Fan assembly for a motor vehicle

Abstract

A fan assembly including a first cooling fan arranged with respect to an air flow direction downstream of a heat exchanger and a second cooling fan. The first cooling fan is a radial fan that draws cooling air axially and expels the cooling air radially and the second cooling fan is an axial fan that draws cooling air axially and expels the cooling air axially. The axial fan is arranged downstream of the heat exchanger and laterally adjacent to the radial fan in a plane parallel to the rear side of the heat exchanger in a plane parallel to the front side of the heat exchanger.

Claims

1. A fan assembly configured to cool an internal combustion engine of a motor vehicle provided with an internal combustion engine, a heat exchanger, and an electric motor supplied by a rechargeable battery, the fan assembly comprising: a first cooling fan disposed behind a heat exchanger, with respect to an airflow direction of cooling air passing through the heat exchanger, wherein the first cooling fan is a radial fan configured to axially suction and radially expel the cooling air; and a second cooling fan, wherein the second cooling fan is an axial fan configured to axially suction and axially expel the cooling air, and wherein the axial fan is disposed behind the heat exchanger and laterally adjacent to the radial fan with respect to a plane parallel to a rear side of said heat exchanger.

2. The fan assembly of claim 1, further comprising: an electric motor configured to drive the axial fan and the radial fan.

3. The fan assembly of claim 1, further comprising: a fan frame, wherein the axial fan and the radial fan are in a common plane and are each disposed in the fan frame.

4. The fan assembly of claim 1, further comprising: a control device configured to command the axial fan and/or the radial fan to operate based on a driving operation or an operating range of the motor vehicle.

5. The fan assembly of claim 4, wherein the control device is further configured to, in response to motor vehicle speed exceeding a threshold, command the axial fan and the radial fan to operate.

6. The fan assembly of claim 5, wherein the control device is further configured to, responsive to motor vehicle speed exceeding the speed threshold, operating the axial fan and the radial fan above a threshold value.

7. The fan assembly of claim 6, wherein the control device is further configured to, responsive to motor vehicle speed falling below the speed threshold, operating the radial fan below a threshold value.

8. The fan assembly of claim 6, wherein the threshold value is based on a volume of cooling air expelled by the radial fan.

9. A method for operating a fan assembly of claim 1, the method comprising: in response to motor vehicle speed exceeding a speed threshold, operating the axial fan and the radial fan simultaneously; and in response to an operating range of the vehicle, operating either the axial fan or the radial fan.

10. The method of claim 9, further comprising: in response to the motor vehicle being stationary, only operating radial fan.

11. The method of claim 10, wherein the operating step includes operating the radial fan below a radial fan threshold.

12. The method of claim 9, further comprising: in response to charging the battery, only operating the radial fan.

13. The fan assembly of claim 1, wherein the axial fan is disposed in front of the heat exchanger, with respect to the airflow direction, and in a plane parallel to a front side of the heat exchanger.

14. A cooling fan assembly for use in a motor vehicle, the cooling fan assembly comprising: a fan frame a first side and a second side each arranged with respect to an airflow direction; a radial fan disposed on the first side of the fan frame and configured to axially suction and radially expel cooling air; and an axial fan disposed adjacent to the radial fan on the first side of the fan frame, wherein the axial fan is configured to axially suction and radially expel the cooling air.

15. The cooling fan assembly of claim 14, further comprising: an electric motor configured to drive the axial fan and the radial fan; and a controller configured to command the electric motor to drive the axial fan and the radial fan.

16. The cooling fan assembly of claim 15, wherein the controller is further configured to, responsive to motor vehicle speed exceeding a speed threshold, command the electric motor to drive the axial fan and the radial fan at the same time.

17. The cooling fan assembly of claim 15, wherein the motor vehicle is a hybrid vehicle including an internal combustion engine, a battery, and a motor powered by the battery and the controller is further configured to, responsive to charging the battery, operate the radial fan and power off the axial fan.

18. The cooling fan assembly of claim 15, wherein the controller is further configured to, responsive to the motor vehicle being stationary, operate the radial fan and power off the axial fan.

