Mixing Valve Flow Ratio Calibration for Vehicle Thermal Control
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Solution Overview
Problem
Thermal management systems in vehicles face challenges due to deviations from pre-programmed maps caused by manufacturing tolerances, machine-to-machine variations, and changes over time, leading to instability and complex controller requirements, especially in heavy-duty vehicles with customizable configurations.
Innovation Solution
A computer system with processing circuitry that adapts the flow ratio mapping of mixing valves by obtaining actual temperatures and flow ratios, updating the map to match real-time conditions, allowing for self-adaptive control of thermal management systems, reducing controller complexity, and enhancing accuracy and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pre-programmed maps are used to control flow ratios in thermal management systems, then the system operation is simple, but the accuracy deteriorates due to deviations from manufacturing tolerances, machine-to-machine variations, and changes over time
Solution Approach 1:
The system performs self-calibration by automatically detecting actual flow ratios through temperature measurements and updating its own control maps without external intervention. The control unit compares measured flow ratios with map values and autonomously updates the map data to match actual system behavior, eliminating the need for manual recalibration while maintaining high accuracy across manufacturing variations and operational changes.
Solution Approach 2:
The system implements feedback control by continuously measuring actual flow ratios using temperature sensors and comparing them against pre-programmed map values. The control unit uses this feedback to identify deviations and update the control maps accordingly, ensuring that the system adapts to manufacturing tolerances, machine-to-machine variations, and temporal changes while maintaining optimal performance.
2Adaptability or versatility
If multiple or variable maps are used to accommodate different vehicle configurations, then the adaptability improves, but the device complexity increases due to multiple controllers and validation requirements
Solution Approach 1:
The control unit is designed to be universal and adaptable to different vehicle configurations through self-calibration. Instead of requiring separate controllers or pre-configured maps for each configuration, the single control unit automatically adapts to any configuration by measuring actual flow ratios and updating its control maps accordingly, providing multi-functionality without increasing hardware complexity.
Solution Approach 2:
The control maps are made dynamic and updateable rather than static and fixed. The system continuously adapts its control parameters based on actual measurements and operational conditions, allowing it to accommodate different vehicle configurations and changes over time without requiring multiple pre-programmed maps or complex switchable controller configurations.
3Measurement precision
If flow meters are incorporated for accurate flow measurement, then the measurement precision improves, but the ease of manufacture deteriorates due to practicality concerns in production
Solution Approach 1:
The system replaces mechanical flow meters with a thermal measurement-based flow ratio detection method. By measuring temperatures at different points in the fluid system and using these thermal measurements to calculate flow ratios, the system achieves accurate flow measurement without requiring physical flow meters, thereby simplifying manufacturing and production while maintaining measurement precision.
Solution Approach 2:
The system uses temperature measurements as an intermediary to indirectly determine flow ratios. Instead of directly measuring flow with complex instruments, the system measures temperature differences caused by heat transfer in the fluid, which serves as a proxy for flow rate. This intermediary approach simplifies the measurement system while maintaining accuracy.
Data Source
AI summary
A computer system has processing circuitry to access a map representing the flow ratio as a function of a position of a mixing valve being configured to provide a specific ratio between at least two incoming flows based on a position of the mixing valve. The mixing valve forms part of a thermal management system. The system obtains the temperatures of the at least two incoming flows and the temperature of at least one outlet flow of the mixing valve; obtains the actual flow ratio for at least one position of the mixing valve based on the obtained temperatures; determines that the obtained flow ratio is different from the corresponding value of the map and with the same mixing valve position; and updates the map with the obtained flow ratio, for the same mixing valve position.