Automotive Thermal Controller with Dynamic Valve Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional automotive thermostats lack the ability to adjust to varying environmental conditions and engine specifics, leading to inefficient temperature control, limited fuel economy, and increased risk of thermal single-point failures.
Innovation Solution
A thermal controller system utilizing a valve, motor, temperature sensor, and controller to regulate coolant flow and temperature dynamically, allowing for real-time adjustments based on inputs from sensors and user-defined settings, including fuel economy and performance goals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a typical thermostat is used to control coolant flow, then the engine can reach operational temperature, but the system cannot adjust to varying environmental conditions or driving conditions
Solution Approach 1:
The patent replaces the static, binary thermostat with a dynamic electronic control system that continuously adjusts the coolant flow valve based on real-time temperature sensor feedback and controller processing. This enables the system to adapt to varying environmental and driving conditions while maintaining manageable complexity through electronic automation.
Solution Approach 2:
The system implements a closed-loop feedback mechanism where temperature sensors continuously monitor coolant temperature and send signals to the controller, which then adjusts the valve position accordingly. This feedback loop enables adaptive control without requiring complex manual intervention or overly sophisticated hardware.
2Measurement precision
If a thermostat operates in binary open/closed mode, then the system is simple, but precise temperature control within a range is not possible
Solution Approach 1:
The patent replaces the purely mechanical bi-metal thermostat with an electronic control system that uses electronic sensors, a microcontroller, and an electronically actuated valve. This substitution enables precise temperature control through digital processing and electronic actuation while keeping the overall system complexity manageable through integration.
Solution Approach 2:
The system changes the control parameter from binary (open/closed) to continuous analog control by using an electronically actuated valve that can position itself at any opening degree between 0% and 100%. This allows precise temperature control within a range by modulating the valve position based on temperature feedback.
3Adaptability or versatility
If the thermostat is fixed at a specific opening temperature, then manufacturing is simple, but fuel economy and performance cannot be optimized for different conditions
Solution Approach 1:
The patent creates a universal thermal control system that can perform multiple functions: it can optimize for fuel economy, performance, or a balance of both, depending on driving conditions and user preferences. The electronic controller can be programmed with different control strategies, making the system adaptable to various operational requirements without requiring different physical thermostats.
Solution Approach 2:
The system transitions from a fixed, static thermostat to a dynamic, reconfigurable electronic control system. The controller can change its control parameters and strategies in real-time based on sensor inputs and pre-programmed logic, enabling the same hardware to serve multiple operational purposes without remanufacturing.
4Reliability
If a typical thermostat is used, then the system is reliable, but it represents a thermal single point of failure
Solution Approach 1:
The patent implements redundant sensing and electronic control with feedback loops that can detect and respond to failures. The temperature sensors continuously monitor the system, and the controller can detect abnormal conditions and adjust the valve or trigger warnings, providing multiple layers of protection against single-point failures while maintaining thermal control flexibility.
Solution Approach 2:
The electronic control system includes monitoring and diagnostic capabilities that can detect potential failures before they cause thermal damage. The system can preemptively adjust coolant flow or alert the driver to impending issues, cushioning against the effects of component failures and improving overall system reliability.
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
Enables precise control of engine temperature, optimizing performance and fuel efficiency while reducing the risk of overheating and accommodating diverse driving conditions and engine variations.
Implementation Method 1
a temperature sensor, and a controller, coupled to the temperature sensor
Implementation Method 2
a motor coupled to the valve
Implementation Method 3
A thermal controller in accordance with one or more aspects of the present disclosure comprises a valve
Data Source
AI summary
A thermal controller for automotive applications. A thermal controller in an aspect of the present disclosure includes a valve, a motor coupled to the valve, a temperature sensor, flow rate sensor, heater/cooler element, and a controller, coupled to the temperature sensor, flow rate sensor and the motor, in which the controller alters volume and temperature of fluid flow through the valve by turning the motor based on inputs from the temperature sensor.