19. The cooling fan assembly of claim 15, wherein the radial fan and the axial fan are disposed in a common plane.

20. The cooling fan assembly of claim 15, wherein the controller is further configured to, responsive to motor vehicle operating load exceeding a threshold, command the electric motor to drive the axial fan and the radial fan at the same time.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Exemplary embodiments of the invention will be explained in more detail below by means of a drawing in which:

(2) FIG. 1 in a schematically simplified manner shows a cooling fan having a fan assembly with a radial and an axial fan;

(3) FIG. 2 in a perspective view shows the fan assembly according to a first variant, having the radial fan and the axial fan on the rear side of a radiator;

(4) FIG. 3 in a perspective view shows the fan assembly according to a second variant, having a radial fan on the rear side and an axial fan on the front side of a radiator, viewed toward the axial fan; and

(5) FIG. 4 in a perspective illustration shows the fan assembly according to the second variant, viewed toward the radial fan.

DETAILED DESCRIPTION

(6) As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

(7) Equivalent parts are provided with the same reference signs in all figures.

(8) The coolant which is directed in pipes that are incorporated in the radiator block of a radiator has in turn to be cooled, to which end cooling air flows across cooling ribs which act as a heat exchanger for the coolant. Since the airstream which serves as cooling air is usually insufficient for cooling, such as at low speeds of the motor vehicle, it is known, for example from DE 10 2013 006 499 U1, to dispose an axial fan within a radiator frame on the radiator that comprises the cooling ribs. The axial fan which may be driven by an electric motor generates an additional airflow, whereby the radiator frame has a number of dynamic pressure flap openings which can be closed by dynamic pressure flaps. In the case of opened dynamic pressure flaps and comparatively high vehicle speeds, a reduced coverage of the cooling area as well as a large area that can be freely passed through by a flow, and thus an increased cooling output, is enabled by virtue of a minor blockage.

(9) The fan in the travel direction is typically disposed behind the radiator block of the radiator (heat exchanger). The air is suctioned through the radiator block with the aid of a fan wheel of the fan and directed onto the internal combustion engine. Should there also be a condenser block of a condenser of an air-conditioning system present in addition to the radiator block, the condenser block in the direction of the airstream (airflow direction) is usually disposed in front of the radiator block. The fan wheel of the fan is disposed in a circular clearance of the frame body of the fan frame, the air being directed through the radiator block by means of said circular clearance, whereby the frame body covers the radiator block in a substantially complete manner.

(10) In order to achieve a high degree of efficiency of the fan, the frame body, with the exception of the circular clearance, is embodied so as to be substantially airtight. In this way, the pressure differential between the region in front of the radiator block and the region behind the frame body, in each case viewed in the travel direction of the vehicle, is comparatively large. In the case of a stationary vehicle, a comparatively large quantity of air is thus suctioned through the radiator block of the radiator by means of the axial fan. As soon as the motor vehicle is moved at a comparatively high speed, the airstream is held back by the frame body and the radiator block. Consequently, only a specific proportion of the airstream passes through the radiator block.

(11) In order for this issue to be alleviated, the dynamic pressure flap openings which are in each case able to be closed by a dynamic pressure flap are incorporated in the frame body. When the fan is operated while the vehicle is stationary, the dynamic pressure flap openings are closed by means of the dynamic pressure flaps, this requiring a comparatively large pressure differential between the region in front of and behind the fan frame. As soon as the dynamic pressure flaps are impinged by an airstream, thus as soon as the motor vehicle is moved, the dynamic pressure flaps pivot to an opened state and the airstream, in addition to the clearance for the fan wheel, also flows through the dynamic pressure flap openings. The volume of air flowing through the radiator block is increased in this way.

(12) A lateral illustration of a radiator or cooling fan system 1 of a motor vehicle (not visualized in more detail) is schematically illustrated in FIG. 1. The cooling fan system 1 comprises a heat exchanger which hereunder is referred to as radiator 2 and on which cooling pipes or cooling hoses 3 are guided. A coolant (a cooling liquid) K is situated within the cooling pipes 3, said coolant/cooling liquid K being kept in circulation by means of a pump (not illustrated). The coolant K is directed through an internal combustion engine (combustion engine) 4 and heated by the latter, whereby the internal combustion engine 4 is cooled. The heated coolant K is again directed through the radiator 2, the latter being impinged by an airstream. The direction of the airstream here is along an airstream direction which corresponds substantially to the main direction of propulsion of the motor vehicle and hereunder is referred to as the airflow direction 5.

