Integrated Gearbox Oil Heat Exchanger With Shape Memory Bypass
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Solution Overview
Problem
Existing heat exchange systems for vehicles, particularly in gearbox oil cooling, face challenges with slow thermal actuator response times leading to hysteresis and lubrication performance issues, and require large installation spaces due to bulky thermal actuators and complex piping arrangements.
Innovation Solution
A heat exchange device incorporating a thermostatic assembly with a shape memory alloy spring and return spring, allowing for fast thermal response and compact design, where the shape memory alloy spring activates above a predetermined temperature to redirect fluid flow through a heat exchange passage, and deactivates below it to use a bypass passage, reducing the need for large thermal actuators and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional thermal actuators are used to control fluid flow paths, then the heat exchange system can regulate temperature, but the response time is slow causing hysteresis and reduced lubrication performance
Solution Approach 1:
The patent changes the material parameter of the actuator from traditional thermal expansion materials to shape memory alloy, which exhibits superelasticity and rapid thermal response characteristics. This material parameter change enables the actuator to respond quickly to temperature changes, eliminating hysteresis and improving lubrication performance by timely redirecting fluid flow when overheating occurs
Solution Approach 2:
The patent replaces the traditional mechanical thermal actuator system with a shape memory alloy-based actuator that utilizes phase transformation mechanics. This substitution eliminates the slow thermal mass heating/cooling cycle of traditional actuators, providing rapid response to temperature changes and immediate control of the thermostatic valve for optimal lubrication
2Reliability
If bulky thermal actuators and complex piping arrangements are used, then the heat exchange system can function properly, but large installation spaces are required
Solution Approach 1:
The patent merges the thermostatic valve assembly with the heat exchanger body into an integrated unit. The shape memory alloy actuator is positioned within the heat exchanger structure, and the bypass passage is incorporated directly into the heat exchanger body. This merging eliminates the need for separate bulky actuators and complex external piping, achieving compact installation while maintaining full heat exchange functionality
Solution Approach 2:
The patent employs a nested structure where the thermostatic valve is embedded within the heat exchanger body. The shape memory alloy actuator is housed inside the valve assembly, and the bypass passage is integrated into the heat exchanger's internal structure. This nesting arrangement minimizes the overall footprint and installation space while preserving all necessary heat exchange and temperature control functions
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 solution provides rapid temperature regulation with minimal space requirements, enhancing transmission performance and safety by reducing hysteresis and simplifying installation, while maintaining efficient cooling of gearbox oil.
Implementation Method 1
a shape memory alloy spring (12), and a valve sleeve (11)... The shape memory alloy spring (12) is made of a memory alloy material... In a case that the temperature is greater than or equal to the predetermined temperature, the elastic potential energy of the shape memory alloy spring (12) is activated
Implementation Method 2
a return spring (13)... under the action of the return spring (13), the valve sleeve (11) is at a first position... under the action of the elastic force difference between the shape memory alloy spring (12) and the return spring (13), the valve sleeve (11) slides to a second position
Implementation Method 3
a heat exchanger body and a thermostatic assembly... The heat exchanger body includes a heat dissipation assembly (21), a fluid inlet (2a), a fluid outlet (2b), a heat exchange passage (2f)... so as to maintain the temperature of the gearbox oil within a certain working temperature range
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A heat exchange device, comprising a heat exchanger main body (2) and a temperature regulation assembly (1); when the temperature of an oil that flows into a valve cavity is higher than or equal to a preset temperature, the elastic potential energy of a memory spring (12) of the temperature regulation assembly (1) is activated, and the oil enters a heat exchange channel (2f) for heat exchange; otherwise, the oil directly flows out of the heat exchanger main body (2) by means of a bypass channel (2e) without passing through a heat dissipation assembly (21); the thermal reaction of the memory spring (12) is fast and response time is short, greatly improving the operating performance and usage safety of a transmission; moreover, the memory spring (12) is small in size, and has higher installation stability, while cooperative use with other parts is not necessary, thus simplifying the structure of the temperature regulation assembly (1), and greatly reducing the size of the temperature regulation assembly (1); the temperature regulation assembly (1) may be installed at the position of a fluid inlet of a plate heat exchanger, the two being integrated into a comprehensive design, and thus on-site installation is not required, increasing installation efficiency, greatly reducing the space occupied in a vehicle, and being beneficial in optimizing overall vehicle design.