Method for remediating loss of coolant flow or charge coolant in thermal management of plant

Abstract

In an embodiment, there is provided a method for controlling thermal management of a device via a thermal system, the method comprising: obtaining, via a flow sensor, flow data regarding a flow of coolant of the thermal system; determining, via the processor, one or more characteristics of the flow of coolant of the thermal system based on the flow data; and adjusting, via instructions provided by the processor, control of the thermal system for thermal management of the apparatus based on the one or more characteristics of the flow of coolant of the thermal system.

Description

[0001] TECHNICAL FIELD

[0002] The technical field relates generally to thermal management of equipment, such as computers in vehicles, and to remediating loss of coolant flow or aerating coolant for thermal management. Background Art

[0002] Thermal management may be used for equipment, including for safety-critical equipment such as computers for vehicles. However, existing technologies may not always provide optimal thermal management, including with respect to losses in coolant flow, aerated coolant, or both.

[0003] Accordingly, it is desirable to provide improved methods and systems for thermal management of devices, including computers for vehicles, and including remediation for loss of coolant flow, aerated coolant, or both for thermal management of devices. In addition, other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. Summary of the invention

[0004] According to an exemplary embodiment, a method for controlling thermal management of a device via a thermal system is provided, the method comprising: obtaining flow data about a flow of a coolant of the thermal system via a flow sensor; determining, via a processor, one or more characteristics of the flow of the coolant of the thermal system based on the flow data; and adjusting control of the thermal system for thermal management of the device based on the one or more characteristics of the flow of the coolant of the thermal system via instructions provided by the processor.

[0005] Also in an exemplary embodiment, the step of determining one or more characteristics includes determining, via a processor, a loss of fluid flow of a coolant of the thermal system based on the flow data; and the step of adjusting control includes adjusting, via instructions provided by the processor, control of the thermal system for thermal management of the device in a manner to remedy the loss of fluid flow.

[0006] Also in the exemplary embodiment, the step of determining one or more characteristics includes determining, via a processor, a charge of a coolant of the thermal system based on the flow data; and the step of adjusting control includes adjusting control of the thermal system, via instructions provided by the processor, in a manner to remediate the charge of the coolant for thermal management of the device.

[0007] Also in the exemplary embodiment, the step of adjusting control includes adjusting speed of one or more pumps of the thermal system for thermal management of the device based on one or more characteristics of flow of a coolant of the thermal system via instructions provided by the processor.

[0008] Also in the exemplary embodiment, the step of adjusting control includes adjusting a power of a cooler coupled to the thermal system of the device based on one or more characteristics of a flow of a coolant of the thermal system via instructions provided by the processor.

[0009] Furthermore, in the exemplary embodiment, the step of adjusting control includes implementing one or more redundant cooling circuits of the thermal system for thermal management of the device based on one or more characteristics of a flow of a coolant of the thermal system via instructions provided by the processor.

[0010] Also in the exemplary embodiment, the step of adjusting control includes adjusting, via instructions provided by the processor, one or more upstream power limits of the thermal system for thermal management of the device based on one or more characteristics of a flow of a coolant of the thermal system.

[0011] Also in the exemplary embodiment, the step of adjusting control includes selectively implementing the emergency cooling system for thermal management of the equipment based on one or more characteristics of a flow of a coolant of the thermal system via instructions provided by the processor.

[0012] Also in the exemplary embodiment, the step of adjusting control includes selectively alternating between separate and combined flows for the plurality of circuits of flow of coolant for the thermal system based on one or more characteristics of the flow of coolant for the thermal system via instructions provided by the processor.

[0013] In another exemplary embodiment, a control system for controlling thermal management of a device via a thermal system is provided. The control system includes a flow sensor and a processor. The flow sensor is configured to obtain flow data regarding a flow of a coolant of the thermal system. The processor is coupled to the flow sensor and is configured to at least facilitate: determining one or more characteristics of the flow of the coolant of the thermal system based on the flow data; and adjusting control of the thermal system for thermal management of the device based on the one or more characteristics of the flow of the coolant of the thermal system via instructions provided by the processor.

[0014] Additionally, in an exemplary embodiment, the processor is configured to at least facilitate: determining a loss of fluid flow of a coolant of the thermal system based on the flow data; and adjusting control of the thermal system for thermal management of the device in a manner to remedy the loss of fluid flow via instructions provided by the processor.

[0015] Additionally, in an exemplary embodiment, the processor is configured to at least facilitate: determining a charge of a coolant of the thermal system based on the flow data; and adjusting control of the thermal system in a manner to remediate the charge of the coolant for thermal management of the device via instructions provided by the processor.

[0016] Furthermore, in the exemplary embodiment, the processor is further configured to at least facilitate: adjusting speed of one or more pumps of the thermal system for thermal management of the device based on one or more characteristics of flow of a coolant of the thermal system via instructions provided by the processor.

[0017] Furthermore, in the exemplary embodiment, the processor is further configured to at least facilitate: adjusting, via the instructions provided by the processor, a power of a cooler coupled to the thermal system of the device based on one or more characteristics of a flow of a coolant of the thermal system.

[0018] Furthermore, in the exemplary embodiment, the processor is further configured to at least facilitate: implementing, via instructions provided by the processor, one or more redundant cooling loops of the thermal system for thermal management of the device based on one or more characteristics of a flow of a coolant of the thermal system.

[0019] Furthermore, in the exemplary embodiment, the processor is further configured to at least facilitate: adjusting, via the instructions provided by the processor, one or more upstream power limits of the thermal system for thermal management of the device based on one or more characteristics of the flow of a coolant of the thermal system.

