Hydrodynamic Clutch Thermal Management via Predictive Control
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Solution Overview
Problem
Dynamic changes in operating or load states can lead to rapid thermal overload in hydrodynamic couplings, causing emergency shutdowns upon restart due to insufficient cooling, resulting in system downtime and reduced availability.
Innovation Solution
A method that calculates an expected temperature profile based on new load or operating conditions, issuing warnings or stop signals when the calculated temperature exceeds a maximum, and incorporating a cooling wait period before restart to ensure the hydrodynamic clutch does not exceed permissible temperatures, while also considering ambient temperature and temperature gradients for accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the system is restarted after thermal overload shutdown, then the drive train can resume operation, but thermal overload occurs very quickly again due to temperature rise during startup
Solution Approach 1:
The controller performs a preliminary calculation of the expected temperature profile before allowing system restart. This pre-calculation determines whether the startup conditions will lead to thermal overload, enabling preventive action before the actual startup occurs. The controller compares the calculated temperature profile against maximum temperature thresholds to decide whether to permit restart, issue warnings, or deny restart authorization.
2Reliability
If the maximum temperature is exceeded during operation, then the system shuts down to protect the hydrodynamic coupling, but this causes system downtime and reduced availability
Solution Approach 1:
The controller calculates the expected temperature profile in advance before allowing startup or load changes. By predicting whether the temperature will exceed maximum thresholds, the system can prevent thermal overload before it occurs, avoiding shutdowns and maintaining continuous operation. This predictive approach eliminates the need for reactive shutdowns while still providing thermal protection.
3Measurement precision
If a non-contact temperature measuring device is used, then temperature can be measured directly in the operating medium with quick detection, but the system lacks intelligence to predict future temperature states
Solution Approach 1:
The controller continuously receives temperature measurements from the non-contact measuring device and uses this feedback to update and recalculate the temperature profile. The actual temperature values are compared against the calculated profile to verify accuracy and adjust predictions. This feedback loop enables the system to maintain an intelligent, adaptive understanding of thermal behavior while leveraging the precision of non-contact measurement.
Solution Approach 2:
The system replaces complex mechanical temperature sensing with non-contact optical or electromagnetic measurement. The temperature measuring device operates without physical contact with the operating medium, using radiation or field-based detection methods. This substitution provides accurate temperature data while simplifying the physical structure and enabling faster response times.
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 prevents premature shutdowns and ensures the hydrodynamic clutch operates within safe temperature limits, reducing downtime and improving system availability by anticipating and managing temperature changes during state changes.
Implementation Method 1
a non-contact temperature measuring device (6), in particular a radiation thermometer, is provided in the drive train (1)
Implementation Method 2
a hydrodynamic clutch (2), in particular a turbo clutch (VTK), via which a work machine (5) is driven by a primary drive machine (3)
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
The invention relates to a method for operating a drive train, comprising: a primary drive machine; a working machine driven by the primary drive machine; a hydrodynamic clutch between the drive machine and the working machine; and a temperature detection device for detecting the temperature in the hydrodynamic clutch. At least in the case of a change in the load state and/or operating state of the drive train, the temperature of the hydrodynamic clutch is detected at the time of the change. An expected temperature progression is calculated on the basis of the detected temperature and the new load state and/or the new operating state of the drive train. A warning and/or a stop signal for the primary drive machine is output if the temperature of the calculated temperature progression exceeds a specified maximum temperature within the expected duration of the new load state and/or of the new operating state.