Charge air cooler fan control

Abstract

The present disclosure relates to charge air cooler fan control. Specifically, it relates to a work vehicle comprising an engine, a compressor configured to compress air destined for the engine, a charge air cooler, a sensor, and a control unit. The charge air cooler comprises a fan or is coupled to a fan. The fan can rotate in a first direction to remove heat from the air, and in a second direction opposite to the first direction to blow away debris. A control unit is electrically coupled to the engine and the fan. The control unit predicts whether a temperature of the air exceeds a threshold value based on a signal received from the sensor. When the temperature of the air is below the threshold value, the fan can rotate in a second direction. When the temperature of the air is equal to or above the threshold value, the fan is prohibited from rotating in the second direction.

Description

Technical Field

[0001] The present disclosure generally relates to charge air coolers for use on work vehicles. Background Art

[0002] To increase an engine's combustion efficiency and power output, a compressor is used to compress (engine intake) air into the engine's combustion chambers. During the air compression process in the compressor, the air's temperature increases. A charge air cooler (CAC) is coupled to the compressor and the engine; it cools the air after it passes through the compressor but before it enters the engine. This cooled air thus has a higher density, further improving combustion within the engine. Summary of the Invention

[0003] According to an aspect of the present disclosure, a work vehicle is provided, which includes: an engine, a compressor configured to compress air going to the engine, a charge air cooler connected to the engine and the compressor, a sensor, and a control unit. The charge air cooler includes a fan or is connected to a fan. The fan is used to rotate in a first direction to remove heat from the air passing through the charge air cooler, and the fan rotates in a second direction opposite to the first direction to blow away debris accumulated on or near the charge air cooler. The control unit is electrically connected to the engine and the fan. The control unit is used to predict whether the temperature of the air exceeds a threshold based on a signal received from the sensor, and when the temperature of the air is lower than the threshold, allow the fan to rotate in the second direction, and when the temperature of the air is equal to or higher than the threshold, prohibit the fan from rotating in the second direction.

[0004] According to another aspect of the present disclosure, a method for controlling a fan is provided, wherein the fan is connected to a charge air cooler of a work vehicle or is included in the charge air cooler of the work vehicle, the charge air cooler being connected to an engine and a compressor, which compresses air going to the engine, the method comprising the following steps: cooling the charge air cooler by rotating the fan in a first direction; detecting a temperature near the charge air cooler by a sensor; determining, by a control unit, whether the temperature near the charge air cooler exceeds a threshold value based on a signal representing the temperature from the sensor; allowing the fan to rotate in a second direction opposite to the first direction when the temperature near the charge air cooler is lower than the threshold value so as to blow away debris accumulated on or near the charge air cooler; and prohibiting the fan from rotating in the second direction when the temperature near the charge air cooler is equal to or higher than the threshold value.

[0005] According to another aspect of the present disclosure, a method for controlling a fan is provided, wherein the fan is connected to a charge air cooler of a work vehicle or is included in the charge air cooler of the work vehicle, the charge air cooler being connected to an engine and a compressor, the compressor compressing air going to the engine, the method comprising the following steps: cooling the charge air cooler by rotating the fan in a first direction; detecting at least one of the characteristics of a transmission component and the activation of a utility by a sensor; predicting, by a control unit, whether the temperature of the air exceeds a threshold value based on a signal from the sensor; allowing the fan to rotate in a second direction opposite to the first direction when the temperature of the air is below the threshold value so as to blow away debris accumulated on or near the charge air cooler; and prohibiting the fan from rotating in the second direction when the temperature of the air is equal to or higher than the threshold value.

[0006] Other features and aspects will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The detailed description of the drawings refers to the accompanying figures, in which:

[0008] Figure 1 This is a block diagram illustrating a first embodiment of a cooling system for a work vehicle.

[0009] Figure 2A A fan of a charge air cooler is illustrated rotating in a first direction.

[0010] Figure 2B The example illustrates a fan of a charge air cooler rotating in a second direction opposite to the first direction when the fan's ambient temperature is low.

[0011] Figure 2C The charge air cooler fan is illustrated as rotating in a second direction when the fan's ambient temperature is high, and such reversal is prohibited to avoid damaging the fan.

[0012] Figure 3 is a block diagram illustrating a second embodiment of a cooling system for a work vehicle, wherein control units are connected via a controller area network.

[0013] Figure 4A A sensor that detects engagement of the power take-off shaft is illustrated.

[0014] Figure 4B A sensor that detects activation of an auger is illustrated.