[0020] Furthermore, in the exemplary embodiment, the processor is further configured to at least facilitate: selectively implementing the emergency cooling system for thermal management of the device based on one or more characteristics of a flow of a coolant of the thermal system via instructions provided by the processor.

[0021] Furthermore, in the exemplary embodiment, the processor is further configured to at least facilitate: via instructions provided by the processor, selectively alternating between separate flows and combined flows for multiple circuits of flow of coolant for the thermal system based on one or more characteristics of the flow of coolant for the thermal system.

[0022] In another exemplary embodiment, a vehicle is provided, comprising a body; a drive system; a device; a thermal system; and a control sensor. The drive system is configured to propel the body. The device is configured to perform one or more safety-critical functions of the vehicle. The thermal system is coupled to the device and configured to provide thermal management for the device. The control system is coupled to the thermal system and configured to control thermal management of the device via the thermal system. The control system includes a flow sensor and a processor. The flow sensor is configured to obtain flow data regarding a flow of a coolant of the thermal system. The processor is coupled to the flow sensor and configured to at least facilitate: determining one or more characteristics of the flow of the coolant of the thermal system based on the flow data; and adjusting control of the thermal system for thermal management of the device based on one or more characteristics of the flow of the coolant of the thermal system via instructions provided by the processor.

[0023] In addition, in an exemplary embodiment, the processor is also configured to at least facilitate: determining a loss of fluid flow of a coolant of the thermal system based on the flow data; determining aeration of the coolant of the thermal system based on the flow data; and adjusting control of the thermal system for thermal management of the device in a manner to remedy the loss of fluid flow and aeration of the coolant via instructions provided by the processor. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present disclosure will be described below in conjunction with the following drawings, wherein like numerals designate like elements, and wherein:

[0025] Figure 1 is a functional block diagram of a vehicle including safety critical equipment requiring thermal cooling and also including a thermal system and an accompanying control system that performs the thermal cooling, according to an exemplary embodiment;

[0026] Figure 2 According to an exemplary embodiment Figure 1 The safety critical equipment is depicted together Figure 1 Functional block diagrams of the thermal and control systems; and

[0027] Figure 3 and Figure 4 is a flow chart of a process for controlling thermal cooling of a device according to an exemplary embodiment, and the process may be combined with Figure 1 and Figure 2 Thermal systems, control systems and safety-critical equipment and Figure 1 This is achieved by using vehicles and their components. DETAILED DESCRIPTION

[0028] The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or its application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

[0029] Figure 1 The figure shows a vehicle 100 according to an exemplary embodiment. As further described in more detail below, among other components, the vehicle 100 includes a device 102 that requires thermal cooling, and a thermal system 104 and an accompanying control system 106 for performing the thermal cooling. In various embodiments, the device 102 includes one or more computers and / or other safety-critical components. In various embodiments, the control system 106 controls the thermal cooling of the device 102 by the thermal system 104, including remediating the loss of coolant flow, aeration of coolant, or both in the thermal management of the device 102 by the thermal system 104.

[0030] like Figure 1As depicted, in various embodiments, thermal system 104 and control system 106 may be collectively referred to as thermal management system 107 , and for ease of reference, the combination of thermal management system 107 and device 102 itself may be referred to as safety critical system 101 .

[0031] According to an exemplary embodiment, the critical safety system 101 is Figure 2 Additional details are depicted in the drawings and are described in more detail further below in conjunction with these details.

[0032] Additionally, in various embodiments, thermal control of device 102 by thermal system 104 and control system 106 is combined with Figure 3 and Figure 4 and also in conjunction with Figure 3 and Figure 4 The steps of the thermal control process 300 are described in more detail further below.

[0033] like Figure 1 As depicted, according to an exemplary embodiment, a critical safety system 101 (including a device 102, a thermal system 104, and a control system 106) is depicted as part of a vehicle 100. In various embodiments, the vehicle 100 includes an automobile, such as any of a number of different types of automobiles, such as, for example, a sedan, a van, a truck, a sport utility vehicle (SUV), etc. In certain embodiments, the vehicle 100 may also include a motorcycle or other vehicle, such as an aircraft, a spacecraft, a boat, etc., and / or one or more other types of mobile platforms (e.g., a robot and / or another mobile platform). In yet other embodiments, the critical safety system 101 (including a device 102, a thermal system 104, and a control system 106) may alternatively be part of and / or coupled to any number of other types of platforms and / or other systems (mobile or non-mobile), such as buildings, infrastructure, and / or other platforms and / or other systems.

[0034] In the depicted embodiment, the vehicle 100 includes a chassis ( Figure 1 1 and 1 . The vehicle 100 is provided with a body 114 on the vehicle 100 (not depicted). The body 114 substantially surrounds the other components of the vehicle 100. The vehicle 100 also includes a plurality of wheels 116. The wheels 116 are each rotationally coupled to an axle 118 about a respective corner of the body 114 to facilitate movement of the vehicle 100. In one embodiment, the vehicle 100 includes four wheels 116, although this may vary in other embodiments (e.g., for trucks, motorcycles, and certain other vehicles).

[0035] The drive system 110 is mounted on the chassis and drives wheels 116, for example, via shafts 118. In certain embodiments, the drive system 110 includes a propulsion system having one or more engines and / or motors.

