Prefabricated Coolant Regulator Assembly for Engine Thermal Control
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Solution Overview
Problem
Existing coolant regulators for internal combustion engines are complex in terms of manufacturing and installation, with separate components requiring individual assembly and connection, which complicates quality assurance and installation processes.
Innovation Solution
A prefabricated assembly integrating the temperature sensor, power supply, and heating element within the coolant regulator housing, allowing for pre-verification of functionality and simplified installation, with flexible connecting lines and a metal tube for efficient temperature sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components (temperature sensor, power supply, heating element) are used individually, then each component can be optimized independently, but the manufacturing complexity and installation difficulty increase
Solution Approach 1:
The patent combines the temperature sensor, power supply, and heating element into a single integrated assembly that is inserted as one unit into the housing. This merging reduces the number of separate manufacturing steps and assembly operations, thereby reducing manufacturing complexity while maintaining the ability to optimize each component within the integrated design
2Reliability
If separate components are assembled individually, then quality assurance can be performed on each component, but the overall assembly process becomes more complex and time-consuming
Solution Approach 1:
The temperature sensor, power supply, and heating element are pre-assembled and pre-tested as an integrated unit before being inserted into the housing. This preliminary assembly and testing of the complete functional group allows quality assurance to be performed on the entire assembly as a single unit, reducing the overall assembly time and improving productivity while maintaining comprehensive quality control
3Reliability
If multiple separate connections are made during installation, then each connection can be verified individually, but the installation process becomes more difficult and time-consuming
Solution Approach 1:
The patent integrates all electrical connections and mounting features into the single assembled unit. During installation, the entire assembly with all its internal connections already made is inserted as one component, reducing the installation process to a single operation while maintaining the reliability of individual connection verification through pre-installation testing of the integrated unit
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 results in a more reliable, easier-to-manufacture, and simpler-to-install coolant regulator with improved temperature sensing and regulation capabilities, ensuring quick and precise coolant temperature measurement and reduced external connections.
Implementation Method 1
the sensor pill preferably being arranged at the end of the metal tube in a heat-conducting manner in the latter. Due to the metal tube, the temperature of the coolant is transferred well to the sensor pill, so that the current value of the coolant temperature can be recorded by the sensor pill very quickly
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A coolant regulator (1) for a coolant circuit of an internal combustion engine essentially consists of a housing (7) and a thermostatic valve (2) arranged therein. The thermostatic valve comprises at least one valve closing element (16', 19') that can be actuated by a working element (20) depending on a temperature value, a temperature sensor (25), and a heating element (21) for the working element (20). The housing (7) has at least one connector (24) from which connecting lines (28) lead to the temperature sensor (25), and a power supply (22) for the heating element (21) is provided. The connector (24), the temperature sensor (25), the connecting lines (28), and the power supply (22) for the heating element (21) are designed as a prefabricated assembly, and this assembly is integrated into the housing (7).