[0015] Figure 4C A sensor that detects the engagement of a felling head is illustrated.

[0016] Figure 5A method of controlling a fan coupled to or included with a charge air cooler of a work vehicle is illustrated. DETAILED DESCRIPTION

[0017] The following description relates to the implementation of a cooling fan in a cooling application with a charge air cooler. Charge air coolers (like other heat exchangers on construction and agricultural equipment) typically require the fan to be reversed to blow debris out of the heat exchanger and inlet screen. However, this reversing operation can pose a risk to the durability of the fan. First, if the fan is an electric fan, it may have a lower ambient temperature limit than other conventional fan drives. In other words, the fan may be susceptible to high temperatures. Second, the temperature of the charge air cooler is typically higher than the temperature of other heat exchangers. Third, the temperature of the charge air cooler can increase and decrease rapidly compared to other heat exchangers. If the fan is commanded to reverse during high engine load, the fan can pull relatively hot air through the charge air cooler and back through the fan, and this hotter air can exceed the fan's temperature limit by a significant amount. Several exemplary embodiments of a cooling system for a work vehicle are disclosed below.

[0018] Reference Figure 1 , this embodiment illustrates a control unit directly connected to the engine and at least one sensor without a controller area network. The cooling system of the work vehicle includes: an engine 10; a control unit 20, which is electrically connected to the engine 10 and the compressor 30 (turbocharger); a charge air cooler 40, which is connected to the engine 10 and the compressor 30; and a sensor 70. The engine 10 in this embodiment is an internal combustion engine that converts the potential energy in the fuel into kinetic energy for mechanical operation. For the sake of simplicity, Figure 1 Other drivetrain components, such as transmissions, are omitted. Engine 10 may be applied to hybrid or fuel-powered vehicles. To enhance the combustion efficiency and power output of engine 10, compressor 30 is configured to compress air to the engine.

[0019] During the compression process, the air is compressed and the temperature of the air rises. A charge air cooler 40 is used to cool the air before it enters the engine 10. A fan 42 is coupled to the charge air cooler 40 or included in the charge air cooler 40 to improve heat dissipation. The charge air cooler 40 is coupled to the compressor 30 via a first connection 44 and to the engine 10 via a second connection 46. Figure 1 and Figure 2A, fan 42 is configured to rotate in a first direction to remove heat from the air passing through charge air cooler 40. At this point, the air passing through second connection 46 is cooler and denser than the air passing through first connection 44. The cooled, higher density air from second connection 46 then enters engine 10 for combustion.

[0020] It should be noted that the fan 42 (e.g. Figure 2B The fan 42 is further configured to rotate in a second direction opposite to the first direction to blow away debris that has accumulated on or near the charge air cooler and / or inlet screen or grille (not shown). When the work vehicle is operating under conditions that allow reversal (such as low engine load or low charge air cooler 40 temperature), the fan 42 rotates in the second direction. However, in contrast, when the work vehicle is operating under conditions that prohibit reversal (such as high engine load or high charge air cooler 40 temperature), if the fan 42 rotates in the second direction, the hot air pulled back from the charge air cooler 40 to the fan 42 may damage the fan 42. Therefore, the fan 42 is prohibited from rotating in the second direction (such as Figure 2C The details of whether to allow the fan 42 to rotate in the second direction will be described later.

[0021] A control unit 20 (or multiple controllers) may be provided to control the rotation of fan 42. In a first embodiment, control unit 20 is an engine control unit, which generally controls various aspects of the operation of engine 10. In the first embodiment, control unit 20 may be defined as a computing device associated with a microprocessor (not shown) and memory 22. Control unit 20 may receive commands from operator control components to perform various tasks associated with engine 10. For example, control unit 20 may determine the amount of fuel injected for combustion by receiving a signal from a throttle position sensor (not shown). Control unit 20 is also configured to receive signals from sensors 70. In the first embodiment, where control unit 20 is an engine control unit, sensors 70 detect characteristics of engine 10. Sensors 70 may include one or more sensors, such as a temperature sensor 72 for detecting the temperature of engine 10, an engine load sensor 74 for detecting the load applied to engine 10, and an engine torque sensor 76 for detecting the torque of engine 10. Control unit 20 may also include a compressor outlet module 24, which includes one or more processors. The compressor outlet module 24 of the control unit 20 is further configured to predict whether one or more conditions are satisfied based on signals from the sensor 70. The control unit 20 may then send one or more signals to control the charge air cooler 40 and the fan 42. Furthermore, the control unit 20 may include a clock (unit) 26 to count time. When the time under certain conditions exceeds a preset time frame, the control unit 20 may check whether the one or more conditions are satisfied and perform an action, such as rotating the fan 42 in the second direction or prohibiting the fan 42 from rotating in the second direction.

