A device for simulating a heat source of a whole vehicle thermal management water-cooling heat dissipation

Abstract

The utility model relates to a whole vehicle heat management water cooling heat dissipation simulation heat source's device, including heat source generating water cooling plate and heat source control box, heat source generating water cooling plate contains aluminium water cooling plate and sets up in the cooling water channel and PTC heating rod of aluminium water cooling plate inside, and the inlet and outlet water end of cooling water channel is connected with inlet and outlet water pipe joint respectively, and heat source control box contains switch panel control box and PID temperature controller, temperature feedback thermocouple, 220V power and air switch assembly, and PID temperature controller, 220V power and air switch assembly all install fixedly in switch panel control box, and temperature feedback thermocouple one end is connected to the signal input end of PID temperature controller, and temperature feedback thermocouple other end is fixed on the aluminium water cooling plate center surface, and the power lead-out end of PTC heating rod is connected to the power output port of PID temperature controller through the wire, the utility model can realize the function of simulation heat source, and heat source generating water cooling plate and PID temperature controller processing period are short, and the cost is low, and the type selection is flexible, and the adaptability is good.

Description

[Technical Field]

[0001] This utility model relates to the field of automotive parts technology, specifically a device for simulating a heat source for water-cooled heat dissipation in vehicle thermal management. [Background Technology]

[0002] In the early stages of vehicle development, during bench or whole-vehicle thermal management testing, before component samples are produced, a common approach for the initial development of electronic control components requiring water cooling is to select a product with similar performance as a substitute. However, this may result in insufficient thermal load to meet design requirements, leading to significant discrepancies between test results and design specifications. To address this issue, a controllable heat source simulation device can be used to meet this requirement.

[0003] As can be seen from the above, existing technologies use products with similar performance to replace or customize parts separately. The main drawbacks are as follows: 1. The performance of the replacement parts cannot fully meet the thermal design requirements; 2. If no replacement product is available, developing a separately compliant part is time-consuming and costly. [Utility Model Content]

[0004] The purpose of this invention is to address the aforementioned shortcomings by providing a device for simulating a heat source for vehicle thermal management using water cooling. This device can simulate the function of a heat source, and the water-cooled plate and PID temperature controller for generating the heat source have a short processing cycle, low cost, flexible selection, and good adaptability.

[0005] To achieve the above objectives, a device for simulating a heat source for vehicle thermal management water cooling is designed, including a heat source generating water-cooled plate and a heat source control box. The heat source generating water-cooled plate includes an aluminum water-cooled plate 1, a cooling water channel 2 and a PTC heating rod 3 disposed inside the aluminum water-cooled plate 1. The inlet and outlet ends of the cooling water channel 2 are respectively connected to inlet and outlet water pipe joints 4. The heat source control box includes a switch panel control box 8, a PID temperature controller 5, a temperature feedback thermocouple 6, a 220V power supply and an air switch assembly 7. The PID temperature controller 5, the 220V power supply and the air switch assembly 7 are all installed and fixed inside the switch panel control box 8. One end of the temperature feedback thermocouple 6 is connected to the signal input terminal of the PID temperature controller 5, and the other end of the temperature feedback thermocouple 6 is fixed to the center surface of the aluminum water-cooled plate 1. The power lead of the PTC heating rod 3 is connected to the power output port of the PID temperature controller 5 through a wire.

[0006] Furthermore, the aluminum water-cooled plate 1 has grooves inside to form a cooling water channel 2. The cooling water channel 2 is connected to the vehicle cooling system pipeline through inlet and outlet water pipe joints 4 and is fastened with spring clamps, thereby preventing water leakage during system operation.

[0007] Furthermore, the cooling water channel 2 is composed of at least two sets of U-shaped channels connected end to end, and adjacent U-shaped channels are connected by inverted U-shaped channels, thereby stabilizing the inlet and outlet cooling water flow.

[0008] Furthermore, the aluminum water-cooled plate 1 has a heating rod groove inside, and the PTC heating rod 3 is pre-embedded in the heating rod groove. The PTC heating rod 3 is composed of at least two sets of U-shaped heating rods connected end to end, and adjacent U-shaped heating rods are connected by inverted U-shaped heating rods.

