Cooling Fan Controller Using Fluid-Air Temperature Difference
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cooling fan control systems for working machinery, such as hydraulic shovels, inadequately account for engine load when determining the revolving speed of cooling fans, leading to potential overheating or excessive noise due to insufficient or excessive fan rotation.
Innovation Solution
A cooling fan controller that calculates the difference between fluid and air temperatures to set the target revolving speed of the cooling fan, using reference differences and temperatures to interpolate and set optimal speeds, ensuring sufficient cooling ability while minimizing noise and fuel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the revolving speed of the cooling fan is increased to improve cooling ability, then the cooling performance is improved, but the noise and rotational resistance increase
Solution Approach 1:
The cooling fan control system dynamically adjusts the fan speed based on real-time temperature conditions. The controller continuously monitors temperatures and modifies the fan revolving speed accordingly, transitioning from static fixed-speed operation to dynamic variable-speed control, thereby optimizing cooling performance while minimizing noise during low-demand periods
Solution Approach 2:
The system changes the operating parameter (revolving speed) of the cooling fan based on detected temperature conditions. By varying the speed parameter according to actual cooling needs, the system achieves efficient cooling when necessary while reducing noise and energy consumption when cooling demand is low
2Reliability
If the revolving speed of the cooling fan is increased to ensure cooling ability during high load, then the engine is prevented from overheating, but the fuel consumption increases
Solution Approach 1:
The control system implements feedback control by continuously detecting temperatures and using this information to adjust fan speed. The controller receives temperature feedback from sensors and modulates the fan operating speed相应地, ensuring reliable cooling during high-load conditions while avoiding unnecessary energy consumption during low-demand periods
Solution Approach 2:
The system transitions from static fixed-speed operation to dynamic variable-speed control, adjusting the fan revolving speed in real-time based on actual cooling requirements. This dynamic adjustment ensures cooling reliability when needed while minimizing fuel consumption during normal operating conditions
3Temperature
If the cooling fan operates at high speed continuously to maintain cooling ability, then the engine temperature is controlled, but the noise and fuel consumption increase unnecessarily during low load
Solution Approach 1:
The system applies partial action by operating the cooling fan at reduced speeds during periods when full cooling capacity is not required. Instead of maintaining constant high-speed operation, the fan provides sufficient cooling at lower speeds during low-load conditions, eliminating unnecessary noise while maintaining adequate temperature control
Solution Approach 2:
The control system dynamically adjusts fan operating speed based on real-time temperature and load conditions. During low-load periods, the fan operates at reduced speeds, while during high-load or high-temperature conditions, the fan increases speed to provide adequate cooling, thereby minimizing noise during normal operation
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
The controller finely controls the revolving speed of the cooling fan based on engine load, optimizing cooling performance and reducing noise and fuel consumption by ensuring the fan operates only as necessary, thus preventing overheating and excessive noise.
Implementation Method 1
a cooling fan that introduces outside air as a cooling wind to cool a fluid (hydraulic operating oil or engine-cooling water) to be cooled
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
A cooling fan controller is provided for controlling the revolving speed of a cooling fan that introduces outside air as a cooling wind to cool a fluid being cooled; in order to optimally control the revolving speed if the cooling fan in accordance with load, and to suppress noise caused by the cooling fan. The cooling fan controller includes a fluid temperature sensor 40 for sensing a temperature To of the fluid, an air temperature sensor 30 for sensing a temperature Ta of the air, and a control means 20 for calculating a difference between the fluid temperature To sensed by the fluid temperature sensor 40 and the air temperature Ta sensed by the air temperature sensor 30, and setting a target revolving speed Nf of the cooling fan in accordance with a magnitude of the calculated difference.