[0036] In various embodiments, the vehicle 100 includes various other systems 112. For example, in various embodiments, the other systems 112 include one or more braking systems, steering systems, rechargeable energy storage systems (RESS), lighting systems, climate control systems, infotainment systems, and / or various other systems. In some embodiments, one or more of the drive system 110 and / or other systems 112 may be controlled in whole or in part by the device 102 (e.g., via a vehicle onboard computer including key components corresponding to the device 102). In some embodiments, the drive system 110 and / or other systems 112 may also be controlled in whole or in part by the control system 106 and / or one or more other systems and / or devices.

[0037] refer to Figure 2 , a functional block diagram of a key safety system 101 of a vehicle 100 according to an exemplary embodiment. Specifically, Figure 2 Additional details are provided regarding thermal management system 107 , including thermal system 104 and its control system 106 , which provides and controls thermal cooling of device 102 , according to an exemplary embodiment.

[0038] like Figure 2 As depicted, in various cases, a device 102 (e.g., a safety-critical component such as Figure 1 The computer of the vehicle 100 ) is cooled by a thermal system 104 , which in turn is controlled by a control system 106 .

[0039] In addition, Figure 2 As depicted, in various embodiments, thermal system 104 includes chiller 208 in addition to climate control system 210 and radiator fan module 212 , as well as various other components as described below.

[0040] In various embodiments, the cooler 208 includes an integrated cooler and cold plate. Figure 2 , the cooler 208 is connected to the device 102 and / or otherwise coupled against the device 102. In various embodiments, the cooler 208 is positioned adjacent to and / or integrated with the device 102 and provides cooling directly thereto. In certain embodiments, the cooler 208 includes a dual-channel cold plate designed to exchange thermal energy between the cooling path or loop and the device 102 and between the refrigerant and the coolant channels. In certain embodiments, the cold plate is part of the device 102 and is combined with the cooler 208 as a signature unit.

[0041] In various embodiments, the climate control system 210 includes an evaporator 214, a condenser 216, and a fan 218. In various embodiments, the climate control system 210 includes a Figure 1 A cabin heating, ventilation, and air conditioning (HVAC) system of a vehicle 100.

[0042] In various embodiments, the radiator fan module 212 includes a condenser 220, a low-temperature radiator 222, and a fan 224. ... Figure 1 A front condenser radiator fan module of a vehicle 100 is provided.

[0043] In addition, in various embodiments, the thermal system 104 also includes a plurality of electronically controlled expansion valves (EXVs) 226, as well as a compressor 228, a heat exchanger / cooler 230 (e.g., which is part of the cooler 208 and / or coupled to the cooler 208), a thermal management device 232, a plurality of cooling pumps 234 (i.e., a first pump 234(1) and a second pump 234(2)), a plurality of coolant buffer tanks 236, a plurality of control valves 238, and an emergency cooling system 240.

[0044] like Figure 2 As depicted, in various embodiments, a first coolant loop 241 provides coolant to the heat exchanger / cooler 230 (and thereby to the cooler 208) via a first pump 234(1) and an emergency cooling system 240, and as Figure 2 This is facilitated via the depicted thermal management device 232 , the coolant surge tank 236 , and the control valve 238 of the first coolant loop 241 .

[0045] In addition, Figure 2 As depicted in FIG. 1 , the second coolant loop 242 provides coolant to the low temperature radiator 222 via the second pump 234 ( 2 ), and as Figure 2 This is facilitated via the depicted thermal management device 232 , the coolant surge tank 236 , and the control valve 238 of the second coolant loop 242 .

[0046] In various embodiments, the control valve 238 is used to control the first and second coolant circuits 241 , 242 , so that the first and second coolant circuits 241 , 242 can be selectively combined with each other or separated from each other according to circumstances.

[0047] Additionally, in certain embodiments, the emergency cooling system 240 injects ammonium nitrite into the coolant flow (in addition to coolant already in the coolant flow) as appropriate for further reducing the temperature, such as in situations where the first and second coolant loops 241, 242 may not otherwise be as effective in reducing the temperature of the device 102 to a desired temperature value or range, and / or in situations where the coolant flow is stopped. In an exemplary embodiment, ammonium nitrite is injected into the coolant flow (in addition to coolant already in the coolant flow). In various other embodiments, one or more other and / or additional techniques may be used for the emergency cooling system 240.

[0048] In addition, Figure 2 As depicted, in various embodiments, the first branch 243 of the refrigerant circuit provides liquid refrigerant to the heat exchanger / cooler 230 (and thereby to the chiller 208) via the radiator fan module 212, and as Figure 2 The depicted regulation is via EXV 226 of the first branch 243 of the refrigerant circuit. In addition, in various embodiments, as Figure 2 As depicted, first branch 243 of the refrigerant circuit also provides liquid refrigerant to climate control system 210 (and as conditioned via EXV 226 ) for operation of climate control system 210 .

[0049] In addition, Figure 2 As depicted, in various embodiments, the second branch 244 of the refrigerant circuit is directed to Figure 2 The depicted heat exchanger / cooler 230 (and thus cooler 208) provides a gaseous refrigerant. Figure 2 As depicted, the second branch 244 of the refrigerant circuit also provides gaseous refrigerant to the radiator fan module 212 and the climate control system 210 via the compressor 228 (and as regulated by the control valve 238 coupled thereto) for operation of their respective condensers 220 , 216 .

[0050] In various embodiments, the first and second branches 243 , 244 of the refrigerant circuit provide redundancy for the first and second coolant circuits 241 , 242 .

[0051] like Figure 2 As depicted, in various embodiments, a control system 106 is coupled to the thermal system 104. In certain embodiments, such as Figure 2 As depicted, control system 106 (and / or components thereof) may also be part of a thermal system, and / or as part of a combined thermal management system 107 .

