Heat Exchanger Reuse of Excess BTMS Cooling and Heating

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Solution Overview

Problem

Existing thermal management systems for non-combustion power sources often have excess cooling or heating capacity, leading to inefficient power usage and increased size and complexity of machines due to additional thermal management systems for other components.

Innovation Solution

A fluid system with a first fluid circuit for cooling or heating a non-combustion power source and a second fluid circuit, where a heat exchanger allows the first fluid to cool or heat the second fluid, and a controller directs the fluids to the heat exchanger based on temperature information to optimize thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the BTMS is sized for use across a variety of different machine types, then the system can serve multiple applications, but the BTMS has excess cooling or heating capacity when used with a particular machine, wasting power

Engineering Contradiction:

ImproveBTMS applicability across machine typesVSAvoidpower waste from excess capacity

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent applies multi-functionality by enabling the BTMS to serve dual purposes: cooling/heating the non-combustion power source and simultaneously cooling/heating a second fluid in a separate circuit through the heat exchanger. This allows the same thermal management system to efficiently handle multiple thermal loads without wasting excess capacity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If additional thermal management systems are added for other machine components, then those components can be properly cooled or heated, but the machine size and weight increase

Engineering Contradiction:

Improvethermal management of machine componentsVSAvoidmachine weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges the BTMS with a second thermal management function by adding a heat exchanger that couples two fluid circuits. This consolidation allows one thermal management system to handle both the non-combustion power source and another machine component (such as hydraulic system, powertrain, or electronic components), eliminating the need for separate thermal management systems and reducing overall machine weight.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If additional thermal management systems are added for other machine components, then those components can be properly cooled or heated, but the machine complexity increases

Engineering Contradiction:

Improvethermal management of machine componentsVSAvoidmachine complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent reduces complexity by creating a universal thermal management architecture where the BTMS with the added heat exchanger can manage multiple components through a single integrated system. This multi-functional approach eliminates the need for separate control systems and components for different thermal management needs, thereby reducing overall system complexity while maintaining reliable thermal management for all components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If the BTMS operates with excess cooling or heating capacity, then the system can handle various machine configurations, but the compressor operation wastes power

Engineering Contradiction:

ImproveBTMS flexibilityVSAvoidcompressor power consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The patent converts the harmful effect of excess cooling or heating capacity into a beneficial effect by using the heat exchanger to transfer the excess thermal energy to or from the second fluid circuit. This allows the BTMS compressor to operate efficiently at full capacity while the excess thermal energy is productively utilized to heat or cool another machine component, transforming what would be wasted energy into a useful function.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

This solution efficiently utilizes excess cooling or heating capacity, reduces the size and complexity of machines by eliminating redundant thermal management systems, and improves thermal regulation speed, thereby conserving power and optimizing machine performance.

Implementation Method 1

The heat exchanger may be configured to cool or heat the second fluid using the first fluid

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS12263720B2Scavenging excess cooling or heating from a thermal management system of a non-combustion power source for a machine

Publication Date: 2025.04.01 CATERPILLAR INC

AI summary

A fluid system may include a first fluid circuit configured to circulate a first fluid to cool or heat a non-combustion power source of a machine. The first fluid circuit may include at least one of a refrigeration unit to cool the first fluid or a heating unit to heat the first fluid. A cooling capacity of the refrigeration unit may exceed a cooling requirement of the non-combustion power source, or a heating capacity of the heating unit may exceed a heating requirement of the non-combustion power source. The fluid system may include a second fluid circuit configured to circulate a second fluid. The fluid system may include a heat exchanger in the first fluid circuit and in the second fluid circuit. The heat exchanger may be configured to cool or heat the second fluid using the first fluid.