Hybrid Powertrain Cooling System with Dynamic Pump Control
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Solution Overview
Problem
Current cooling systems for hybrid traction chains in motor vehicles face inefficiencies due to temperature differences between heat engines and electric traction assemblies, leading to continuous pump operation and increased pressure drops, which affect fuel consumption and carbon dioxide emissions.
Innovation Solution
A cooling system with a main circuit for the heat engine and a secondary circuit for the electric traction assembly, where hydraulic pumps are controlled based on vehicle dynamics, such as speed, steering angle, and road slope, to optimize heat transfer fluid flow rates and temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a common cooling circuit is used for the heat engine and electric traction assembly, then the device complexity is reduced, but the temperature control precision for different components deteriorates
Solution Approach 1:
The cooling circuit is segmented into a main circuit for the heat engine and a secondary circuit for the electric traction assembly, with the possibility to connect or disconnect them. This allows independent temperature control for each component while using a unified pump system, resolving the contradiction between system simplicity and temperature control precision.
Solution Approach 2:
The system dynamically adjusts the connection state between the main and secondary circuits based on operating conditions. The secondary circuit can be connected to the main circuit when cooling demand is high, or disconnected when independent temperature control is needed, providing adaptive temperature management without increasing structural complexity.
2Reliability
If the circulation pump operates continuously to ensure adequate cooling, then the reliability of cooling is improved, but the energy consumption increases
Solution Approach 1:
The circulation pump operates periodically rather than continuously, adjusting its operation based on the cooling demands of the heat engine and electric traction assembly. The pump activates when cooling is needed and rests when temperature levels are acceptable, maintaining cooling reliability while significantly reducing energy consumption.
Solution Approach 2:
The system incorporates temperature sensors and control logic that monitor the thermal state of the heat engine and electric traction assembly, providing feedback to the pump control. This enables the pump to operate only when and where cooling is actually needed, optimizing the balance between cooling reliability and energy consumption.
3Temperature
If the radiator of the second cooling circuit is placed in front of the first radiator, then the cooling performance of electric components is improved, but the pressure drop of cooling air increases
Solution Approach 1:
Instead of arranging radiators in a single linear sequence (one in front of the other), the system uses spatial distribution and alternative positioning strategies. The second radiator can be positioned alongside or in a different spatial arrangement relative to the first radiator, maintaining effective cooling airflow paths while reducing cumulative pressure drops.
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 enhances cooling efficiency, reduces fuel consumption, and minimizes carbon dioxide emissions by dynamically adjusting pump flow rates according to vehicle conditions, ensuring optimal performance of both heat engines and electric motors.
Implementation Method 1
each of the circuits comprising a radiator capable of cooling the heat transfer fluid by heat exchange with an air flow
Data Source
Figure 1
Figure 2
AI summary
A cooling system for a hybrid powertrain of a motor vehicle comprising a internal combustion engine (2) and an electric traction assembly (3), comprising a main circuit (10) that can be traversed by a coolant in order to cool the internal combustion engine (2) to a first temperature level and a secondary circuit (20) that can be traversed by a coolant to cool the electric traction assembly (3) to a second temperature level, lower than the first level, each of the circuits (10 and 20) comprising a radiator (11 and 21) capable of cooling the coolant by means of heat exchange with an air flow, at least one hydraulic pump (12, 22, 23 and 24) for circulating the coolant in the coolant circuits (10 and 20), and one electronic control unit (30) capable of controlling the hydraulic pumps (12, 22, 23 and 24). The control unit (30) comprises a module for recovering information on the dynamics of the vehicle and a module for controlling the flow from the hydraulic pumps (12, 22, 23 and 24) on the basis of that information.