Engine Coolant Regulator for Thermal Loss Reduction
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Solution Overview
Problem
Modern combustion machines experience thermal energy losses and delayed warm-up due to excessive coolant exchange between the cooling system and expansion tank during the warm-up phase, leading to increased fuel consumption and emissions.
Innovation Solution
A combustion machine with a regulator that controls coolant flow through the cooling system, allowing minimal coolant exchange with the expansion tank during warm-up, and enables as-needed activation of expansion tank functionality, reducing thermal energy losses by regulating coolant distribution and venting through a connecting line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coolant exchange between cooling system and expansion tank is allowed during warm-up phase, then venting and filling functionality is maintained, but thermal energy losses increase and warm-up efficiency decreases
Solution Approach 1:
The regulator is designed to dynamically change its valve positions based on operating conditions (warm-up phase vs. normal operation). During warm-up, it maintains positions that prevent coolant exchange with the expansion tank, while during normal operation it enables venting and filling functionality, thus adapting the system behavior to different operational states
Solution Approach 2:
The regulator proactively prevents coolant exchange with the expansion tank during the warm-up phase before thermal energy losses can occur. By anticipating the warm-up need and pre-configuring the valve positions to minimize exchange, the system preserves thermal energy while still maintaining the capability to vent and fill when needed
2Loss of energy
If regulator controls coolant flow to minimize exchange with expansion tank, then thermal energy losses are reduced, but system complexity increases
Solution Approach 1:
The regulator performs multiple functions: it controls coolant distribution to minimize thermal losses, maintains venting capability, enables filling operation, and adapts to different operating phases. By consolidating these diverse functions into a single multi-functional component, the system achieves complex control without proportionally increasing overall system complexity
Solution Approach 2:
The regulator combines the functions of coolant flow control, expansion tank isolation, venting management, and filling control into a single integrated component. This merging of functions reduces the number of separate control elements needed and simplifies the overall system architecture while achieving the desired thermal energy preservation
3Productivity
If coolant pump is mechanically driven by internal combustion engine, then pump capacity is proportional to engine speed, but cooling capacity does not match actual demand in many operating states
Solution Approach 1:
The regulator dynamically adjusts coolant flow distribution to match actual cooling demand in different operating states. By changing valve positions based on engine conditions, it ensures that cooling capacity is optimized for each operating phase, preventing both overheating and unnecessary energy consumption from excessive cooling
Solution Approach 2:
The system changes the flow distribution parameters of coolant to different components (cylinder head, cylinder block, expansion tank) based on operating conditions. This parameter adjustment allows the mechanically driven pump to deliver appropriate cooling capacity across various engine speeds and loads, optimizing fuel consumption
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 configuration minimizes thermal energy losses, reduces fuel consumption, and enhances the warm-up efficiency of the internal combustion engine, while maintaining effective venting and filling of the cooling system without increasing system complexity.
Implementation Method 1
thermal energy is absorbed from components that are integrated into the cooling circuit... in an ambient heat exchanger, the so-called primary cooler... this thermal energy is subsequently released into the ambient air
Implementation Method 2
a coolant is pumped in at least one cooling circuit by means of one or more pumps
Implementation Method 3
in an ambient heat exchanger, the so-called primary cooler... this thermal energy is subsequently released into the ambient air
Data Source
AI summary
The invention relates to an internal combustion engine comprising a combustion engine (10) and a cooling system, which has a coolant pump (40), a main cooler (38), a heating heat exchanger (36), coolant channels (28, 30) in the combustion engine (10), and a control device (20) having an actuator (26) for the closed-loop distribution of a coolant according to at least one local coolant temperature, characterised in that the control device (20) can be connected to a coolant compensation container (106) via a connection in line and, with an actuation of the actuator (26) in one direction, the control device (20): permits a coolant flow through the coolant channels (28, 30) of the combustion engine (10), and through the heating heat exchanger (36), and prevents same through the main cooler (38), and closes the connection line in a first primary position (80); releases the connection line in a second primary position (96); and also permits a coolant flow though the main cooler (38) in a third primary position (126).