Engine Cooling Circuit Segmentation for Cold-Start Thermal Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cooling systems for internal combustion engines face challenges in efficiently managing coolant flow during cold-start conditions, leading to increased fuel consumption, sub-optimal combustion, and condensation issues due to the need for separate pump systems and complex configurations.
Innovation Solution
A cooling arrangement with a high-temperature cooling circuit and a low-temperature cooling circuit, where the primary pump is deactivated during cold-start, and the secondary pump activates coolant flow only through the upper cylinder-head portion, bypassing the engine block, to quickly warm up the charge-air cooler and prevent condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a normal cooling circuit is used during cold-start, then the engine block is cooled, but the charge-air cooler is not warmed up quickly enough leading to condensation and misfiring
Solution Approach 1:
The cooling circuit is segmented into multiple pathways: a first cooling circuit for the engine block and a second cooling circuit for the charge-air cooler. During cold-start, the system selectively activates only the second circuit to warm the charge-air cooler quickly, while keeping the first circuit inactive to avoid cooling the engine block. This segmentation allows independent temperature control of different components, preventing condensation in the charge-air cooler without compromising engine block cooling when needed.
2Ease of operation
If separate pump systems are used for different cooling circuits, then independent flow control is achieved, but system complexity and cost increase
Solution Approach 1:
A single coolant pump is designed to serve multiple functions by controlling flow to different circuits through valve mechanisms. The pump can direct coolant to the engine block cooling circuit, the charge-air cooler circuit, or both simultaneously based on operational requirements. This multi-functional approach eliminates the need for separate pump systems while maintaining independent flow control capability, thereby reducing system complexity and cost.
3Use of energy by moving object
If coolant flow is blocked to the engine block during cold-start, then fuel consumption is reduced, but the charge-air cooler cannot be warmed up effectively
Solution Approach 1:
The cooling system is divided into separate circuits for the engine block and charge-air cooler, allowing selective activation. During cold-start, only the charge-air cooler circuit is activated to warm it up quickly and prevent condensation, while the engine block circuit remains inactive to minimize energy consumption and reduce fuel consumption. This segmented approach enables targeted thermal management without unnecessary energy expenditure on the entire cooling system.
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 reduces fuel consumption, minimizes friction losses, and prevents misfiring by using waste heat to warm the charge-air cooler, thereby improving engine efficiency and reducing system complexity and cost.
Implementation Method 1
By doing this, heating of a charge-air cooler, such as a water charge-air cooler (WCAC), may occur faster during the cold-start via waste heat from the cylinder head
Data Source
AI summary
Methods and systems are provided for a cooling arrangement. In one example, the cooling arrangement comprises flowing coolant to only an upper portion of a cylinder head during a cold-start. The cooling arrangement comprises flowing coolant to a cylinder block, a lower portion of the cylinder-head, and the upper portion of the cylinder head outside of the cold-start.