Coolant Regulator Valve Failsafe With Spring-Triggered Default Return
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Solution Overview
Problem
Coolant control regulators in vehicles lack a failsafe mechanism to automatically return to a default position in case of valve control failure, potentially leading to larger system failures due to disrupted fluid flow.
Innovation Solution
A valve assembly failsafe system comprising a wind arm, spring, latch, drive gear, and wax driver that engages the actuator to rotate the valve to a default position upon receiving a failure signal, ensuring fluid flow continuity by using spring tension and a heating element to expand and contract wax for mechanical tripping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coolant control regulator valve is used without a failsafe mechanism, then the device complexity is reduced, but the reliability deteriorates because the valve cannot automatically return to a default position in case of control failure
Solution Approach 1:
The spring is pre-loaded and the wind arm is positioned in advance to store potential energy. When failure occurs, the pre-loaded spring automatically drives the wind arm to rotate and engage the drive gear, returning the valve to its default position without requiring active control signals or additional power.
Solution Approach 2:
The wind arm acts as an intermediary mechanical element between the spring's stored energy and the drive gear. It transfers and amplifies the spring force through rotational motion to engage the drive gear and rotate the actuator, providing a mechanical mediation that converts small spring displacement into significant valve position correction.
2Reliability
If a spring-driven failsafe mechanism is added to the valve assembly, then the reliability improves by ensuring default position return, but the device complexity increases due to additional components
Solution Approach 1:
The drive gear serves multiple functions: it is engaged by the wind arm during failsafe operation to return the valve to default position, and it is also engaged by the actuator during normal operation to control valve positioning. This multi-functionality reduces the need for separate mechanisms for normal control and failsafe operation.
Solution Approach 2:
The failsafe mechanism components (spring, wind arm, latch) are integrated with the existing actuator and drive gear assembly. The spring is positioned within the actuator housing, the wind arm connects to both the spring and drive gear, and the latch mechanism combines with the actuator's rotational movement, merging failsafe functionality into the existing valve control structure.
3Reliability
If a latch mechanism is used to retain the wind arm under spring tension, then the reliability improves by maintaining the set state, but the device complexity increases due to additional retaining components
Solution Approach 1:
The latch mechanism automatically engages with the wind arm when the actuator rotates to the desired position, and it automatically disengages when the wind arm rotates during failsafe operation. The latch uses the existing rotational movement of the actuator and wind arm to its own advantage, requiring no additional actuators or control systems to operate.
Solution Approach 2:
The latch mechanism replaces the need for electrical sensors, control circuits, and powered position-holding systems. Instead of using electronic feedback and powered actuators to maintain valve position, the mechanical latch physically blocks the wind arm's rotation, providing passive position holding through pure mechanical means.
4Reliability
If a driver mechanism is added to trip the latch and engage the drive gear, then the reliability improves by enabling automatic failsafe activation, but the device complexity increases due to additional tripping components
Solution Approach 1:
The driver mechanism utilizes the phase transition of wax from solid to liquid in response to heat from the heating element. This phase change causes the driver to expand and physically push the latch out of engagement with the wind arm, triggering the failsafe mechanism through a simple thermal-to-mechanical conversion that requires no complex control systems.
Solution Approach 2:
The heating element and wax driver mechanism replace complex electronic detection systems, sensors, and controlled actuation systems. Instead of using electronic sensors to detect failure conditions and controlled motors to activate the failsafe, the system uses thermal expansion of wax to automatically trigger the mechanical release, providing a simpler, more reliable activation method.
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 valve assembly failsafe mechanism effectively ensures fluid flow to critical components by automatically positioning the coolant control regulator to a default state in case of failure, preventing system failures and allowing for easy reset and reuse.
Implementation Method 1
a spring that engages the wind arm under spring tension
Implementation Method 2
using spring tension and a heating element to expand and contract wax for mechanical tripping
Data Source
AI summary
A valve assembly failsafe configured to be coupled to an actuator of a coolant control regulator assembly is provided. The valve assembly failsafe includes a wind arm, a spring that engages the wind arm under spring tension, a latch that engages the wind arm, a drive gear that engages the wind arm and the actuator, and a driver that engages the latch. The valve assembly failsafe is configured to be positioned in a set state where the latch engages and retains the wind arm under spring tension and the drive gear freely rotates during rotation of the actuator, and a tripped state where the driver rotates the latch to disengage the latch from the wind arm, causing the wind arm to rotate under the spring tension to engage the drive gear and cause the drive gear to drive the actuator to a default position.