[0022] As mentioned earlier, control unit 20 is configured to predict whether the temperature of the air (in second connection 46, at the compressor outlet) exceeds a threshold based on the signal received from sensor 70. One or more data may be pre-stored in memory 22, and control unit 20 may use this data to predict the temperature of the air (the temperature of the air in second connection 46). For example, if sensor 70 is a temperature sensor 72 that measures the temperature of engine 10, control unit 20 may compare the temperature measured by temperature sensor 72 with the temperature data pre-stored in memory 22 to predict whether the temperature of the air in second connection 46 exceeds a threshold (e.g., the ambient temperature limit of fan 42). When the temperature measured by temperature sensor 72 is lower than the pre-stored temperature, this indicates that the air temperature is lower than the threshold, thereby allowing fan 42 to rotate in the second direction. When the temperature measured by temperature sensor 72 is equal to or higher than the pre-stored temperature, this indicates that the air temperature is equal to or higher than the threshold, thereby prohibiting fan 42 from rotating in the second direction to protect fan 42 or other components.

[0023] For another example, if sensor 70 is an engine load sensor 74 that measures the load of engine 10, control unit 20 can compare the load of engine 10 measured by engine load sensor 74 with pre-stored engine load data in memory 22 to predict whether the temperature of the air in second connection 46 exceeds a threshold value (e.g., an ambient temperature limit for fan 42). When the load of engine 10 measured by engine load sensor 74 is lower than the pre-stored engine load value, this indicates that the air temperature is lower than the threshold value, thereby allowing fan 42 to rotate in the second direction. When the load of engine 10 measured by engine load sensor 74 is equal to or higher than the pre-stored engine load value, this indicates that the air temperature is equal to or higher than the threshold value, thereby prohibiting fan 42 from rotating in the second direction to protect fan 42 or other components. Alternatively, control unit 20 can calculate the engine percent load by comparing the load of engine 10 measured by engine load sensor 74 with pre-stored engine load data. The value of the engine percent load can be used to predict whether the threshold value has been exceeded.

[0024] For another example, if sensor 70 is an engine torque sensor 76 that measures the torque of engine 10, control unit 20 can compare the torque of engine 10 measured by engine torque sensor 76 with pre-stored engine torque data in memory 22 to predict whether the temperature of the air in second connection member 46 exceeds a threshold value (e.g., the ambient temperature limit of fan 42). When the torque of engine 10 measured by engine torque sensor 76 is lower than the pre-stored engine torque, this indicates that the air temperature is lower than the threshold value, thereby allowing fan 42 to rotate in the second direction. When the torque of engine 10 measured by engine torque sensor 76 is equal to or higher than the pre-stored engine torque, this indicates that the air temperature is equal to or higher than the threshold value, thereby prohibiting fan 42 from rotating in the second direction to protect fan 42 or other components. Alternatively, control unit 20 can calculate engine percentage torque by comparing the torque of engine 10 measured by engine torque sensor 76 with pre-stored engine torque data. The value of engine percentage torque can be used to predict whether the threshold value has been exceeded.

[0025] It should be noted that engine 10 characteristics such as engine 10 temperature, load, and torque are merely examples; measurements of other types of characteristics may be used to predict whether the temperature of the air in the second connection 46 (compressor outlet) exceeds a threshold value. In one implementation, the control unit 20 may calculate the temperature of the air in the second connection 46 based on a comparison between the measurement of the characteristic and pre-stored data. In another implementation, the control unit 20 may not need to directly calculate the temperature of the air; a comparison between the measurement of the characteristic and pre-stored data may be sufficient to predict whether the temperature of the air in the second connection 46 (compressor outlet) exceeds a threshold value.

[0026] As previously mentioned, the sensor 70 can detect characteristics of the engine 10. In another implementation, the sensor 70 is Figure 1 Temperature sensor 78 is shown. Temperature sensor 78 is positioned on or near the charge air cooler and is configured to measure the ambient temperature surrounding charge air cooler 40. Control unit 20 can determine whether the ambient temperature surrounding charge air cooler 40 exceeds a threshold based on a signal from sensor 78 indicating the ambient temperature surrounding charge air cooler 40. When the ambient temperature surrounding charge air cooler 40 is below the threshold, control unit 20 allows fan 42 to rotate in a second direction, opposite to the first direction, to blow away debris accumulated on or near the charge air cooler. When the ambient temperature surrounding charge air cooler 40 is equal to or above the threshold, control unit 20 can prohibit fan 42 from rotating in the second direction.

