Electric Cooling Fan Control for Vehicle Thermal Management
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Solution Overview
Problem
Current vehicle cooling systems are inefficient as they maintain high engine coolant temperatures to minimize fuel and power consumption, leading to increased fuel costs and reduced productivity, particularly in vehicles like haul trucks where cooling is mechanically linked to engine speed.
Innovation Solution
A thermal management system with a controllable electric cooling device independent of engine speed, utilizing multiple energy sources such as dynamic braking and energy storage systems, allowing for an overcooling mode that reduces engine coolant temperature to lower thresholds using low-cost electrical power, thereby optimizing fuel usage and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cooling system is mechanically linked to engine speed, then the cooling system operates automatically with engine power, but fuel consumption increases and productivity decreases
Solution Approach 1:
The patent replaces the mechanical linkage between the engine and cooling fan with an electric motor-driven cooling system. The electric cooling fan can be controlled independently of engine speed, allowing the system to operate only when needed rather than continuously with engine operation. This substitution of mechanical coupling with electrical control enables decoupling of cooling operation from engine speed, reducing unnecessary fuel consumption while maintaining automatic operation through electronic control.
Solution Approach 2:
The patent implements dynamic control of the cooling system by allowing the electric cooling fan to operate at variable speeds based on real-time thermal conditions and energy availability. The system can adjust cooling intensity dynamically, operating at full capacity when needed and reducing or stopping operation when thermal conditions permit, thereby optimizing the balance between cooling effectiveness and energy consumption.
2Use of energy by moving object
If the cooling system maintains high engine coolant temperature, then fuel consumption is minimized, but productivity and energy availability for other systems are reduced
Solution Approach 1:
The patent applies preliminary action by using excess electrical energy (such as during regenerative braking) to pre-cool the engine coolant below the minimum required temperature threshold. This proactive cooling stores thermal headroom that can be utilized later during high-load operations, allowing the engine to operate at higher temperatures (and thus lower fuel consumption) during productive work periods while maintaining overall thermal management effectiveness.
Solution Approach 2:
The patent changes the operating parameters of the cooling system by introducing independent electrical control of the cooling fan, enabling the system to operate in modes beyond traditional thermal equilibrium maintenance. The system can deliberately maintain temperatures above or below conventional operating ranges based on energy availability and productivity requirements, transforming the cooling system from a passive thermal regulator to an active thermal management tool that optimizes both fuel efficiency and productivity.
3Productivity
If an electric cooling device is used independent of engine speed, then cooling control is optimized, but additional energy sources and system complexity are required
Solution Approach 1:
The patent achieves universality by designing the electric cooling system to leverage existing electrical infrastructure in hybrid and electric vehicles, such as the battery pack, regenerative braking system, and power electronics. The cooling fan motor and control system share electrical components and control architecture with other vehicle systems, reducing the net increase in system complexity. The same power electronics that manage traction motor power also manage cooling system power, creating multi-functional use of system components.
4Use of energy by moving object
If the cooling system operates at minimum cooling necessary, then fuel cost is reduced, but engine temperature may exceed optimal ranges
Solution Approach 1:
The patent implements feedback control by continuously monitoring engine coolant temperature, thermal load conditions, and electrical energy availability to dynamically adjust cooling system operation. The control system processes real-time thermal data and electrical system status to determine optimal cooling fan operation, ensuring the engine maintains temperatures within optimal ranges while minimizing energy consumption. This closed-loop control prevents both overheating and excessive cooling, optimizing the balance between fuel efficiency and thermal management.
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 reduces fuel consumption and increases vehicle productivity by independently controlling the cooling system, delaying the need for cooling and providing additional traction power during periods of low energy availability, while maintaining engine components within acceptable temperature ranges.
Implementation Method 1
a cooling system for cooling an engine
Implementation Method 2
The controller is operable to select a first energy source from among the plurality of energy sources and to direct the electrical power from the first energy source to the cooling system
Data Source
AI summary
A system includes a cooling system having a cooling fluid for cooling an engine and a radiator fan motor; a dynamic braking system configured to supply electrical energy to the fan motor during a braking event; and a controller that is operable to direct the electrical energy from the dynamic braking system to the fan motor to cool the coolant to a predetermined minimum threshold temperature. A method includes switching a vehicle thermal management system from a first mode of operation in which the coolant is maintained at a steady operating temperature to a second mode of operation in which the coolant is cooled to a minimum threshold temperature.