[0052] In addition, Figure 2As depicted, in various embodiments, the control system 106 includes a sensor array 250 and a controller 252 as described in greater detail below.

[0053] In various embodiments, the sensor array 250 includes various sensors that obtain sensor data for controlling thermal management of the device 102. In various embodiments, the sensor array includes a flow sensor 254 that measures fluid flow within the thermal system 104, including measurements of the level of the fluid flow and its aeration. In certain embodiments, one or more other sensors 256 (e.g., one or more temperature sensors, etc.) may also be utilized.

[0054] In various embodiments, the controller 252 is coupled to the sensor array 250 and receives sensor data therefrom. In various embodiments, the controller 252 is further coupled to the thermal system 104. Additionally, in certain embodiments, the controller 252 may also be coupled to one or more other systems and / or devices of the vehicle 100, such as the device 102, the drive system 110, and / or other systems 112, for example, to receive inputs therefrom and / or for controlling the same.

[0055] In various embodiments, controller 252 controls the operation of thermal system 104, including cooling for device 102. In various embodiments, controller 252 controls the operation of thermal system 104, including cooling for device 102. Figure 3 and 4 Described in and combined below Figure 3 and Figure 4 The steps of process 300 are described in further detail to provide these functions.

[0056] like Figure 1 As depicted, in various embodiments, controller 252 comprises a computer system (also referred to herein as computer system 252 ), and includes a processor 258 , a memory 260 , an interface 262 , a storage device 264 , and a computer bus 266 .

[0057] Processor 258 performs the computational and control functions of controller 252 and may include any type of processor or multiple processors, a single integrated circuit such as a microprocessor, or any suitable number of integrated circuit devices and / or circuit boards that work in cooperation to implement the functions of a processing unit. During operation, processor 258 executes one or more programs 268 contained in memory 260 and, as such, controls the general operation of controller 252 and the computer system of controller 252 (typically while performing the processes described herein (such as Figure 3 and Figure 4 and combined below Figure 3 and Figure 4 The process 300) is further described.

[0058] The memory 260 can be any type of suitable memory, including various types of non-transitory computer-readable storage media. In some examples, the memory 260 is located and / or co-located on the same computer chip as the processor 258. In the depicted embodiment, the memory 260 stores the above-described program 268 as well as stored values ​​270 (e.g., lookup tables, thresholds, and / or other values ​​related to the control of the thermal system 104).

[0059] The interface 262 allows, for example, communication from a system drive and / or another computer system to the computer system of the controller 252, and can be implemented using any suitable method and apparatus. In one embodiment, the interface 262 obtains various data from the sensor array 250 and other possible data sources. The interface 262 may include one or more network interfaces for communicating with other systems or components. The interface 262 may also include one or more network interfaces for communicating with a technician, and / or one or more storage interfaces connected to a storage device (such as a storage device 264).

[0060] Storage device 264 may be any suitable type of storage device, including various types of direct access storage and / or other memory devices. In an exemplary embodiment, storage device 264 includes a program product from which memory 260 may receive a program 268 that performs one or more embodiments of one or more processes of the present disclosure, such as Figure 3 and 4 and combined below Figure 3 and Figure 4 The steps of process 300 are further described. In another exemplary embodiment, the program product may be stored directly in and / or otherwise accessed by memory 260 and / or a disk (eg, disk 272), such as referenced below.

[0061] The bus 266 is used to send programs, data, status and other information or signals between the various components of the computer system of the controller 252. The bus 266 can be any suitable physical or logical means of connecting the computer system and components. This includes but is not limited to direct hard-wired connections, optical fiber, infrared and wireless bus technologies. During operation, the program 268 is stored in the memory 260 and executed by the processor 258.

[0062] It will be understood that while this exemplary embodiment is described in the context of a fully functional computer system, those skilled in the art will recognize that the mechanisms of the present disclosure can be distributed as a program product using one or more types of non-transitory computer-readable signal-bearing media that are used to store the program and its instructions and to perform its distribution, such as a non-transitory computer-readable medium that carries the program and contains computer instructions stored therein that are used to cause a computer processor (such as processor 258) to execute and run the program.

[0063] Figure 3 and Figure 4 is a flow chart of a process 300 for controlling thermal cooling of a device according to an exemplary embodiment. In various embodiments, according to exemplary embodiments, the process 300 may be combined with Figure 1 and Figure 2 The thermal system 104, the control system 106 and the device 102 and Figure 1 This is achieved by using a vehicle 100 and its components.

[0064] like Figure 3 As depicted, in various embodiments, process 300 begins at step 302. In one embodiment, process 300 begins when device 102 begins operation and / or requires thermal cooling.

[0065] In various embodiments, data is obtained (step 304). In various embodiments, the data is obtained from Figure 2 In various embodiments, the sensor array 250 may include flow rate data within the thermal system 104 obtained via one or more flow sensors 254. Figure 2 Flow rate data of one or more of the first and second coolant circuits 241, 242 and / or one or more of the refrigerant circuits 243, 244 of the thermal system 104 is obtained. In some embodiments, flow rate data about the flow of coolant in both the first and second coolant circuits 241, 242 and about the flow of refrigerant in both the refrigerant circuits 243, 244 is obtained. In addition, in some embodiments, other data may be obtained, such as Figure 1 100 means of transportation Figure 1 and Figure 2 equipment and / or Figure 2 The temperature and / or other parameters associated with the thermal system 104 and / or its components.

