Coolant Control Valve Stall Detection and Emergency Coolant Bypass
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Solution Overview
Problem
The coolant control valve's fail-safety thermostat experiences frequent failures due to repeated liquefaction and solidification of wax, leading to increased maintenance costs and reduced cost-effectiveness, especially during cold engine starts where it is not needed.
Innovation Solution
A diagnostic apparatus and method for the coolant control valve that uses control logic, position sensors, and a current detector to determine if the valve is stuck, allowing for a stuck release operation and generating a warning signal, and includes an emergency switch device to redirect coolant flow to prevent overheating, thereby reducing the need for a thermostat during cold starts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thermostat is provided to force coolant flow during cold start, then overheating can be prevented, but the thermostat is not needed during cold starts and cost-effectiveness is reduced
Solution Approach 1:
The patent removes the unnecessary thermostat component from the system. Since the thermostat is not needed during cold starts (when the valve is already open) and only provides limited benefit during normal operation, its elimination simplifies the system structure, reduces manufacturing costs, and eliminates the source of repeated failures while maintaining overheating prevention through electronic monitoring and emergency switch device
Solution Approach 2:
The patent applies fail-safety functionality only where truly needed - during detected valve failures - rather than using a thermostat that operates during all temperature conditions. The emergency switch device activates selectively based on diagnostic apparatus detection of actual valve failures, providing targeted protection without the continuous operation and repeated cycling that causes thermostat degradation
2Reliability
If the entire coolant control valve is replaced due to thermostat failure, then the valve can function normally, but maintenance costs increase
Solution Approach 1:
The patent segments the coolant control valve into controllable components: the electronically controlled valve body, the diagnostic apparatus, and the separate emergency switch device. This segmentation allows the emergency switch device to be activated independently when valve failure is detected, enabling partial system operation and reducing the need for complete valve replacement, thereby lowering maintenance costs while maintaining functionality
Solution Approach 2:
The diagnostic apparatus continuously monitors valve position and control signals, providing feedback about valve status. When a failure is detected, the system activates the emergency switch device as a corrective action. This feedback-based approach enables early detection and response to failures, allowing for simpler, less costly repairs rather than complete valve replacement
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 diagnostic apparatus effectively warns operators of valve failures, ensures driving stability, and reduces maintenance costs by simplifying the coolant control valve structure and eliminating the need for a thermostat during cold starts, while preventing overheating through emergency coolant redirection.
Implementation Method 1
one or more position sensors (41, 42) for sensing a position of the valve member (16)
Implementation Method 2
a driving device (17) for rotating the valve member (16)
Implementation Method 3
an emergency switch device (50) for allowing the coolant to flow toward the radiator (3)
Data Source
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AI summary
A diagnostic apparatus for a coolant control valve including a housing having a plurality of ports, a valve member provided to be rotatable in the housing, and a driving device rotating the valve member between two end positions, the diagnostic apparatus including at least one position sensor provided on an external surface of the housing for sensing a position of the valve member, a determination device for determining whether or not the valve member is stuck using the position of the valve member sensed by the position sensor and a controller for controlling the driving device.