Engine Block Liquid Warm-Up Using Controlled Thermal Loads

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Solution Overview

Problem

Internal combustion engines in hybrid vehicles take longer to reach normal operating temperature from cold conditions, leading to increased raw hydrocarbon release and potential component failures, which affects reliability and fuel efficiency.

Innovation Solution

A controller and method that determine the temperature of a working liquid in the engine block circuit, engaging thermal loads such as increasing pumping load or changing the air/fuel ratio to add heat when below a threshold, and disengaging when above, using thermal control logic to maintain the temperature within a range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the engine is idled to warm the engine from cold conditions, then the engine temperature increases, but the idle speed can only be increased while the vehicle is parked, limiting the warming capability during operation

Engineering Contradiction:

Improveengine temperatureVSAvoidwarming capability during operation

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The patent introduces an intermediary heating system that uses a separate heat source (exhaust gas or dedicated heater) to warm the engine coolant, rather than relying solely on engine idle operation. This mediator enables effective warming during vehicle operation without requiring high idle speeds

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system changes the thermal parameters by introducing external heat energy into the coolant system through the intermediary heating mechanism, allowing temperature control independent of engine load and speed parameters

Inventive Principle:

Principle #35Parameter changes

2Temperature

If the engine operates for a longer time to reach normal operating temperature from cold conditions, then the temperature eventually stabilizes, but more raw hydrocarbons are released to the exhaust system, potentially fouling exhaust after-treatment components

Engineering Contradiction:

Improveoperating temperature stabilityVSAvoidhydrocarbon release

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The system applies preliminary heating action using the intermediary heating system to rapidly bring the coolant temperature close to the optimal range before normal engine operation takes over, reducing the prolonged cold operation period that generates excessive hydrocarbons

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system converts the harmful effect of extended cold operation (hydrocarbon release) into a benefit by using controlled auxiliary heating to achieve faster warm-up, thereby reducing overall emissions while ensuring proper engine temperature

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Temperature

If thermal loads are engaged to accelerate the warming process, then the temperature increases faster, but additional energy is consumed and engine load increases

Engineering Contradiction:

Improvewarming speedVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The intermediary heating system applies partial heating action only when and where needed (in the coolant system) rather than heating the entire engine block, achieving effective warm-up with reduced energy input compared to full engine load increases

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system changes the energy parameter by using a more efficient heating mechanism that directly transfers thermal energy to the coolant, reducing the overall energy consumption compared to traditional methods of increasing engine load for warming

Inventive Principle:

Principle #35Parameter changes

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 approach accelerates the warming process, reduces hydrocarbon production, and improves engine reliability and fuel efficiency by strategically managing thermal loads and parasitic loads to maintain optimal temperature ranges.

Implementation Method 1

engaging a thermal load responsive to the temperature of the liquid being below a first temperature threshold... thereby adding heat to the engine block circuit

Methodology Applied

Scientific EffectThermal load: Heating

Data Source

PatentUS11639693B2Internal combustion engine and method to increase the temperature of a liquid in the internal combustion engine

Publication Date: 2023.05.02 CUMMINS INC

AI summary

A method, controller, and internal combustion engine including the controller and operable in accordance with the method by: determining a temperature of a working liquid in an engine block circuit (31, 35) of the internal combustion engine (10), the working liquid comprising a cooling liquid or a lubrication liquid; operating the internal combustion engine (10); engaging a thermal load responsive to the temperature of the liquid being below a first temperature threshold, wherein engaging the thermal load comprises at least one of increasing a pumping load of the internal combustion engine (10), or changing an air/fuel ratio, thereby adding heat to the engine block circuit (31, 35); controlling the thermal load as a function of the temperature of the liquid; and disengaging at least a portion of the thermal load responsive to the temperature of the liquid being above the low temperature limit.