[0066] In an exemplary embodiment, a determination is made as to whether a coolant loss is detected (step 306). Specifically, in various embodiments, a processor (such as Figure 2The processor 258 of the embodiment of the present invention determines whether a loss of coolant is detected in the first coolant loop 241, the second coolant loop 242, or both based on the data from the flow sensor 254 in step 304. In addition, in some embodiments, a loss of coolant is detected when the amount of coolant and / or its flow rate in one or both of the first or second coolant loops 241, 242 decreases below a predetermined threshold.

[0067] In various embodiments, if it is determined in step 306 that a coolant loss is detected, a determination is made regarding an expected flow rate (step 308). In some embodiments, this determination is made based on a typical or expected flow rate, and / or based on one or more other parameters (such as the temperature of the device 102 and / or the temperature of one or both of the first or second coolant loops 241, 242, etc.). Further, in some embodiments, this determination is made by a processor (such as Figure 2 ) is made based on the data from step 304 of the flow sensor 254.

[0068] Furthermore, in various embodiments, the flow rate is set equal to the desired flow rate (step 310). Specifically, in various embodiments, during step 310, the current flow rate of the coolant for the first and / or second coolant circuits 241, 242 is determined via a processor such as a Figure 2 The processor 258) sends a signal to a pump (such as Figure 2 The flow rate is set equal to the desired flow rate of step 308 by the instruction provided by the first pump 234 ( 1 )).

[0069] Additionally, in various embodiments, the actual flow rate is measured (step 312). In various embodiments, during step 312, Figure 2 The one or more flow sensors 254 measure the actual flow rate for the first and / or second coolant circuits 241 , 242 .

[0070] In various embodiments, a determination is made as to whether the flow rate is excessive (step 314). Specifically, in various embodiments, a processor (such as Figure 2 The processor 258) determines whether the flow rate of step 312 exceeds a predetermined threshold.

[0071] In various embodiments, if it is determined in step 314 that the flow rate is not excessive, a determination is made as to whether the flow rate is correct (step 316). In various embodiments, this determination is made by a processor (such as Figure 2 The processor 258 of step 304 (including, for example, Figure 2 whether the flow sensor 254 is operating correctly).

[0072] In various embodiments, if it is determined in step 316 that the flow rate is correct, then a determination that there is no fault is made (step 318). Specifically, in various embodiments, during step 318, a processor (such as Figure 2 Processor 258) sets the fault status to "None" during step 318.

[0073] In addition, in various embodiments, a determination is made as to whether the flow is charged (step 320). In various embodiments, this determination as to whether the amount of air in either or both of the first and second coolant circuits 241, 242 exceeds a predetermined threshold is made by a processor such as Figure 2 The processor 258 of step 304 (e.g., from Figure 2 made by one or more flow sensors 254).

[0074] In various embodiments, if it is determined in step 320 that the flow is not aerated, a first set of settings for thermal system 104 are implemented (step 322 ). Specifically, in various embodiments, during step 322, the first set of settings includes the following: (i) the coolant cooling power of the chiller 208 is set to optimized (i.e., set to an optimized level that would correspond to an optimal setting without thermal considerations); (ii) the fail-operation cooling mode is set to optimized (i.e., set to an optimized level that would correspond to an optimal setting without thermal considerations); (iii) the alternative flow path is set to optimized (i.e., set to an optimized level that would correspond to an optimal setting without thermal considerations); (iv) the coolant circuit combination is set to optimized (i.e., set to an optimized level that would correspond to an optimal setting without thermal considerations); (v) the upstream power limit is set to normal (e.g., a standard or typical setting for the thermal system 104); (vi) emergency cooling is set to none (i.e., so that emergency coolant is not provided or required); (vii) the compute distribution function is set to optimized (i.e., set to an optimized level that would correspond to an optimal setting without thermal considerations); and (viii) the compute power limit is set to normal (i.e., a typical or standard setting for the thermal system 104). In various embodiments, each of the "optimal" settings (e.g., as referenced above) includes a respective setting that will balance thermal performance and energy efficiency under conditions of a correct (or typical) coolant flow rate without charging. In various embodiments, process 300 then terminates at step 370.

[0075] Referring back to step 320, if it is determined in step 320 that the flow is inflated, then process 300 proceeds to step 324. In various embodiments, during step 324, the target flow rate is set to remediate. In various embodiments, this is accomplished by a processor such as Figure 2 The processor 258) executes instructions provided by the processor.

[0076] In various embodiments, the fault state is set to a "degraded" fault state (step 326). In various embodiments, this is accomplished by a processor such as Figure 2 In various embodiments, a "degraded" power state refers to a condition in which the thermal system 104 (or components thereof) is still performing but not at an expected or optimal performance level.

[0077] Furthermore, in various embodiments, process 300 then proceeds to step 328, which is to implement a second set of settings for thermal system 104. Specifically, in various embodiments, the second set of settings for step 328 includes the following: (i) setting the coolant cooler power to "enhance" (i.e., increase the power); and (ii) setting the fail-operation cooling mode to "both". Furthermore, in various embodiments, during step 328, the settings are set via a processor (such as Figure 2 This is implemented by instructions provided by the processor 258).

[0078] In addition, in various embodiments, Figure 3 As depicted, process 300 then proceeds to step 330. During step 330, a determination is made as to whether the thermal state is "normal". In various embodiments, during step 330, a determination as to whether the temperature is within the first predetermined range (i.e., such that the temperature is greater than a first predetermined temperature threshold and less than a second predetermined temperature threshold) is made by a processor (such as Figure 2 In some embodiments, the temperature refers to one or more temperatures of the thermal system 104 (such as in one of the first or second coolant loops 241, 242 thereof).

