Vehicle Cooling System with Bypass Radiator Valve
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Solution Overview
Problem
Heavy vehicle cooling systems face challenges in maintaining sufficient cooling for components like charge air, exhaust gases, gearbox oil, and other media, especially during heavy engine loads, leading to impaired vehicle performance and reduced component lifespan due to inadequate cooling.
Innovation Solution
A dual-line cooling system with a bypass line and an extra radiator, where coolant flow is controlled by a valve and temperature sensors to optimize coolant distribution, ensuring effective cooling of both the engine and other media by adjusting flow through the extra radiator based on load conditions and temperature requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant is led mainly through the extra radiator to cool other media, then cooling of other media is improved, but engine operating temperature may become too low
Solution Approach 1:
The system dynamically adjusts coolant flow distribution between the bypass line and the extra radiator line using a control unit that monitors temperatures and actuates a three-way valve. This dynamic control allows the system to optimize coolant routing based on real-time thermal conditions, preventing both overheating and excessive cooling of the engine.
Solution Approach 2:
The control system continuously monitors the temperature of the coolant and the medium to be cooled, and uses this feedback information to adjust the valve position. This closed-loop control ensures that the engine operating temperature is maintained within the optimal range while providing sufficient cooling to other media.
2Productivity
If coolant flow through the extra radiator is increased, then cooling capacity for other media is improved, but coolant flow resistance increases
Solution Approach 1:
The three-way valve dynamically adjusts the flow distribution between the bypass line and the extra radiator line based on cooling demands. When high cooling capacity is needed, the valve directs more coolant through the extra radiator; when cooling demand is low, it redirects coolant through the bypass line to reduce flow resistance and maintain optimal engine temperature.
Solution Approach 2:
The cooling system is segmented into two parallel lines: one through the extra radiator and one through the bypass. This segmentation allows independent control of coolant flow paths, enabling the system to optimize the balance between cooling capacity and flow resistance by selectively activating different paths.
3Reliability
If the bypass line is used to maintain engine temperature, then engine operating temperature is preserved, but cooling of other media becomes insufficient
Solution Approach 1:
The control unit continuously monitors the temperature of the medium to be cooled and adjusts the valve position dynamically. When the medium temperature exceeds the threshold, the valve directs coolant through the extra radiator line to provide additional cooling; when the medium is adequately cooled, the valve redirects coolant through the bypass line to maintain engine temperature.
Solution Approach 2:
The system uses temperature feedback from both the coolant and the medium to be cooled to control valve actuation. This dual-temperature feedback ensures that the system can simultaneously maintain engine operating temperature while providing sufficient cooling to other media by adjusting the coolant flow distribution in real-time.
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 ensures consistent and efficient cooling of vehicle components, preventing overheating and thermal fatigue, while maintaining optimal engine operating temperatures, thereby extending component lifespan and improving vehicle performance.
Implementation Method 1
a second line circuit which comprises at least one heat exchanger in which another medium in the vehicle is intended to be cooled by coolant received from the first line circuit
Implementation Method 2
the coolant is led mainly through the extra radiator. The coolant is thus brought to a sufficiently low temperature for cooling the medium as necessary when it reaches the heat exchanger
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a cooling system in a vehicle (1) powered by a combustion engine (2). The cooling system comprises a first line circuit (4) for cooling the combustion engine (2) and a second line circuit (5) which receives coolant from the first line circuit (4) for cooling at least one medium in a heat exchanger (14a, 14b). The second line circuit (5) comprises a line (5b) with an extra radiator (9) and a bypass line (5c) with a valve means (12) by which it is possible to distribute the coolant flow between the parallel lines (5b, 5c). A control unit (13) is adapted to controlling the valve means (12) so that it leads at least a major part of the coolant through the line (5b) with the extra radiator (9) when there is need for extra cooling of the medium in the heat exchanger (14a, 14b) and so that it leads at least a major part of the coolant through the bypass line (5c) when there is no need for extra cooling of the medium in the heat exchanger (14a, 14b).