[0027] Reference Figure 3 In the second embodiment, the control unit can communicate with various systems of the work vehicle via a controller area network (CAN) bus. In one implementation, the control unit can be the (engine) control unit 20, which receives a signal representing at least one characteristic of the engine 10 from the sensor 70 (72, 74, 76, 78) to predict whether the temperature of the air exceeds a threshold value, as described above. Alternatively, the control unit can be an (electronic) control unit 99, which is coupled to the sensor 70 (72, 74, 76, 78) and controls the fan 42 to rotate in the second direction, similar to the description of the control unit 20 in the first embodiment.

[0028] In another implementation, the sensor 70 may be used to detect activation of a utility tool, and the control unit may be the (engine) control unit 20 or the (electronic) control unit 99 coupled to the fan 42 to control the rotation in the second direction based on a signal received from the sensor 70 via the controller area network. Activation of the utility tool may indicate that the load on the engine 10 will increase and the temperature of the air will increase, thereby prohibiting the fan 42 from rotating in the second direction. The work vehicle may be a tractor, a crop harvester, a fellerbuncher, etc. Figure 3 and Figure 4A As shown, the work vehicle is a tractor. Activation of the utility includes engagement of a power take-off shaft 52. Engagement of an implement such as a sowing or tilling device with the power take-off shaft 52 is detected by sensors 70, 82 which may be proximity sensors. Figure 3 and Figure 4B As shown, the work vehicle is a crop harvester, and activation of the utility tool includes activation of the auger 54, which is detected by sensors 70, 84. Figure 3 and Figure 4C As shown, the work vehicle is a feller buncher and activation of the utility tool includes engagement of the felling head 56 , which is detected by the sensors 70 , 86 .

[0029] In another implementation, similar to how at least one of the characteristics of engine 10 is detected / measured by a sensor, at least one characteristic of transmission 12 can be detected / measured by a sensor to control fan 42. The control unit can be (transmission) control unit 60, which receives a signal from sensor 70 representing at least one characteristic of transmission 12, such as transmission load, transmission torque, or temperature. The signal received by control unit 60 can be compared with pre-stored data stored in a memory (not shown) of control unit 60 to predict whether the temperature of the air exceeds a threshold. It should be noted that control unit 60 can directly control the fan or send a signal representing the comparison result to another control unit (such as control unit 20 or control unit 99) to control the rotation direction of fan 42.

[0030] like Figure 5 As shown, the present disclosure also includes a method for controlling a fan that is coupled to or included in a charge air cooler of a work vehicle. The charge air cooler is coupled to an engine and a compressor. The compressor compresses air destined for the engine. The method includes the following steps:

[0031] S1 : Cooling the charge air cooler by rotating the fan in a first direction.

[0032] S2: Detecting, via a sensor, at least one of characteristics of a driveline component and activation of a utility tool. The driveline component may be an engine, a transmission, or the like, and the characteristics may include temperature, torque, and load of the driveline component. The utility tool may be an auger, a power take-off shaft, or a felling head, or the like.

[0033] S3: Predicting, by a control unit, whether the temperature of the air exceeds a threshold based on the signal from the sensor. As mentioned above, the control unit may be an engine control unit, a transmission control unit, an electronic control unit, or a combination thereof.

[0034] S4: When the temperature of the air is lower than the threshold, the fan is allowed to rotate in a second direction opposite to the first direction to blow away debris accumulated on or near the charge air cooler.

[0035] S5: When the temperature of the air is equal to or higher than a threshold, the fan is prohibited from rotating in the second direction. In one implementation, the control unit of the work vehicle prohibits the fan from rotating in the second direction until the temperature of the air has dropped below the threshold (ambient temperature limit) for a certain duration of time, where the time is counted by a clock connected to or included in the control unit. In another implementation, the control unit of the work vehicle prohibits the fan from rotating in the second direction until the temperature of the air has dropped below the threshold (ambient temperature limit) for a certain number of temperatures (the temperature number is predicted by the control unit).

[0036] It should be noted that predicting whether the temperature of the air at the compressor outlet exceeds a threshold value is merely an example. Whether the temperature of another component (related to the temperature of the air), such as a charge air cooler, exceeds a threshold value can also be predicted using a different algorithm and data pre-stored in the control unit to determine whether to prohibit the fan from rotating in the second direction.