[0079] In various embodiments, if it is determined in step 330 that the thermal condition is normal (i.e., within the first predetermined range of step 330), then a third set of settings is implemented (step 332). Specifically, in various embodiments, the third set of settings of step 332 includes the following: (i) setting the upstream power limit to a low power setting; (ii) setting the emergency cooling setting to a standby mode; (iii) setting the computer distribution function to an optimized (i.e., to an optimized level that would correspond to an optimal setting without including thermal considerations); and (iv) setting the computing power limit function to a low power mode. Also in various embodiments, during step 332, the third set of settings is implemented via a processor (such as Figure 2 In various embodiments, each of the "optimal" settings (e.g., as referenced above) includes a corresponding setting that will balance thermal performance and energy efficiency under conditions of a correct (or typical) coolant flow rate without charging. In various embodiments, process 300 then terminates at step 370.

[0080] Referring back to step 330, in various embodiments, if it is determined in step 330 that the thermal state is not normal (i.e., the temperature is not within the first range of step 330), the process proceeds to step 334 instead. In various embodiments, during step 334, a determination is made as to whether the thermal state is hot. In various embodiments, this determination as to whether the temperature is within a second temperature range that is greater than the first range of step 330 (i.e., such that the temperature is greater than the second predetermined temperature threshold of step 330 but less than the third predetermined threshold) is made by a processor (such as a processor). Figure 2 Similar to the above discussion, in some embodiments, the temperature refers to one or more temperatures of the thermal system 104 (such as in one of the first or second coolant loops 241, 242 thereof).

[0081] In various embodiments, if the thermal state is determined to be hot (i.e., within the second predetermined range of step 334) in step 334, then a fourth set of settings is implemented (step 336). Specifically, in various embodiments, the fourth set of settings of step 336 includes the following: (i) setting the upstream power limit to a safe minimum value (i.e., to a minimum value that still provides safe operation); (ii) setting the emergency cooling mode to standby; (iii) setting the computing distribution mode to spinning; and (iv) setting the computing power limit to a safe minimum value (i.e., to a minimum value that still provides safe operation). Also in various embodiments, during step 336, the fourth set of settings is implemented via a processor (such as Figure 2 In various embodiments, process 300 then terminates at step 370.

[0082] Referring back to step 334, in various embodiments, if it is determined in step 330 that the thermal condition is not hot (i.e., the temperature is not within the second temperature range of step 334), then the process proceeds to step 338 instead. In various embodiments, during step 338, a determination is made as to whether the thermal condition is extremely hot. In various embodiments, this determination as to whether the temperature is within a third temperature range that is greater than the second range of step 334 (i.e., such that the temperature is greater than the third predetermined temperature threshold of step 334) is made by a processor (such as a processor). Figure 2 made by processor 258).

[0083] In various embodiments, if the thermal state is determined to be extremely hot (i.e., the temperature is within the third range of step 338) in step 338, then a fifth set of settings is implemented (step 340). Specifically, in various embodiments, the fifth set of settings of step 340 includes the following: (i) setting the upstream power limit to a safe minimum value (i.e., to a minimum value that still provides safe operation); (ii) setting the emergency cooling mode to correspond to a coolant temperature decrease; (iii) setting the computing distribution mode to rotation; and (iv) setting the computing power limit to a safe minimum value (i.e., to a minimum value that still provides safe operation). Also in various embodiments, during step 340, the fifth set of settings is implemented via a processor (such as Figure 2 In various embodiments, process 300 then terminates at step 370.

[0084] Referring back to step 316, in various embodiments, if it is determined in step 316 that the flow rate is incorrect, process 300 proceeds to step 342. In various embodiments, during step 342, the pump speed is increased. In various embodiments, based on the flow rate determined by Figure 2 The processor 258 provides instructions, Figure 2 The speed of the first pump 234(1) is increased to compensate for the flow rate.

[0085] In various embodiments, a determination is then made as to whether the pump speed compensation of step 342 successfully achieved the correct flow rate (step 344). In various embodiments, this determination of step 344 is made by a processor (such as Figure 2 Processor 258) uses the Figure 2 This is performed based on updated flow sensor data of the flow sensor 254.

[0086] In various embodiments, if it is determined in step 344 that pump speed compensation successfully achieved the correct flow rate, process 300 proceeds to step 346. In various embodiments, during step 346, the fault status is set to "degraded". In various embodiments, this is determined by a processor (such as Figure 2 In addition, in various embodiments, such as Figure 3 As depicted, process 300 then proceeds to 320 as described above.

[0087] In contrast, in various embodiments, if it is instead determined in step 344 that pump speed compensation was unsuccessful in achieving the correct flow rate, process 300 proceeds instead to step 348. In various embodiments, during step 348, a test path is executed. In various embodiments, the test path is executed via a processor such as Figure 2 The processor 258) is used to execute.

[0088] refer to Figure 4 , providing Figure 3 Flowchart of step 348 (i.e., execution of the test flow path). Figure 4 As depicted, in various embodiments, this begins at step 400 (i.e., based on Figure 3 (determination of the correct flow rate in step 344 where pump speed compensation was unsuccessful).

[0089] like Figure 4 As depicted, in various embodiments, flow rate resolution is attempted by flow path adjustment (step 402). Specifically, in some embodiments, this includes setting an alternate flow path as a split flow path (step 404). In various embodiments, this is performed by a processor (such as Figure 2 Executed by processor 258).

[0090] In various embodiments, a determination is made as to whether the flow rate has been successfully corrected (ie, fixed) (step 406). In various embodiments, this determination is made by a processor (such as Figure 2 made by processor 258).