(13) The airstream is reinforced by means of a fan assembly 6, or in the case of a stationary motor vehicle generated by said fan assembly 6. The fan assembly 6 comprises a radial fan 6a and an axial fan 6b. The radial fan 6a and the axial fan 6b in one or more embodiments are disposed on the rear side 7 of the radiator 2, and there are situated beside one another in a plane which is parallel to the rear side 7 of the radiator 2, that is to say so as to be behind one another perpendicular to the drawing plane of FIG. 1.

(14) According to one alternative, the radial fan 6a in the airflow direction 5 is disposed behind the radiator 2 and thus again on the rear side 7 of the latter, while the axial fan 6b in the airflow direction 5 is disposed in front of the radiator 2 and there in turn disposed in a plane which is parallel to the front side 8 of said radiator 2. The radial fan 6a and the axial fan 6b are in each case driven by an electric motor 9 and 10, thus driven by electric motors.

(15) A control device 11 sets the operation of the radial fan 6a and axial fan 6b. This means that the control installation 11 by way of corresponding control signals SR, SA sets in operation the radial fan 6a or the axial fan 6b, or the radial fan 6a as well as the axial fan 6b. This takes place as a function of the travel situation, the respective operating range, the operating load (for example in uphill travel and/or when driving with a trailer) and as a function of the speed of the vehicle. At a high or maximum vehicle speed (rapid travel) and/or at a particularly high temperature load (high-temperature requirement), the radial fan 6a as well as the axial fan 6b are thus suitably actuated for operation. To this end, the respective electric motor 9, 10 of said radial fan 6a and said axial fan 6b are correspondingly energized.

(16) At a comparatively low vehicle speed, only the axial fan 6b can be operated, for example. During slow travel and when the vehicle is stationary, the operation of only the radial fan 6a may be suitable because the latter operates in an efficient and very silent manner.

(17) In the case of a hybrid vehicle with a further propulsion machine in the form of the electric motor 12 in addition to the internal combustion engine 4, the operation of only the radial fan 6a may be required during a charging procedure of a battery 13 which then supplies the electric current required for operating the electric motor 12.

(18) As an example, the operating mode of the fan assembly 6 is of such a type that only the axial fan 6b, or the latter and the radial fan 6a, are operated during the travel of the vehicle, while only the radial fan 6a is operated during a stoppage of the vehicle and/or a charging operation of the battery 13 for supplying the electric motor 12.

(19) The radial fan 6a suctions the cooling air L by way of the radiator 2, deflects said cooling air by 90°, and radially expels (exhausts) the deflected cooling air L. This is visualized by the flow arrows 14. The axial fan 6b axially suctions the cooling air L and also axially expels (exhausts) said cooling air L. This is visualized by the flow arrows 15, 16.

(20) As an example, in the embodiment having the radial fan 6a and the axial fan 6b disposed beside one another on the rear side 7 of the radiator 2, said radial fan 6a and said axial fan 6b are suitably disposed on a common fan frame 17. A suitable dual fan module having a radial fan 6a and an axial fan 6b can be provided in this way.

(21) In the embodiment having the axial fan 6b and the radial fan 6a disposed behind one another in the airflow direction 5, a common radiator frame can likewise be provided. Said common radiator frame in this instance is constructed in such a manner that, in the case of an assembled radiator 2, the axial fan 6b is positioned on the front side 8 of said radiator 2, and the radial fan 6a is positioned on the rear side 7 of said radiator 2.

(22) FIG. 2 shows the fan assembly 6 having a radial fan 6a and an axial fan 6b which are disposed beside one another in the common fan frame 17 so as to be in a plane parallel to the rear side 7 of the radiator 2. The mutually parallel rotation axes of the radial fan 6a and of the axial fan 6b are identified by the reference signs 18 and 19, respectively. The electric motor 10 of the axial fan 6b can be seen when viewed toward a motor electronics system 20. The electric motor 10 is disposed in a central, stationary hub 21 having substantially radial support stays 22 which in the region of an opening periphery 23 of a throughflow opening 24 are connected to the fan frame 17. The axial fan 6b in the region of the hub 21 or of the motor electronics system 20, respectively, can be provided with a cover.

(23) A wheel hub 25 of an axial impeller 26 of the axial fan 6b is aligned with the central, stationary hub 21. Proceeding from the external circumference of the wheel hub 25, a number of blades or vanes 27 which are disposed so as to be circumferentially distributed extend in a crescent-shaped and substantially radial manner. By virtue of the electric motor 10 being disposed in the region of the hubs 21 and 25, the axial installation size or installation depth of the axial fan 6b in the direction of the rotation axis 19 thereof is particularly minor.