[0009] Furthermore, the other end of the temperature feedback thermocouple 6 is fixed to the center surface of the aluminum water-cooled plate 1 with aluminum foil tape, so as to serve as temperature feedback and isolate the influence of external temperature; the power lead of the PTC heating rod 3 is connected to the power output port of the PID temperature controller 5 with a wire and is completely wrapped with electrical tape to prevent electric shock.

[0010] Furthermore, the front end of the PID temperature controller 5 is provided with a PID temperature controller control panel 9. The PID temperature controller control panel 9 is provided with a rotary mode knob 10, an SV panel, and a PV panel. The SV panel is used to set the target temperature during the operation of the simulated part, the PV panel is used to display the current water-cooled plate temperature in real time, and the rotary mode knob 10 is used to rotate to the automatic mode.

[0011] Compared with the prior art, this utility model has the following advantages:

[0012] (1) The water-cooled heat dissipation simulated heat source device of this utility model can be used as a substitute part for the actual electronic control unit before the design part is finalized or the sample is produced.

[0013] (2) In the thermal management system bench or whole vehicle thermal management test, this utility model is connected to the entire thermal management system to simulate the heat generated under the design state during system operation;

[0014] (3) This utility model can simulate the real heat that the coolant can carry away under the rated flow rate of the system or help to evaluate the heat dissipation capacity of the cooling system during actual bench and vehicle tests.

[0015] (4) This utility model can automatically adjust and stabilize the heat generation of the water-cooled plate. By turning the mode knob on the switch panel to automatic mode, the system can automatically control according to the temperature feedback signal and eventually stabilize to the set target temperature.

[0016] (5) This utility model can be customized according to the size of the simulated part, cooling water channel parameters, heat consumption and other parameters. The heat source generating water cooling plate and PID temperature controller have a short processing cycle, low cost, flexible selection and good adaptability.

[0017] (6) This utility model can realize the function of simulating a heat source, and can provide a stable and effective heat load for the vehicle cooling system, providing effective data support for evaluating the heat dissipation system capability. [Image Description]

[0018] Figure 1 This is a schematic diagram illustrating the installation effect of the water-cooled heat dissipation simulation heat source device of this utility model on a vehicle;

[0019] Figure 2 This is a schematic diagram of the temperature control PID parameter control panel of this utility model;

[0020] Figure 3 This is a schematic diagram of the internal cooling water channels of the water-cooled plate of this utility model;

[0021] Figure 4 This is a schematic diagram of the internal heating rod arrangement of the water-cooled plate of this utility model;

[0022] In the diagram: 1. Aluminum water-cooled plate; 2. Cooling water channel; 3. PTC heating rod; 4. Inlet and outlet water pipe joints; 5. PID temperature controller; 6. Temperature feedback thermocouple; 7. 220V power supply and air switch assembly; 8. Switch panel control box; 9. PID temperature controller control panel; 10. Rotary mode knob. [Detailed Implementation]

[0023] The present invention will be further described below with reference to the accompanying drawings:

[0024] As attached Figure 1 To be continued Figure 4 As shown, this utility model provides a water-cooled heat dissipation simulation heat source device for vehicle thermal management testing, including a heat source generating water-cooled plate and a heat source control box. The heat source generating water-cooled plate includes an aluminum water-cooled plate 1 and a cooling water channel 2 and a PTC heating rod 3 disposed inside the aluminum water-cooled plate 1. The inlet and outlet ends of the cooling water channel 2 are respectively connected to inlet and outlet water pipe joints 4. The heat source control box includes a switch panel control box 8, a PID temperature controller 5, a temperature feedback thermocouple 6, a 220V power supply and an air switch assembly 7. The PID temperature controller 5, the 220V power supply and the air switch assembly 7 are all installed and fixed inside the switch panel control box 8. One end of the temperature feedback thermocouple 6 is connected to the signal input end of the PID temperature controller 5, and the other end of the temperature feedback thermocouple 6 is fixed to the center surface of the aluminum water-cooled plate 1. The power lead of the PTC heating rod 3 is connected to the power output port of the PID temperature controller 5 through a wire.

