Coolant Sensor Assembly Self-Diagnostic Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional vehicle cooling systems face inefficiencies in identifying and addressing failure modes, particularly with coolant level sensors, leading to vehicle downtime and potential system damage due to manual and labor-intensive diagnostic methods.
Innovation Solution
A coolant sensor assembly with a transparent sight glass and additional sensors, coupled with a controller that executes diagnostic self-tests by cycling the system through various modes, isolating the sensor, and analyzing sensor data to detect and isolate failure modes, facilitating visual inspection and efficient maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual system checks are performed to identify failure modes, then failure detection capability is improved, but vehicle downtime and labor requirements increase significantly
Solution Approach 1:
The cooling system performs self-diagnosis through an ECU-controlled diagnostic mode that automatically cycles through operating modes, isolates the coolant sensor assembly, drains coolant, and analyzes sensor data to identify failure modes without requiring manual intervention or vehicle downtime
Solution Approach 2:
The system continuously monitors sensor data output from the coolant sensor assembly during different operating modes and uses this feedback to automatically analyze and identify failure modes, enabling real-time detection without manual checks
2Reliability
If frequent manual system checks are performed to identify failure modes, then failure detection capability is improved, but labor requirements and diagnostic complexity increase
Solution Approach 1:
The ECU automatically executes the complete diagnostic sequence including cycling through operating modes, isolating the sensor assembly, draining coolant, and analyzing sensor data without requiring manual intervention or complex diagnostic procedures
Solution Approach 2:
The system performs preliminary diagnostic actions automatically during normal operation by cycling through operating modes and isolating the coolant sensor assembly before failures occur, eliminating the need for manual diagnostic procedures
3Reliability
If compression or squeeze tests are performed to diagnose cooling system issues, then failure identification is improved, but stress is added to the system reducing operational lifetime
Solution Approach 1:
The patent replaces mechanical compression or squeeze tests with an electrical/diagnostic approach where the ECU analyzes sensor data output during controlled operating modes to identify failures without applying mechanical stress to the cooling system
Solution Approach 2:
The system uses feedback from sensor data analysis during normal operation to identify failures, eliminating the need for stress-inducing mechanical tests and preserving system operational lifetime
4Reliability
If coolant level sensors are installed in conventional positions, then system functionality is maintained, but sensor inspection and maintenance become difficult requiring significant dismantling
Solution Approach 1:
The coolant sensor assembly is segmented as a separate, isolatable unit that can be independently accessed and inspected without dismantling other cooling system components, with the ECU controlling isolation valves to separate the sensor assembly from the rest of the system
Solution Approach 2:
The coolant sensor assembly is designed as a removable unit that can be extracted or isolated from the cooling system for inspection or replacement without requiring significant dismantling of other components, improving maintenance accessibility
Data Source
AI summary
A cooling system includes a coolant tank, a coolant sensor assembly, and a controller. The coolant sensor assembly includes a sensor package having a first end and a second end, the sensor package including a partially transparent or semi-transparent sight glass housing a coolant level sensor and configured to receive a flow of coolant therethrough. The coolant sensor assembly also includes a first valve coupled between the first end of the sensor package and a coolant tank, a second valve coupled between the second end of the sensor package and the coolant tank, and a third valve coupled in flow communication with the second end of the sensor package. The controller is configured to execute one more diagnostic self-tests for the coolant sensor assembly and the cooling system.