(24) The radial fan 6b, which on the rear side is or may be provided with a housing cover (not shown), has a motor electronics system 28 (on the rear side). The electric motor 9 and the motor electronics system 28 thereof are in turn disposed in a central, stationary hub 29 having substantially radial support stays 30 which are connected to the fan frame 17. An axial intake opening 31 of the radial fan 6a that is directed toward the rear side 7 of the radiator 2 can be seen in FIG. 2. The electric motor 9 drives a radial impeller 32 having a number of blades or vanes 33 of the radial fan 6a. In order to achieve an ideally minor axial installation size, the electric motor 9 is at least partially, such as at the side proximal to the rotor, that is to say when said electric motor 9 is embodied as external-rotor motor by way of the rotor of said electric motor 9, situated in a wheel hub of the radial impeller 32. The blades or vanes 33 of the radial impeller 32 extend axially in the direction of the rotation axis 18 and circumferentially form an outflow opening 34. The cooling air L which has been axially suctioned, upon being deflected by 90°, flows out radially by way of the outflow opening 32 of the radial fan 6a.

(25) FIGS. 3 and 4 show the disposal of the radial fan 6a and of the axial fan 6b so as to be axially behind one another, wherein the radial fan 6a is disposed in a plane which is parallel to the rear side 7, and the axial fan 6b is disposed in a plane which is parallel to the front side 8 of the radiator 2. In the exemplary embodiment, the rotation axes 18, 19 of the radial fan 6a and of the axial fan 6b, respectively, run so as to be coaxial (in the same axis). The construction of the radial fan 6a and of the axial fan 6b in the embodiment according to FIGS. 3 and 4 is otherwise identical to that of the embodiment according to FIG. 2.

(26) The motor electronics system 20, 28 of the electric motors 9, 10 of the radial fan 6a or of the axial fan 6b, respectively, may contain functional building blocks of the control device 11. The control device 11 can also be completely integrated in the motor electronics system 20, 28 of the axial fan 6b and/or the radial fan 6a, respectively. The control signals SR and SA can thus be generated by the respective motor electronics system 20, 28. The electric motors 9, 10 of the two fans 6a, 6b in this instance are connected to the on-board vehicle electric system only by way of supply lines.

(27) The claimed invention is not restricted to the exemplary embodiments described above. Rather, it is also possible for other variants of the invention to be derived therefrom in the scope of the disclosed claims by a person skilled in the art without departing from the subject matter of the claimed invention. As an example, it is also the case that all individual features in the scope of the disclosed claims described in conjunction with the various exemplary embodiments may also be combined with one another in some other way without departing from the subject matter of the claimed invention.

(28) The following is a list of reference numbers shown in the Figures. However, it should be understood that the use of these terms is for illustrative purposes only with respect to one embodiment. And, use of reference numbers correlating a certain term that is both illustrated in the Figures and present in the claims is not intended to limit the claims to only cover the illustrated embodiment.

LIST OF REFERENCE SIGNS

(29) 1 Radiator system/cooling fan system

(30) 2 Radiator/heat exchanger

(31) 3 Cooling pipe/cooling hose

(32) 4 Internal combustion engine

(33) 5 Airstream direction/airflow direction

(34) 6 Fan assembly

(35) 6a Radial fan

(36) 6b Axial fan

(37) 7 Rear side

(38) 8 Front side

(39) 9,10 Electric motor

(40) 11 Control device

(41) 12 Electric motor/Drive

(42) 13 Battery

(43) 14 Radial flow arrow

(44) 16 Axial flow arrow

(45) 17 Fan frame

(46) 18,19 Rotation axis

(47) 20 Motor electronics system

(48) 21 Hub

(49) 22 Stay

(50) 23 Opening periphery

(51) 24 Throughflow opening

(52) 25 Wheel hub

(53) 26 Axial impeller

(54) 27 Blade/vane

(55) 28 Motor electronics system

(56) 29 Hub

(57) 30 Support stay

(58) 31 Intake opening

(59) 32 Radial fan wheel

(60) 33 Blade/Vane

(61) 34 Outflow opening

(62) K Coolant

(63) L Cooling air

(64) S.sub.A,R Control signal

(65) While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.