Flow control device, and control system and control method therefor
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Solution Overview
Problem
The existing coolant reversing devices in electric vehicle thermal management systems, such as motor-driven piston valves, face issues with seal ring deformation and damage, leading to valve blockage and operational failures over time.
Innovation Solution
A flow control device with a housing, valve body, and drive control component, featuring a magnetic element, detection element, and control unit, which uses a stepping motor to rotate the magnetic element and sense magnetic pole changes to detect feedback signals, determining the operation state and preventing stalling through real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a motor-driven piston valve with a rubber seal ring is used to switch coolant flow direction, then the flow control function is achieved, but the seal ring is easily over-deformed or damaged under the squeezing of the movable valve core, leading to valve blockage and operational failures after a period of use
Solution Approach 1:
The patent replaces the traditional motor-driven piston valve mechanism with a magnetic drive system. A magnetic coupling transmits rotational motion from the motor to the valve core without physical contact between the motor shaft and valve core. This eliminates the mechanical squeezing and friction that caused seal ring deformation and damage, thereby improving both reliability and seal durability.
Solution Approach 2:
The patent introduces a magnetic coupling as an intermediary between the motor and valve core. This magnetic coupling transfers rotational motion through magnetic fields rather than direct mechanical contact, serving as a mediator that eliminates the harmful mechanical squeezing forces while maintaining the drive function.
2Reliability
If a traditional piston valve without real-time monitoring is used, then the structure is simpler, but the operation state cannot be detected in real-time, making it difficult to prevent stalling and operational failures
Solution Approach 1:
The patent incorporates a detection element that monitors the rotational position and speed of the valve core in real-time and feeds this information back to the control unit. The control unit processes this feedback to detect abnormal conditions such as stalling or blockage, and can respond by stopping the motor or alerting the operator, thereby preventing operational failures.
Solution Approach 2:
The patent replaces mechanical position indicators with a magnetic detection system. A magnetic marker on the valve core interacts with a magnetic sensor (such as a Hall sensor or magnetoresistive sensor) to provide non-contact, real-time position feedback, enabling reliable stalling detection without adding complex mechanical monitoring mechanisms.
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 solution enhances the detection accuracy and operational reliability of the flow control device, reducing the likelihood of valve blockage and improving the overall performance of the thermal management system by providing real-time feedback and stalling detection.
Implementation Method 1
A magnetic element is assembled with and is fixed relative to the power output unit. A sensing part of the detection element is located within the magnetic field of the magnetic element
Implementation Method 2
The detection element is capable of sensing a magnetic pole change generated by rotation of the magnetic element
Data Source
AI summary
A flow control device for use in a heat exchange system, including: a housing, a movable valve member and a drive control member, the housing being formed to have a mounting cavity, a first interface and a second interface, while the drive control member includes a control unit, a power output unit, a magnetic element and a detection element; the power output unit provides power to the movable valve member, while the detection element and the control unit are electrically connected, and the magnetic element and the power output unit are mutually assembled and oppositely fixed, the power output unit may drive the magnetic element to rotate; the detection element and the magnetic element are oppositely disposed, the detection element being located within the range of the magnetic field of the magnetic element, the detection element may sense a magnetic pole change of the magnetic element.