[0037] In another embodiment, a method of controlling a fan coupled to or included in a charge air cooler of a work vehicle, the charge air cooler coupled to an engine and a compressor that compresses air to the engine, is provided, the method comprising the steps of:

[0038] M1: Cooling the charge air cooler by rotating the fan in a first direction.

[0039] M2: Detects the temperature near the charge air cooler via a sensor.

[0040] M3: Determining, by the control unit, whether the temperature in the vicinity of the charge air cooler exceeds a threshold value based on a signal from a sensor representing this temperature.

[0041] M4: When the temperature near the charge air cooler is lower than a threshold, allow the fan to rotate in a second direction opposite to the first direction to blow away debris accumulated on or near the charge air cooler.

[0042] M5: When the temperature near the charge air cooler is equal to or higher than a threshold, prohibiting the fan from rotating in the second direction.

[0043] Without in any way limiting the scope, interpretation, or application of the presented claims, a technical effect of one or more of the example embodiments disclosed herein is to prevent the fan from being damaged by heat from the compressor.

[0044] Although example embodiments of the present disclosure are described above, these descriptions should not be considered in a limiting sense. Rather, other changes and modifications may be made without departing from the scope and spirit of the present disclosure as defined in the following claims.

Claims

1. A work vehicle, comprising: engine; a compressor configured to compress air to the engine; a charge air cooler coupled to the engine and the compressor, the charge air cooler including or coupled to a fan, the fan configured to rotate in a first direction to remove heat from air passing through the charge air cooler, and the fan configured to rotate in a second direction opposite the first direction to blow away debris accumulated on or near the charge air cooler; a sensor configured to detect activation of the utility to send a signal; as well as a control unit electrically coupled to the engine and the fan, the control unit being configured to predict whether the temperature of the air exceeds a threshold value based on the signal received from the sensor, and to allow the fan to rotate in the second direction when the temperature of the air is lower than the threshold value, and to prohibit the fan from rotating in the second direction when the temperature of the air is equal to or higher than the threshold value.

2. The work vehicle according to claim 1, wherein: The control unit includes at least one of an electronic control unit, an engine control unit, and a transmission control unit.

3. The work vehicle according to claim 1, wherein: When the work vehicle is a crop harvester, activation of the utility tool includes activation of an auger.

4. The work vehicle according to claim 1, wherein: When the work vehicle is a feller buncher, activation of the utility tool includes engagement of a felling head.

5. The work vehicle according to claim 1, wherein: When the work vehicle is a tractor, activation of the utility implement includes engagement of a power take-off shaft.

6. The work vehicle according to claim 1, wherein: The control unit is coupled to the sensor via a controller area network.

7. A method of controlling a fan coupled to or contained within a charge air cooler of a work vehicle, the charge air cooler coupled to an engine and a compressor that compresses air for the engine, the method comprising the steps of: cooling the charge air cooler by rotating the fan in a first direction; Detecting activation of a utility through a sensor; predicting, by a control unit, whether the temperature of the air exceeds a threshold based on a signal from the sensor; allowing the fan to rotate in a second direction opposite to the first direction to blow away debris accumulated on or near the charge air cooler when the temperature of the air is below the threshold; as well as When the temperature of the air is equal to or higher than the threshold, the fan is prohibited from rotating in the second direction.

8. The method according to claim 7, wherein: When the work vehicle is a crop harvester, activation of the utility tool includes activation of an auger.

9. The method according to claim 7, wherein: When the work vehicle is a feller buncher, activation of the utility tool includes engagement of a felling head.

10. The method according to claim 7, wherein: When the work vehicle is a tractor, activation of the utility implement includes engagement of a power take-off shaft.

11. The method according to claim 7, wherein: Signals from the sensors are received by the control unit via a controller area network.

12. A method of controlling a fan coupled to or contained within a charge air cooler of a work vehicle, the charge air cooler coupled to an engine and a compressor that compresses air for the engine, the method comprising the steps of: cooling the charge air cooler by rotating the fan in a first direction; detecting, by a sensor, at least one of a characteristic of a powertrain component and activation of a utility; predicting, by a control unit, whether the temperature of the air exceeds a threshold based on a signal from the sensor; allowing the fan to rotate in a second direction opposite to the first direction to blow away debris accumulated on or near the charge air cooler when the temperature of the air is below the threshold; as well as When the temperature of the air is equal to or higher than the threshold, prohibiting the fan from rotating in the second direction; When the time during which the temperature of the air is lower than the threshold is shorter than a preset time frame, the step of prohibiting the fan from rotating in the second direction is performed.

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