[0025] The aluminum water-cooled plate 1 has internal slots forming cooling water channels 2. These channels connect to the vehicle's cooling system piping via inlet and outlet water pipe joints 4 and are secured with spring clamps to prevent leakage during system operation. Each cooling water channel 2 consists of at least two sets of U-shaped channels connected end-to-end, with adjacent U-shaped channels connected by inverted U-shaped channels to stabilize the inlet and outlet cooling water flow. The aluminum water-cooled plate 1 also has internal heating rod slots, into which PTC heating rods 3 are embedded. Each PTC heating rod 3 consists of at least two sets of U-shaped heating rods connected end-to-end, with adjacent U-shaped heating rods connected by inverted U-shaped heating rods.

[0026] The PID temperature controller 5 has a PID temperature controller control panel 9 at its front end. The PID temperature controller control panel 9 has a rotary mode knob 10, an SV panel, and a PV panel. The SV panel is used to set the target temperature during the operation of the simulated part, and the PV panel is used to display the current water-cooled plate temperature in real time. The rotary mode knob 10 is used to turn to the automatic mode. The other end of the temperature feedback thermocouple 6 is fixed to the center surface of the aluminum water-cooled plate 1 with aluminum foil tape, so as to serve as temperature feedback and isolate the influence of external temperature. The power lead of the PTC heating rod 3 is connected to the power output port of the PID temperature controller 5 with a wire and is completely wrapped with electrical tape to prevent electric shock.

[0027] This utility model's water-cooled heat dissipation simulation heat source device comprises two components: 1. A heat source generating water-cooled plate, which includes an aluminum water-cooled plate containing a Φ12 diameter cooling water channel and a Φ10 diameter PTC heating rod. The cooling water channel is connected to the vehicle's thermal management cooling system for circulation via Φ19 outer diameter inlet and outlet water pipe joints. The heating rod is controlled by a PID temperature controller to achieve the heating function; 2. A heat source control box, which includes a PID temperature controller, a temperature feedback thermocouple, a 220V power supply and air switch assembly, and a switch panel control box. This water-cooled heat dissipation simulation heat source device adjusts the design temperature value of the simulated component through the parameter setting panel of the PID temperature controller. The temperature feedback thermocouple is in close contact with the surface of the heat source generating water-cooled plate. Based on the difference between the current temperature fed back by the thermocouple and the set target temperature, PID logic processing is performed, and the result is converted into heating power, which is output to the PTC heating rod to perform temperature control. The heating rod heats the water-cooled plate body and the internal coolant, simulating the design heat load (TDP) generated by the component during operation. This utility model water-cooled heat dissipation simulated heat source device can automatically adjust and stabilize the heat generation of the water-cooled plate. By turning the mode knob on the switch panel to automatic mode, the system will automatically control and eventually stabilize to the set target temperature based on the temperature feedback signal.

[0028] Example:

[0029] The effect of water-cooled heat dissipation simulating the heat source device installed on the vehicle is shown in the attached image. Figure 1As shown, based on the dimensions of the ADC autonomous driving control unit of a certain vehicle model, a heat source water-cooled plate of the same size is manufactured using the same aluminum material as the heat sink housing. The inlet and outlet water pipes are connected sequentially to the vehicle's cooling system via inlet and outlet pipe joints 4 and secured with spring clamps to prevent water leakage during system operation. The power leads of the PTC heating rod 3 are connected to the power output port of the temperature control box with wires and completely wrapped with electrical tape to prevent electric shock. The PID temperature controller 5, the 220V power supply, and the air switch assembly 7 are installed and fixed inside the switch panel control box 8. One end of the temperature feedback thermocouple 6 is connected to the signal input terminal of the temperature controller, and the other end is fixed to the center surface of the aluminum water-cooled plate 1 with aluminum foil tape, serving as temperature feedback and isolating it from external temperature influences.

