Engine Control Valve with Bypass for Overheating Prevention
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Solution Overview
Problem
Existing engine-controlling systems fail to prevent overheating when the control valve for radiator flow rate malfunctions, particularly due to valve-stuck malfunctions, which limits engine output and complicates limp-home mode operation.
Innovation Solution
An engine-controlling device with a pump, coolant passage, radiator, and control valve configuration that includes a first valve driven by an electric actuator, a second valve responsive to pressure or temperature, and a malfunction-diagnosing unit to detect valve-stuck malfunctions, limiting engine output based on the maximum flow rate from the second valve to prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a detector of the degree of valve opening is used to detect valve-stuck malfunction, then the malfunction can be detected, but the system cannot prevent overheating if the detector itself malfunctions
Solution Approach 1:
The patent introduces a bypass valve as an intermediary component that provides an alternative coolant flow path when the primary control valve fails. This mediator ensures that even if the detector or control valve malfunctions, the coolant can still flow through the bypass passage to prevent overheating, thus resolving the reliability issue without adding complex detector systems
Solution Approach 2:
The bypass valve is designed to activate automatically upon detecting valve-stuck malfunction, providing beforehand cushioning against overheating. The system prepares an alternative cooling path in advance that activates when the primary control fails, ensuring continuous cooling protection without requiring complex real-time detection systems
2Reliability
If the control valve is stuck in a low opening state, then the coolant flow rate decreases, but the engine output is greatly limited and insufficient for vehicle travelling
Solution Approach 1:
The patent implements a dynamic control strategy where the engine output limitation is adjusted based on the malfunction state. When valve-stuck malfunction is detected, the system dynamically limits engine output to a level that can be safely cooled by the available coolant flow through the bypass valve, rather than applying a fixed severe limitation. This dynamic adjustment maintains sufficient productivity for vehicle travelling while ensuring overheating prevention
3Temperature
If the engine output is limited to prevent overheating, then overheating is avoided, but the engine performance decreases
Solution Approach 1:
The patent changes the operating parameters of the engine based on the malfunction state. When valve-stuck malfunction occurs, the system modifies engine parameters such as output limitation to match the reduced coolant flow capacity. This parameter adjustment ensures that the engine operates within safe temperature limits while maximizing the available power for vehicle travelling, rather than applying excessive limitations
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
Effectively prevents engine overheating by limiting output when a valve-stuck malfunction occurs, ensuring sufficient coolant flow and maintaining engine performance during traveling in limp-home mode.
Implementation Method 1
a valve member that is opened in accordance with one or both of a pressure or a temperature of the coolant
Implementation Method 2
a valve member that is opened in accordance with one or both of a pressure or a temperature of the coolant
Implementation Method 3
a radiator, which is a heat exchanger that cools the cooling water by using, for instance, air during travelling
Data Source
AI summary
An engine-controlling device includes a coolant passage, a radiator, and a control valve. A coolant discharged from a pump circulates through the coolant passage. The radiator cools the coolant. The control valve includes a first valve that adjusts a flow rate of the coolant to be introduced into the radiator and that includes a valve member driven by an electric actuator, a second valve that is arranged in parallel with the first valve and that includes a valve member that is opened in accordance with a pressure or a temperature, and a malfunction-diagnosing unit that detects a valve-stuck malfunction of the first valve. An output of the engine is limited to an output equal to or less than a limiting value determined on a basis of a maximum flow rate of the coolant introduced into the radiator from the second valve when the valve-stuck malfunction of the first valve occurs.