Engine Overheat Prevention via Coolant Temperature Diagnosis
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Solution Overview
Problem
Existing engine systems face challenges in preventing engine overheat due to coolant temperature monitoring limitations, particularly the high cost of flow sensors and abrupt shutdowns caused by coolant temperature sensors indicating overheating without adequate preparation for vehicle movement cessation.
Innovation Solution
A method using an integrated thermal management (ITM) system with a controller that predicts coolant temperature increases by diagnosing coolant amount shortages through temperature sensors, delaying overheating by controlling the ITM valve and cooling fan to enable minimal vehicle movement and protect the engine and mechanical devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a flow sensor is applied to monitor coolant amount, then the coolant monitoring precision is improved, but the device cost increases
Solution Approach 1:
The patent uses temperature sensors to indirectly monitor coolant amount by measuring coolant temperature, replacing the need for direct flow sensors. This copying approach allows inferring coolant status through temperature data, achieving monitoring precision without the high cost of flow sensors
Solution Approach 2:
The patent replaces the mechanical flow sensor system with a thermal-based monitoring system using temperature sensors and control algorithms. This substitution eliminates the need for expensive mechanical flow measurement devices while maintaining monitoring capability through thermal field measurements
2Reliability
If the coolant temperature sensor indicates overheating at a specific temperature value, then the engine protection is improved, but the vehicle operation continuity deteriorates
Solution Approach 1:
The patent implements preliminary cooling actions before the coolant reaches dangerous overheating temperatures. The controller activates the cooling fan and adjusts the ITM valve in advance when temperature thresholds are approached, preventing overheat conditions before they occur and avoiding abrupt vehicle shutdowns
Solution Approach 2:
The patent creates a buffer zone by monitoring coolant temperature trends and activating cooling measures before critical overheating occurs. This cushioning approach allows the system to handle thermal fluctuations gracefully, protecting the engine while maintaining vehicle operation through preparatory cooling actions
3Temperature
If the cooling fan is operated at high speed to cool the coolant, then the cooling efficiency is improved, but the energy consumption increases
Solution Approach 1:
The patent dynamically adjusts the cooling fan speed based on real-time coolant temperature measurements and thermal management requirements. The controller modulates fan operation to provide optimal cooling only when necessary, reducing energy consumption during normal operating conditions while maintaining cooling efficiency when temperature thresholds are approached
Solution Approach 2:
The patent changes the operating parameters of the cooling system by adjusting fan speed and ITM valve position based on coolant temperature conditions. This parameter modulation allows the system to optimize between cooling efficiency and energy consumption, operating at high performance only when thermal conditions require it
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 allows for preemptive fail-safe control to prevent engine overheat, enabling continued engine operation and safe vehicle movement by maximizing cooling efficiency and alerting drivers to potential coolant issues before dangerous situations arise.
Implementation Method 1
operating a cooling fan to cool the coolant
Implementation Method 2
distributing the coolant under the control of an opening degree of an integrated thermal management (ITM) valve
Implementation Method 3
distributing the coolant to a radiator and a heat exchanger
Data Source
AI summary
A method for preventing an engine overheat based on a coolant temperature applied to an engine system 1 is provided, in which a controller 50 checks if a coolant coming from an engine 10 is distributed to any one of a heater core 25B and an ATF warmer 25A as a radiator 23 is switched from a distribution blocking state (i.e., radiator closed) at a diagnosis start to a distribution state (i.e., radiator open) during the diagnosis under the control of an opening degree of an ITM valve 40, diagnoses lack of a coolant amount using factors B determined by an inlet/outlet coolant temperature difference T of the engine 10 through first and second water temperature sensors 30A and 30B as a factor cumulative value A, and then controls the ITM valve 40 to a full open state in a state where a coolant temperature increase is predicted.