Engine Cooling Valve Linear Actuation for Precise Coolant Flow

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Solution Overview

Problem

Existing control valve units for liquid circuits in internal combustion engines lack precise control over liquid flow through closable openings, particularly in cooling circuits, due to hysteresis and delayed responses in thermostatic wax elements, which hinder efficient temperature regulation and engine warm-up.

Innovation Solution

An electrically driven linear actuator directly coupled with a piston is used to control closable openings, allowing for precise control of liquid flow through the use of an electronic control unit (ECU) or separate electronic control device, with temperature sensors for real-time adjustments, eliminating hysteresis and enabling continuous variable temperature balancing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thermostatic wax element is used to control the valve, then the structure is simple and self-regulating, but the control precision is poor due to hysteresis and delayed response

Engineering Contradiction:
Improvecontrol precisionVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical thermostatic wax element with an electrically driven linear actuator system. The actuator is controlled by an electronic control unit that receives temperature signals from sensors, enabling precise electronic control of the closing element position. This substitution eliminates the hysteresis and delayed response inherent in wax elements while achieving accurate flow control through electronic actuation.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Speed

If a thermostatic wax element is used, then no external power source is needed, but the response time to temperature changes is delayed

Engineering Contradiction:
Improveresponse timeVSAvoidenergy consumption
Core Design Contradiction:
SpeedVSUse of energy by moving object

Solution Approach 1:

The patent substitutes the passive thermal response of wax elements with an active electronic control system. Temperature sensors continuously monitor the liquid temperature and transmit signals to an electronic control unit, which immediately actuates the linear actuator to adjust the valve position. This electronic system eliminates the thermal inertia and delayed response of wax elements, achieving rapid response times despite increased energy consumption from the actuator and control electronics.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If a simple valve structure is used, then manufacturing is easier, but flow control precision is insufficient

Engineering Contradiction:
Improveflow control precisionVSAvoidease of manufacture
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces simple mechanical valve structures with an electronically controlled actuation system. The linear actuator provides precise positional control of the closing element through electronic signaling from the control unit, enabling accurate flow regulation. While this increases manufacturing complexity compared to simple mechanical valves, it achieves superior flow control precision through electronic actuation and sensor feedback.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

4Loss of time

If thermostatic wax elements are used for temperature regulation, then the system is self-regulating, but the engine warm-up time is extended

Engineering Contradiction:
Improveengine warm-up timeVSAvoiddevice complexity
Core Design Contradiction:
Loss of timeVSDevice complexity

Solution Approach 1:

The patent replaces the slow, hysteresis-prone wax element system with an electronically controlled actuator that responds immediately to temperature sensor signals. The electronic control unit continuously monitors temperature and adjusts the valve position in real-time, enabling rapid engine warm-up by precisely controlling coolant flow. This substitution eliminates the delayed response of wax elements, significantly reducing warm-up time despite increased system complexity.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical 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 provides precise control over liquid flow, reduces engine warm-up time, and minimizes space requirements, with improved response times and reduced hysteresis compared to traditional thermostatic wax elements.

Implementation Method 1

the control device comprises an electrically driven linear actuator and at least one piston, which is drivable at least by the actuator, is arranged between the actuator and the at least one closing element for direct coupling of the actuator with the at least one closing element

Methodology Applied
Scientific EffectLinear actuator: Linear Motor

Implementation Method 2

at least one piston, which is drivable at least by the actuator, is arranged between the actuator and the at least one closing element for direct coupling of the actuator with the at least one closing element

Methodology Applied
Scientific EffectMechanical force transmission: Mechanical Force

Data Source

PatentEP2660495B1Control valve unit of a liquid circuit of an internal combustion engine
Publication Date: 2021.07.07 THERMAL CONTROL SYST AUTOMOTIVE TCFR
  • EP2660495B1 patent drawingFigure 1
  • EP2660495B1 patent drawingFigure 2
  • EP2660495B1 patent drawingFigure 3

AI summary

Control valve unit (10) of a liquid circuit, in particular a cooling circuit, of an internal combustion engine in particular of a motor vehicle. The control valve unit (10) comprises a valve housing (12), which has at least one inlet/outlet opening (38) and at least one closable outlet/inlet opening (20, 28). At least one closing element (62, 64), actuated by a control device (72), can open or close the at least one closable outlet/inlet opening (20, 28). The control device comprises an electrically driven linear actuator (72). At least one piston (60, 78), which is drivable at least by the actuator (72), is arranged between the actuator (72) and the at least one closing element (62, 64) for direct coupling of the actuator (72) with the at least one closing element (62, 64) at least in one actuation direction (80).