[0091] In various embodiments, if it is determined in step 406 that the flow rate has been successfully corrected, the process proceeds to step 408. In various embodiments, during step 408, the flow rate is remedied. In various embodiments, the sub-process of step 348 then terminates at step 430, and process 300 then returns to Figure 3 , and then begins with step 350 as further described below.

[0092] Conversely, in various embodiments, if it is instead determined in step 406 that the flow rate has not been successfully corrected, the process instead proceeds to step 410. In various embodiments, during step 410, a determination is made as to whether the thermal system 104 is currently operating in a separate mode (e.g., a separate mode for the first coolant loop 241 and the second coolant loop 242) or a loop combination mode (e.g., a combination mode for both the first and second coolant loops 241, 242). In various embodiments, this determination is made by a processor (such as Figure 2 made by processor 258).

[0093] In various embodiments, if it is determined in step 410 that the thermal system 104 is currently operating in a separate mode, the process proceeds to step 412. In various embodiments, during step 412, the operating mode is set to a flow combination mode (e.g., a combined mode for both the first and second coolant loops 241, 242). In various embodiments, this is done via a processor (such as Figure 2 This is implemented by instructions provided by the processor 258).

[0094] In addition, in various embodiments, the pump speed is increased (step 414). In various embodiments, based on the Figure 2 Based on instructions provided by the processor 258 , the speed of the second pump 234 ( 2 ) is increased to the maximum allowable speed for the second pump 234 ( 2 ) (eg, in accordance with its safety specifications, etc.).

[0095] In various embodiments, a determination is then made as to whether the flow rate has been successfully corrected (ie, fixed) (step 416). In various embodiments, this determination is made by a processor (such as Figure 2 processor 258) via the Figure 2 The updated sensor data of one or more flow sensors 254 is made.

[0096] In various embodiments, if it is determined in step 416 that the flow rate has been successfully corrected, the process proceeds to step 408 as described above. In various embodiments, as described above, the flow rate is remedied in step 408, the subprocess of step 348 terminates (step 430), and the process 300 then returns to Figure 3 , and then begins with step 350 as further described below.

[0097] Conversely, in various embodiments, if it is instead determined in step 416 that the flow rate has not been successfully corrected, the flow rate is not remedied (step 418). In various embodiments, the subprocess of step 348 terminates (step 430), and process 300 then returns to Figure 3 , and then begins with step 350 as further described below.

[0098] Referring back to step 410, in various embodiments, if it is instead determined in step 410 that thermal system 104 is currently operating in the circuit combination mode, the process instead proceeds to step 418. In various embodiments, during step 418, the operating mode continues in the circuit combination mode and the pump speed is increased. In various embodiments, the pump speed is increased based on the information provided by a processor such as Figure 2 Based on instructions provided by the processor 258 , the speed of the second pump 234 ( 2 ) is increased to the maximum allowable speed for the second pump 234 ( 2 ) (eg, in accordance with its safety specifications, etc.).

[0099] In various embodiments, a determination is then made as to whether the flow rate has been successfully corrected (ie, fixed) (step 420). In various embodiments, this determination is made by a processor (such as Figure 2 The processor 258) is based on the Figure 2 The flow rate sensor 254 is based on updated sensor data of one or more of the flow sensors 254.

[0100] In various embodiments, if it is determined in step 420 that the flow rate has been successfully corrected, the process proceeds to step 408 as described above. In various embodiments, as described above, the flow rate is remedied in step 408, the subprocess of step 348 terminates (step 430), and the process 300 then returns to Figure 3 , and then begins with step 350 as further described below.

[0101] Conversely, in various embodiments, if it is instead determined in step 420 that the flow rate has not been successfully corrected, the process instead proceeds to step 422. In various embodiments, during step 422, the operating mode is set to a separate mode (e.g., a separate mode for the first coolant loop 241 and the second coolant loop 242). In various embodiments, this is done via a processor (such as Figure 2 This is implemented by instructions provided by the processor 258).

[0102] In various embodiments, a determination is then made as to whether the flow rate has been successfully corrected (ie, fixed) (step 424). In various embodiments, this determination is made by a processor (such as Figure 2 Processor 258) uses the Figure 2 The flow rate sensor 254 is based on updated sensor data of one or more of the flow sensors 254.

[0103] In various embodiments, if it is determined in step 424 that the flow rate has been successfully corrected, the process proceeds to step 408 as described above. In various embodiments, as described above, the flow rate is remedied in step 408, the subprocess of step 348 terminates (step 430), and the process 300 then returns to Figure 3 , and then begins with step 350 as further described below.

[0104] Conversely, in various embodiments, if it is instead determined in step 424 that the flow rate has not been successfully corrected, the process instead proceeds to step 418 described above, where the flow rate is not remedied. In various embodiments, the sub-process of step 348 terminates (step 430), and the process 300 then returns to Figure 3 , and then begins with step 350 as further described below.

[0105] Return to reference Figure 3 In various embodiments, a determination is made as to whether the flow rate is remedied (step 350). In various embodiments, this determination is made by a processor (such as Figure 2 The processor 258) is based on the above reference Figure 4 The subroutine of step 348 described above is performed.

[0106] In various embodiments, if it is determined in step 350 that the flow rate is remedied, the process proceeds to step 346 described above, where the fault status is set to "degraded," and the process then continues to step 320 and beyond.

[0107] Conversely, in various embodiments, if it is instead determined in step 350 that the flow rate is not remedied, the process instead proceeds to step 352. In various embodiments, during step 352, a determination is made as to whether the flow rate is equal to zero. In various embodiments, this determination is made by Figure 2 The processor 258 uses the Figure 2 The flow sensor 254 is used for sensor data.

