Vehicle Cooling Circuit Switching for Backup Overheat Protection
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Solution Overview
Problem
Current vehicle cooling systems for new energy vehicles are complex, heavy, and expensive, with a high risk of overheating due to malfunctioning cooling circuits, particularly in critical components like CPUs, where leaks or blockages are difficult to detect and address efficiently.
Innovation Solution
A cooling system with a main and temporary circuit connected via a valve unit, allowing the temporary circuit to activate in case of main circuit malfunction, using sensors to detect issues and a thermal buffer for efficient cooling, thereby simplifying design and ensuring quick action against malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex thermal management system with multiple cooling circuits is used, then the cooling capability and reliability are improved, but the system weight, cost, and space occupation increase
Solution Approach 1:
The single cooling circuit is designed to perform both normal cooling operation and emergency backup cooling functions. The circuit can switch between different operational modes (normal cooling, emergency cooling, idle) to serve multiple purposes, eliminating the need for separate dedicated backup cooling systems and reducing overall system weight.
Solution Approach 2:
The cooling circuit is divided into functional segments (first cooling circuit portion, second cooling circuit portion, third cooling circuit portion) that can be independently controlled and activated. This segmentation allows the system to activate only the necessary portions during emergency conditions, reducing the amount of cooling infrastructure needed compared to a fully redundant system.
2Reliability
If a redundant cooling circuit is added for emergency backup, then the reliability upon malfunction is improved, but the device complexity increases
Solution Approach 1:
The single cooling circuit performs dual functions: normal cooling operation and emergency backup cooling. The same physical infrastructure (pump, heat exchangers, fluid pathways) serves both purposes through controlled activation of different portions of the circuit, eliminating the need for a completely separate redundant system and reducing overall complexity.
Solution Approach 2:
The cooling circuit incorporates dynamic switching capability through the valve unit, which can redirect fluid flow between different circuit portions based on operational conditions. This dynamic reconfiguration allows the system to adapt between normal and emergency modes using the same hardware, avoiding the complexity of multiple fixed dedicated circuits.
3Device complexity
If the cooling system uses a single main cooling circuit, then the system simplicity is improved, but the risk of overheating upon malfunction increases
Solution Approach 1:
The cooling system pre-configures multiple functional portions (first, second, third cooling circuit portions) within the single circuit that can be selectively activated. During normal operation, the primary portion handles cooling, while backup portions remain ready to be activated upon detecting malfunction conditions, preventing overheating without requiring a completely separate redundant system.
Solution Approach 2:
The valve unit acts as an intermediary component that directs cooling fluid flow to different circuit portions based on operational needs. During normal conditions, it routes flow through the primary cooling path; upon malfunction detection, it redirects flow through alternative portions of the same circuit, providing backup cooling capability while maintaining system simplicity.
4Reliability
If multiple cooling circuits are implemented for redundancy, then the cooling reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The single cooling circuit is designed to fulfill multiple roles: primary cooling and emergency backup cooling. By making the same infrastructure multi-functional through controlled activation of different portions, the system achieves redundancy benefits without duplicating the entire cooling infrastructure, thereby reducing manufacturing costs.
Solution Approach 2:
The first, second, and third cooling circuit portions are merged into a single integrated cooling circuit rather than being implemented as separate physical systems. This merging allows the system to achieve redundant cooling capability through intelligent control and fluid routing within one unified infrastructure, reducing the total component count and manufacturing complexity.
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 system ensures efficient cooling of vehicle components by quickly switching to the temporary circuit upon main circuit failure, reducing the risk of overheating and maintaining operational stability with a simpler, lighter design.
Implementation Method 1
cooling circuits with heat transfer fluid are operated to control the temperature levels of the vehicle components
Implementation Method 2
cooling circuits with heat transfer fluid are operated to control the temperature levels
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
A cooling system for cooling a vehicle component. The cooling system comprises a main cooling circuit connected to the vehicle component and a temporary cooling circuit connected to the vehicle component. The cooling system is configured for being operated in a normal operational state by means of the main cooling circuit, or in a redundant operational state by means of the temporary cooling circuit upon malfunction of the main cooling circuit. The cooling system comprises a valve unit. The main cooling circuit is connected to the vehicle component via the valve unit in the normal operational state, and the temporary cooling circuit is connected to the vehicle component via the valve unit in the redundant operational state. The cooling system is configured for activating the temporary cooling circuit for cooling the vehicle component in the redundant operational state.