Coolant Control Valve Sensor for Fail-Safe Coolant Flow
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Solution Overview
Problem
Coolant control valves (CCVs) in fluid cooling systems lack a reliable fail-safe mechanism to manage coolant flow effectively in case of functional failures, particularly in managing excessive fluid temperatures or pressures.
Innovation Solution
A CCV design incorporating a temperature sensor with a displaceable body and dual force generators, where a first force generator provides a biasing force and a second force generator, such as a wax material, generates an actuation force to move the sensor between axial positions, controlling coolant flow between zero and non-zero states, and communicating electronically with an actuator and controller to manage fluid temperatures and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temperature sensor with displaceable body and dual force generators is added to provide fail-safe mechanism, then reliability is improved, but device complexity increases
Solution Approach 1:
The temperature sensor integrates multiple functions: temperature sensing, pressure sensing, and automatic valve actuation. The displaceable body combines the sensor elements and force generators (spring and wax material) into a single integrated component that directly actuates the valve, eliminating the need for separate fail-safe devices and reducing overall system complexity despite adding functionality.
Solution Approach 2:
The temperature sensor system is self-actuating through its dual force generator mechanism. When the coolant temperature exceeds the threshold, the wax material expands automatically, generating force to displace the body and open the valve without requiring external power, control signals, or additional actuation mechanisms. This self-service capability improves reliability while minimizing the complexity of control systems.
2Productivity
If continuous variable positioning of valve body is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The valve body is designed with continuous variable positioning capability, allowing it to assume any angular position within a continuous range rather than discrete positions. This dynamic positioning enables precise control of coolant flow rates to match varying thermal demands, improving cooling efficiency and system productivity while the electro-mechanical actuator provides the necessary control capability.
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 CCV effectively manages coolant flow by transitioning between zero and non-zero flow states based on temperature and pressure conditions, providing a fail-safe mechanism to prevent engine or component failure due to excessive fluid conditions, while allowing continuous variable positioning for efficient coolant management.
Implementation Method 1
The second force generator can include a wax material that expands with increasing temperature
Data Source
AI summary
A coolant control valve includes an actuator, at least one valve body, an outer housing, and a temperature sensor having a first flow state and a second flow state. The first and second flow states can be achieved by first and second axial positions of the temperature sensor.