Patent Application
20080225483
Hybrid drive vehicles, which use both electrical and internal combustion engine power, include certain power electronic devices that convert, manage, and distribute power and energy in hybrid vehicle applications. These devices, such as semiconductors, converters/inverters, battery packs, controllers, and switches, are important to developing an efficient and high-performance hybrid vehicle system. For instance, in heavy hybrid vehicles, converters and inverters condition and control the electrical signal between the energy storage unit (such as the battery pack) and the motor/generator to provide power to various components at critical times.
Hybrid drive vehicles need proper thermal management of the hybrid components for optimum performance and durability. Therefore, hybrid vehicles typically require supplemental cooling loops, separate from the primary engine, to maintain a proper operating temperature for the heat-generating components of the hybrid drive system. Typically, the components of a cooling system are individually mounted to the vehicle in a suitable location for cooling the desired component. The cooling components are thereafter placed into fluid communication with a coolant loop or coolant lines and heat-generating components. The necessary electrical systems must also be installed for controlling the cooling components.
Separately installing each cooling component and associated electrical control system increases installation time and cost. Moreover, planning the location for each cooling component relative to the heat-generating components can take significant amounts of time, especially when installing the components on various vehicle models. These installation and design costs contribute to the overall cost of manufacturing the vehicle, thus increasing the cost to the purchaser or reducing the profit of the manufacturer. It is desired to have a cooling system that can be used to cool a variety of heat-generating components and mounted to a variety of different vehicles in a simplified manner to reduce installation time and costs.
A modular cooling system for a vehicle is provided. The modular cooling system includes a frame adapted to be mounted to a portion of a vehicle. A heat-generating component and a plurality of cooling components are received on the frame. At least one of the cooling components is placed into fluid communication with the heat-generating component.
A method for providing a cooling system for cooling a heat-generating component of a vehicle is also provided. The method includes securing a heat-generating component on a frame, securing a plurality of cooling components on the frame, placing at least one of the cooling components into fluid communication with the heat-generating component, and mounting the frame to the vehicle.
By installing and plumbing the cooling components and the heat-generating component prior to mounting the frame to the vehicle, vehicle assembly costs are minimized. Rather than securing each component individually to the vehicle and thereafter placing the component into communication with the other components, the components are mounted to the vehicle in one step. Moreover, packaging the cooling system together with the heat-generating component allows the cooling system to be mounted in a variety of locations on the vehicle and on a variety of different vehicles.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
A modular cooling system 10 constructed in accordance with one embodiment of the present disclosure is best seen by referring to
Referring to
The cooling components of the modular cooling system 10 are packaged together on a suitable frame 12. The cooling components include, but are not limited to, a coolant pump 18 (with an optional integrated controller), a cooling fan 22, a heat exchanger 24, and a fan controller 26. The cooling components may be any suitable off-the-shelf components that are adapted to cooperate and sufficiently cool the heat-generating component(s), such as the inverter 16. Other cooling components may be included in the modular cooling system 10 in addition to or instead of the cooling components listed above. For instance, the system may include a cooling reservoir or additional fans or heat exchangers.
Referring to
In the alternative, the frame 12 may be a suitable platform device that is adapted to receive the heat-generating component and the cooling components thereon. The platform device may be formed from a sheet of material, such as metal, that is either bent at the edges or includes mounting brackets secured thereto for mounting the platform horizontally to the frame rail B. A plurality of fasteners may be used to secure the components to the platform.
A separate bracket may be secured to the frame 12 for mounting any of the various components to the frame 12. For instance, a pump bracket 32 is used to mount the coolant pump 18 to the frame 12. The pump bracket 32 is adapted to receive the coolant pump 18 and secure it to the frame 12 such that the pump 18 may be placed into communication with the other components. Preferably, the pump bracket 32 includes a flange 33 that is mounted to the forward portion 38 of either mounting bracket 34.
The cooling fan 22 may be secured to the frame 12 with a fan bracket 40. The fan bracket 40 includes a fan-receiving portion 41 for receiving the cooling fan 22 therewithin and side flanges 42 formed on each side of the fan-receiving portion 41. The side flanges 42 are mateable with the vertical side portions 30 of the frame 12. The fan controller 26 is mounted in any suitable manner to the interior surface of the frame 12 such that it may be placed into electrical communication with the fan 22. The heat exchanger 24 is mounted to the bottom of the fan bracket 40 with a plurality of fasteners, and a grill 44 is secured to the frame 12 to substantially enclose the fan 22 and heat exchanger 24 within the frame 12.
The inverter 16 is suitably mounted to the horizontal portion 28 of the frame 12 such that it may be placed into communication with the cooling components. The inverter 16 is coupled to the exterior surface of the horizontal portion 28 of the frame 12. In this manner, the inverter 16 is accessible such that it may be easily placed into electrical communication with other vehicle components. It should be appreciated that the inverter 16 may instead be mounted to any portion of the frame 12. Moreover, other heat-generating components may also be suitably mounted to the frame 12.
The frame 12, brackets 32, 34, and 40, and grill 44 are made from any suitable material, such as sheet metal. It should be appreciated that frame 12, brackets 32, 34, and 40, and grill 44 may be formed in any suitable shape and size such that the cooling components and the heat-generating components are mountable within the frame 12 to package all the components into a modular cooling system 10.
The frame 12 may be mounted to the vehicle A such that it provides structural support for the vehicle or other vehicle components. For instance, the frame 12 may include a pair of steps (not shown) mounted to its exterior such that when the system 10 is mounted beneath the truck cab B, a user could climb the steps to access upper portions of the cab exterior. The frame 12 may also include mounting features for securing other vehicle components to the frame 12. In this manner, the frame rail B could be reserved for other components, such as larger fuel tanks.
To use the modular cooling system 10, the cooling components and heat-generating components are mounted to the frame 12 in the manner described above. The coolant pump 18, heat exchanger 24, and inverter 16 are placed into fluid communication with coolant lines (not shown) to define a coolant loop within the modular cooling system 10. A suitable coolant is thereafter added to the coolant loop in a manner well known in the art. The components are also wired together as necessary in a manner well-known in the art.
After securing the components to the frame 12 and placing the components into fluid and/or electrical communication with each other, the frame 12 is mounted to the frame rail B by securing the mounting brackets 34 to the frame rail B. The electrical components are thereafter placed into electrical communication with a power source on the vehicle (not shown). It should be appreciated that the electrical components may instead be placed into electrical communication with a power source on the frame 12 before the frame 12 is mounted to the vehicle. If needed, the cooling components may also be placed into fluid communication with other heat-generating components on the vehicle A.
Packaging the components together as a single modular cooling system 10 allows an operator to mount the cooling components and the heat-generating component to the vehicle in a single installation. Having the ability to mount the components to the vehicle at one time in a single installation, as well as being able to wire and plumb the components prior to installation, reduces manufacturing time and costs.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
