Adaptive Sensor Cooling with Air-Channel Heat Exchanger Control
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Solution Overview
Problem
Existing cooling devices for motor vehicle sensors, such as environmental and lidar sensors, face inefficiencies when external air flow is insufficient, leading to continuous energy consumption by fans even when sufficient wind is present, and cannot adapt to varying cooling demands effectively.
Innovation Solution
A cooling device with a housing frame, heat exchanger, electrically driven fan unit, and control unit that automatically switches between active and passive cooling modes based on temperature measurements, utilizing external air flow when available to conserve energy and enhance flexibility in installation locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrically driven fans are used to dissipate heat through convection when there is no external airflow, then cooling reliability is improved, but energy consumption increases
Solution Approach 1:
The fan operation mode is made dynamic and adaptive rather than static. The control unit continuously monitors temperature and adjusts fan operation accordingly, switching between active cooling (fan on) and passive cooling (fan off) modes. This dynamic adjustment resolves the contradiction by making fan operation conditional rather than continuous, ensuring cooling reliability only when necessary while reducing energy consumption when external airflow suffices.
Solution Approach 2:
A feedback control mechanism is implemented where the control unit receives temperature information from sensors and adjusts fan operation based on actual cooling needs. The system monitors temperature parameters and activates the fan only when temperature exceeds thresholds or external airflow is insufficient. This feedback loop resolves the contradiction by linking fan operation to actual thermal conditions, preventing unnecessary energy consumption while maintaining cooling reliability when needed.
2Temperature
If fans run continuously to ensure adequate cooling, then temperature control is improved, but energy efficiency deteriorates
Solution Approach 1:
Instead of continuous fan operation, the system employs periodic or conditional activation based on temperature thresholds and external airflow detection. The fan operates periodically only when temperature exceeds predetermined limits or when external airflow conditions are insufficient. This periodic action pattern resolves the contradiction by eliminating continuous energy consumption while maintaining temperature control through targeted intermittent cooling cycles.
Solution Approach 2:
The system changes operational parameters (fan speed, on/off state) based on varying temperature conditions and external airflow parameters. The control unit adjusts fan operation parameters dynamically according to real-time temperature measurements and environmental conditions. This parameter adaptation resolves the contradiction by matching fan operation intensity to actual cooling demands, improving energy efficiency while maintaining adequate temperature control.
3Adaptability or versatility
If the cooling device uses both active and passive cooling modes, then adaptability is improved, but device complexity increases
Solution Approach 1:
The cooling system is segmented into distinct functional modules: passive cooling structure (heat sink, air ducts), active cooling component (fan unit), sensing module (temperature sensors), and control unit. Each module performs a specific function, and their integration enables adaptable cooling modes. This segmentation resolves the contradiction by organizing complexity into manageable, independent modules that can be controlled through simple logical rules in the control unit, making the dual-mode system adaptable without proportionally increasing overall complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for efficient and flexible cooling of high-waste-heat sensors like lidar sensors by leveraging external air flow when available, reducing energy consumption and enabling optimal cooling performance without continuous fan operation, thus preventing overheating and extending sensor lifespan.
Implementation Method 1
an air flow is directed along multiple paths through a cooling structure
Implementation Method 2
a second surface of the heat exchanger opposite the first surface of the heat exchanger can be arranged in heat-conducting contact with a heat-emitting device
Implementation Method 3
The fan unit is arranged such that when the fan unit is in operation, a first air flow is generated in the direction of the first surface of the heat exchanger
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to a cooling device (1) which comprises a housing frame (10), a heat exchanger (20), an electrically operatable fan unit (30), a control unit (40), and a sensor unit (50). The housing frame (10) can be arranged on a first surface of the heat exchanger (20) in particular. The fan unit (30), for example a fan or a ventilator, is arranged such that a first flow of air (60) is generated in the direction of the first surface (22) of the heat exchanger (20) when the fan unit (30) is operated. The fan unit (30) is received in a recess (18) of the housing frame (10) for example. According to the invention, the housing frame (10) has at least one air channel (12) with an air inlet opening (14) and an air outlet opening (16), wherein the air channel (12) is formed parallel to the first surface (22) of the heat exchanger (20) so that a second flow of air (70) can be conducted along the first surface (22) through the air channel (12). At least one measurement variable is detected using the sensor unit (50), and the fan unit (30) can be actuated depending on the at least one detected measurement variable by means of the control unit (30).