Engine Thermal Management with Split Cooling for NOx and Fuel Use

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Solution Overview

Problem

Conventional internal combustion engine cooling systems, controlled by thermostats, fail to optimize cooling capacity based on engine load, leading to increased nitrogen oxide emissions (NOx) and fuel consumption, especially during warm starts and urban driving conditions.

Innovation Solution

A thermal management system with dynamic cooling capacity control, featuring separate fluid chambers around the cylinder head and piston, allowing for independent coolant flow regulation based on engine load, speed, and temperature, to prevent temperature peaks and optimize exhaust aftertreatment system heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a thermostat controls the cooling system to maintain a constant coolant temperature, then component overheating is avoided and nitrogen oxide emissions are minimized, but at low engine loads parts of the engine are cooled too much and at high engine loads other parts are not cooled enough

Engineering Contradiction:

Improvecoolant temperatureVSAvoidengine performance optimization

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The cooling system is divided into separate cooling circuits for the cylinder head and cylinder block, each with independent thermostat control. This allows different temperature regulation for different engine parts, enabling optimal cooling at various engine loads without compromising overall engine performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cooling system uses electronically controlled thermostats that can dynamically adjust coolant flow based on engine load conditions. The control unit receives engine load signals and adjusts the thermostat opening accordingly, transforming the static thermostat system into a dynamic one that adapts to varying engine demands

Inventive Principle:

Principle #15Dynamics

2Use of energy by moving object

If the coolant flow rate through the radiator is reduced when coolant temperature is below a threshold, then the engine warms up quicker and fuel consumption is reduced, but the temperature of the cylinder head increases leading to increased nitrogen oxide emissions

Engineering Contradiction:

Improvefuel consumptionVSAvoidnitrogen oxide emissions

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The system separates the cooling control for the cylinder head from the cylinder block by using independent thermostats and cooling circuits. This allows the cylinder head to maintain lower temperatures for NOx reduction while the cylinder block can be warmed up efficiently for fuel consumption reduction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different temperature conditions are applied to different parts of the engine based on their specific requirements. The cylinder head is kept cooler to prevent NOx formation, while the cylinder block is allowed to warm up faster to reduce overall fuel consumption

Inventive Principle:

Principle #3Local quality

3Reliability

If the cooling capacity is increased to prevent overheating, then component protection is improved, but fuel consumption increases and engine performance decreases

Engineering Contradiction:

Improvecomponent protectionVSAvoidfuel consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The electronically controlled thermostats dynamically adjust coolant flow based on actual engine conditions and load. This prevents unnecessary cooling at low loads (reducing fuel consumption) while ensuring adequate cooling protection when needed (maintaining reliability)

Inventive Principle:

Principle #15Dynamics

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

Significantly reduces NOx emissions and fuel consumption by maintaining optimal cooling levels across varying engine conditions, enhancing engine performance and reducing pollutant formation.

Implementation Method 1

at least one fluid chamber with at least one inlet line and at least one outlet line, disposed at least partially around a cylinder head or below a cylinder piston

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

the fluid chamber is connected to at least one coolant delivery device for supplying a coolant and is connected to at least one heat sink, wherein the heat sink is particularly ambient air or a radiator

Methodology Applied

Scientific EffectHeat dissipation: Heat Sink

Data Source

PatentUS20240418118A1Heat Management System and Heat Management Method of an Internal Combustion Engine

Publication Date: 2024.12.19 INO8

AI summary

A thermal management method for operating a thermal management system of an internal combustion engine. The thermal management system comprises at least one fluid chamber which is arranged at least partially around a cylinder head of a cylinder of the internal combustion engine and has at least one inlet line and at least one outlet line, the fluid chamber being connected to at least one coolant pumping device for pumping a coolant, and to at least one heat sink. According to a thermal management method, with increasing temperature of the at least one fluid chamber after a warm-up phase at a constant or decreasing engine speed, the coolant flow rate is temporarily increased through the at least one heat sink. At a constant engine speed or at an engine speed increasing at maximum 100 revolutions per minute and with reducing engine load, the coolant flow rate is maintained or increased through the at least one heat sink after the load change within a temperature range of 60° C. to 100° C. of the at least one fluid chamber