Cam-Driven Multiport Valve Assembly for Compact Thermal Routing
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Solution Overview
Problem
Complex thermal management systems in electric vehicles face challenges with large multiport fluid valves that hinder packaging efficiency, requiring innovative solutions to manage coolant and refrigerant flow effectively.
Innovation Solution
A cam-driven fluid valve assembly integrated into a single module, featuring a valve housing with lobed cams and sliding gate valves, allowing precise control of fluid flow and reducing component size through plastic or reinforced plastic construction, enabling efficient fluid communication and directional control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiport fluid valves are used to control complex thermal management systems, then fluid flow control capability is improved, but valve size becomes excessively large
Solution Approach 1:
The valve assembly is divided into multiple individual gate valves, each controlling a specific fluid passage. Each gate valve is actuated by a separate cam mechanism, allowing independent control of different fluid flows. This segmentation enables complex thermal management control while keeping each valve component compact and manageable in size.
2Area of stationary object
If multiple fluid valves are integrated into a single module, then packaging efficiency is improved, but component complexity increases
Solution Approach 1:
Multiple gate valves and cam mechanisms are integrated into a single valve assembly housing, forming one compact module. The housing contains internal passages that connect all valves, and a single actuator shaft carries all cams in sequential arrangement. This merging achieves high packaging efficiency while the modular design keeps complexity manageable through standardized components.
Solution Approach 2:
The valve assembly serves multiple functions within a single component: it controls coolant flow to various thermal management components (battery, motor, heat exchangers), integrates multiple gate valves in one housing, and provides centralized actuation through a single motor-driven shaft. This multi-functionality reduces the number of separate components needed in the thermal management system.
3Weight of moving object
If plastic or reinforced plastic is used for valve components, then weight and cost are reduced, but durability concerns arise
Solution Approach 1:
The valve components use plastic reinforced with metal inserts or fibers at strategic locations. The reinforced plastic provides lightweight construction while metal reinforcement at high-stress areas (gate edges, cam contact surfaces, mounting points) ensures durability and resistance to wear and deformation. This composite approach achieves both weight reduction and 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
The cam-driven fluid valve assembly enhances operational and packaging efficiency by precisely controlling fluid flow, reducing weight and cost while maintaining durability, and accommodating complex fluid circuits in compact packages.
Implementation Method 1
The cam shaft and cams are arranged to open and close the fluid valves of the assembly in such a way that multiple fluid valves may allow direction of fluid to a single location and/or a single fluid valve may direct fluid to multiple locations depending on the vehicle operating conditions.
Data Source
AI summary
A valve assembly includes an assembly housing and fluid valves disposed in the assembly housing. The assembly housing includes a first manifold that defines a plurality of first ports and a second manifold that defines a plurality of second valve ports. Each second valve port is associated with a corresponding one of the first ports to form a port pair. The assembly housing includes a valve chamber disposed between the first manifold and the second manifold. The valve chamber is in fluid communication with an interior space of the first manifold via the first ports and is in fluid communication with an interior space of the second manifold via the second valve ports. Each fluid valve is configured to control fluid flow between the first valve port and the second valve port of a respective port pair.