[0108] In various embodiments, if it is determined in step 352 that the flow rate is not equal to zero, the process proceeds to step 326 described above. As described above, in various embodiments, the fault status is set to "degraded" in step 326, and the process then proceeds to step 328 as described above where the second set of settings is implemented.

[0109] Conversely, in various embodiments, if the flow rate is instead determined to be zero in step 352, the process instead proceeds to step 354. In various embodiments, during step 354, the fault condition is detected by a processor such as Figure 2 Processor 258) is set to "fault".

[0110] In various embodiments, the process then proceeds to step 356, where a sixth set of settings is implemented. Specifically, in various embodiments, during step 356, the sixth set of settings includes the following: (i) the coolant cooling power of chiller 208 is set to a reduced level; (ii) the fail-operation cooling mode is set to both; (iii) the upstream power limit is set to a safe minimum level; (iv) the emergency cooling is set to include coolant flow replacement in addition to temperature reduction; (v) the computational distribution function is set to rotate; and (vi) the computational power limit is set to equal the safe minimum value. In various embodiments, these settings are implemented via Figure 2 The process 300 is implemented by the processor 258 of the processor 258. In various embodiments, the process 300 then terminates at step 370.

[0111] Accordingly, methods, systems, and vehicles are provided for controlling thermal management of devices, including computers and / or other critical components of vehicles and / or other platforms. In various embodiments, the methods and techniques described herein measure the flow rate and charge of coolant in a thermal system and provide increased pump speed, enhanced chiller power, redundant cooling methods, upstream power limiting, and other techniques as appropriate to remedy low flow rate and charge while providing thermal management for the device.

[0112] It should be understood that systems, vehicles, and methods may vary from those depicted in the figures and described herein. Figure 1 The vehicle 100 (including the critical safety system 101 and / or other components thereof) may be in communication with Figure 1 As described in and / or in combination with the above Figure 1 It should also be understood that the device 102, thermal system 104 and control system 106 and / or their components and / or their implementations may also be used in conjunction with Figure 2 as described in and / or in combination with Figure 2 Similarly, it will be appreciated that the steps of process 300 may differ from those described herein. Figure 3 and Figure 4 The steps depicted in, and / or various steps of process 300 may occur simultaneously and / or in parallel. Figure 3 and Figure 4 As described in and / or in combination with Figure 3 and Figure 4 The order described occurs in a different order.

[0113] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Specifically, the foregoing detailed description will provide a convenient roadmap for implementing one or more exemplary embodiments for those skilled in the art. It should be understood that various changes may be made to the functions and arrangements of the elements without departing from the scope of the present disclosure as set forth in the attached claims and their legal equivalents.

Claims

1. A method for controlling thermal management of a device via a thermal system, the method comprising: obtaining flow data regarding a flow of a coolant of the thermal system via a flow sensor; determining, via a processor, one or more characteristics of the flow of the coolant of the thermal system based on the flow data; as well as Via the instructions provided by the processor, control of the thermal system is adjusted for the thermal management of the device based on the one or more characteristics of the flow of the coolant of the thermal system.

2. The method according to claim 1, wherein: The step of determining the one or more characteristics includes determining, via the processor, a loss of fluid flow of the coolant of the thermal system based on the flow data; as well as The step of adjusting the control includes adjusting, via instructions provided by the processor, the control of the thermal system for the thermal management of the device in a manner to remediate the loss of fluid flow.

3. The method according to claim 1, wherein: The step of determining the one or more characteristics includes determining, via the processor, a charge of the coolant of the thermal system based on the flow data; and The step of adjusting the control includes adjusting, via instructions provided by the processor, the control of the thermal system for the thermal management of the device in a manner that remediates the charging of the coolant.

4. The method of claim 1 , wherein the step of adjusting the control comprises: Via the instructions provided by the processor, a speed of one or more pumps of the thermal system is adjusted based on the one or more characteristics of the flow of the coolant of the thermal system for the thermal management of the device.

5. The method of claim 1 , wherein the step of adjusting the control comprises: Via the instructions provided by the processor, a power of a cooler of the thermal system coupled to the device is adjusted based on the one or more characteristics of the flow of the coolant of the thermal system.

6. The method of claim 1 , wherein the step of adjusting the control comprises: Via the instructions provided by the processor, one or more redundant cooling circuits of the thermal system are implemented based on the one or more characteristics of the flow of the coolant of the thermal system for the thermal management of the device.

7. The method of claim 1 , wherein the step of adjusting the control comprises: Via the instructions provided by the processor, one or more upstream power limits of the thermal system are adjusted based on the one or more characteristics of the flow of the coolant of the thermal system for the thermal management of the device.

8. The method of claim 1 , wherein the step of adjusting the control comprises: An emergency cooling system is selectively enabled based on the one or more characteristics of the flow of the coolant of the thermal system via instructions provided by the processor.

9. The method of claim 1 , wherein the step of adjusting the control comprises: Via instructions provided by the processor, selectively alternate between separate flows and combined flows for multiple circuits of the flow of the coolant of the thermal system based on the one or more characteristics of the flow of the coolant of the thermal system.

10. A control system for controlling thermal management of a device via a thermal system, the control system comprising: a flow sensor configured to obtain flow data regarding a flow of a coolant of the thermal system; as well as a processor coupled to the flow sensor and configured to at least facilitate: determining one or more characteristics of the flow of the coolant of the thermal system based on the flow data; as well as Via the instructions provided by the processor, control of the thermal system is adjusted for the thermal management of the device based on the one or more characteristics of the flow of the coolant of the thermal system.

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