.

4. The automotive corner module air-cooled heat dissipation drive braking integrated system assembly according to claim 3, characterized in that: The centrifugal impeller component (4) includes an end shell (401) connected to the corner module housing (1) and guide vanes (402) rotatably disposed inside the end shell (401) and arranged radially; the guide vanes (402) are connected to the external wheel.

5. The automotive corner module air-cooled heat dissipation drive braking integrated system assembly according to claim 4, characterized in that: The corner module housing (1) is provided with a water baffle plate (12) and multiple sets of water baffles (13) are arranged radially at intervals along the water baffle plate (12); there are gaps between the water baffles (13) to form an annular water baffle groove (14).

6. The automotive corner module air-cooled heat dissipation drive braking integrated system assembly according to claim 5, characterized in that: The baffle plate (13) is provided with a water collection trough (15); the baffle plate (12) is provided with a drain hole (16) communicating with the water collection trough (15), and the baffle plate (12) is provided with an air inlet (17) communicating with the annular baffle trough (14).

7. The automotive corner module air-cooled heat dissipation drive braking integrated system assembly according to claim 6, characterized in that: A one-way gravity drain valve (18) or a hydrophobic and breathable membrane structure is added to the air inlet (17) and the drain hole (16).

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