[0030] Automatic heating control panel, as attached Figure 2 As shown, after connecting the above components, turn on the power, and set the target temperature of the simulated part to 60°C in the SV row of the PID temperature controller control panel 9; rotate the mode knob 10 to the automatic position, and after the green light is lit, the simulated heat source device will start to adjust automatically; the current water cooling plate temperature is displayed in real time on the PV panel of the PID temperature controller control panel 9.

[0031] After installation and completion of the above operations, a vehicle thermal management test can be conducted to test the data. Through the test, the simulated ADC inlet and outlet temperature test data under a certain test condition shows that the device can simulate the function of a heat source and provide a stable and effective heat load to the vehicle cooling system, providing effective data support for evaluating the heat dissipation system capability.

[0032] The contents not described in detail in this specification are existing technologies known to those skilled in the art. The standard parts used can be purchased from the market, and the irregular parts can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the existing technology. The machinery, parts and equipment adopt conventional models in the existing technology, and the circuit connection adopts conventional connection methods in the existing technology, which will not be described in detail here.

[0033] This utility model is not limited to the above-described embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of this utility model shall be considered equivalent substitutions and shall be included within the protection scope of this utility model.

Claims

1. A device for simulating a heat source for water-cooled heat dissipation in vehicle thermal management, characterized in that: The device includes a heat source generating water-cooled plate and a heat source control box. The heat source generating water-cooled plate includes an aluminum water-cooled plate (1) and a cooling water channel (2) and a PTC heating rod (3) disposed inside the aluminum water-cooled plate (1). The inlet and outlet ends of the cooling water channel (2) are respectively connected to inlet and outlet water pipe joints (4). The heat source control box includes a switch panel control box (8) and a PID temperature controller (5), a temperature feedback thermocouple (6), a 220V power supply and an air switch assembly (7). The PID temperature controller (5), the 220V power supply and the air switch assembly (7) are all installed and fixed inside the switch panel control box (8). One end of the temperature feedback thermocouple (6) is connected to the signal input end of the PID temperature controller (5), and the other end of the temperature feedback thermocouple (6) is fixed to the center surface of the aluminum water-cooled plate (1). The power lead of the PTC heating rod (3) is connected to the power output port of the PID temperature controller (5) through a wire.

2. The device for simulating a heat source for vehicle thermal management water cooling as described in claim 1, characterized in that: The aluminum water-cooled plate (1) has grooves inside to form a cooling water channel (2), and the cooling water channel (2) is connected to the vehicle cooling system pipeline through inlet and outlet water pipe joints (4) and fastened with spring clamps. 3.The whole vehicle thermal management water-cooling heat-dissipation simulation heat source device of claim 2, wherein: The cooling water channel (2) is composed of at least two sets of U-shaped channels connected end to end, and adjacent U-shaped channels are connected by an inverted U-shaped channel. 4.The whole vehicle thermal management water-cooling heat-dissipation simulation heat source device according to claim 1, 2 or 3, characterized in that: The aluminum water-cooled plate (1) has a heating rod groove inside, and the PTC heating rod (3) is embedded in the heating rod groove. The PTC heating rod (3) is composed of at least two sets of U-shaped heating rods connected end to end, and adjacent U-shaped heating rods are connected by inverted U-shaped heating rods. 5.The whole vehicle thermal management water-cooling heat-dissipation simulation heat source device of claim 1, wherein: The other end of the temperature feedback thermocouple (6) is fixed to the center surface of the aluminum water-cooled plate (1) with aluminum foil tape. The power lead of the PTC heating rod (3) is connected to the power output port of the PID temperature controller (5) with a wire and wrapped completely with electrical tape to prevent electric shock.

6. The device for simulating a water-cooled heat source for vehicle thermal management as described in claim 1, characterized in that: The front end of the PID temperature controller (5) is provided with a PID temperature controller control panel (9). The PID temperature controller control panel (9) is provided with a rotary mode knob (10), an SV panel, and a PV panel. The SV panel is used to set the target temperature when the simulated part is running. The PV panel is used to display the current water-cooled plate temperature in real time. The rotary mode knob (10) is used to rotate to the automatic mode.

Images