Mixing Valve Flow Ratio Mapping for Stable 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 that adaptively updates the flow ratio map of a mixing valve in thermal management systems by obtaining actual flow ratios based on temperature measurements, allowing for self-adaptive mapping and reducing controller complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pre-programmed maps are used to control flow ratios in thermal management systems, then the control logic is simple and easy to implement, but the system becomes unstable and inaccurate due to manufacturing tolerances, machine-to-machine variations, and changes over time
Solution Approach 1:
The patent implements a feedback mechanism where the control unit continuously monitors actual flow ratios and compares them against target values. Based on deviations detected through temperature measurements and flow ratio calculations, the system automatically adjusts mixing valve positions to correct discrepancies. This closed-loop feedback approach resolves the contradiction by maintaining system stability and accuracy without requiring overly complex pre-programmed maps, as the system adapts dynamically to manufacturing variations and operational changes.
Solution Approach 2:
The thermal management system performs self-calibration and self-adjustment by using its own operational data (temperature measurements from various points in the fluid circuit) to determine actual flow ratios. The control unit calculates deviations from expected behavior and autonomously adjusts valve positions without external intervention. This self-service capability allows the system to compensate for manufacturing tolerances and drift over time, maintaining reliability without increasing controller complexity.
2Adaptability or versatility
If multiple or variable maps are used to account for different vehicle configurations and conditions, then the system becomes more accurate and adaptable, but the controller complexity and validation scope increase significantly
Solution Approach 1:
The patent employs a universal control approach where a single control unit handles multiple vehicle configurations and operating conditions through real-time calculations rather than maintaining separate maps for each scenario. The system calculates actual flow ratios based on temperature measurements and adjusts valve positions dynamically to achieve target flow ratios regardless of the specific vehicle configuration. This multi-functional capability resolves the contradiction by providing system adaptability without requiring multiple specialized maps, thereby avoiding the associated complexity and validation burden.
Solution Approach 2:
The system transitions from static pre-programmed maps to dynamic real-time adjustment. The control unit continuously calculates actual flow ratios based on current operating conditions and adjusts valve positions dynamically to maintain accuracy across different vehicle configurations and operational states. This dynamic approach provides the adaptability of multiple maps while using a single unified control logic, thereby reducing controller complexity and validation scope.
3Measurement precision
If flow meters are incorporated to measure actual flow ratios accurately, then the system achieves precise control, but the cost and practicality decrease for production applications
Solution Approach 1:
The patent uses temperature measurements from existing sensors in the thermal management system as an intermediary to infer actual flow ratios. Instead of directly measuring flow with expensive flow meters, the system calculates flow ratios based on temperature differences and heat transfer principles. This intermediary approach achieves the measurement precision needed for accurate control while avoiding the cost and complexity of incorporating flow meters in production vehicles.
Solution Approach 2:
The system replaces mechanical flow measurement devices (flow meters) with a thermal-based calculation approach. By measuring temperatures at various points in the fluid circuit and applying heat transfer equations, the system derives actual flow ratios without requiring direct mechanical flow measurement. This substitution maintains measurement precision while significantly improving ease of manufacture and production practicality, as it uses existing thermal sensors rather than adding expensive flow measurement hardware.
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 provides accurate and robust control of thermal management systems, enhancing performance and reducing instability while maintaining simplicity, especially in complex and customizable heavy-duty vehicle applications.
Implementation Method 1
a mixing valve being configured to provide a specific ratio between at least two incoming flows based on a position of the mixing valve
Implementation Method 2
obtain the temperatures of the at least two incoming flows and the temperature of at least one outlet flow of the mixing valve
Data Source
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AI summary
A computer system is provided, comprising processing circuitry configured to access a map (312) representing the flow ratio as a function of a position of a mixing valve (260) being configured to provide a specific ratio between at least two incoming flows based on a position of the mixing valve (260), said mixing valve (260) forming part of a thermal management system (200); obtain the temperatures of the at least two incoming flows and the temperature of at least one outlet flow of the mixing valve (260); obtain the actual flow ratio for at least one position of the mixing valve (260) based on the obtained temperatures; determine that the obtained flow ratio is different from the corresponding value of the map (312) and with the same mixing valve position; and update the map (312) with the obtained flow ratio, for the same mixing valve position.