Mixing Valve Map Self-Calibration for Vehicle Thermal Control
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Solution Overview
Problem
Thermal management systems in vehicles face challenges due to manufacturing tolerances and machine-to-machine variations, requiring multiple maps and controllers to adapt to different vehicle configurations, which is impractical for customizable heavy-duty vehicles.
Innovation Solution
A computer system with processing circuitry that self-adaptively updates the mixing valve map by measuring actual flow ratios based on temperatures and positions, allowing for accurate control without complex networks of flow diverting valves and pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple maps and controllers are used to adapt to different vehicle configurations, then manufacturing precision and adaptability are improved, but device complexity and ease of manufacture deteriorate
Solution Approach 1:
The system performs self-calibration by automatically comparing sensor measurements with map predictions and updating the map data structure without external intervention. This self-service mechanism eliminates the need for manual calibration of multiple maps for different vehicle configurations, resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The patent changes the parameters stored in the map data structure from fixed pre-programmed values to dynamically adjustable values that are automatically corrected through self-calibration. This allows a single map to adapt to different vehicle configurations by modifying its parameters based on actual sensor data, rather than requiring multiple separate maps.
2Measurement precision
If flow meters are incorporated for calibration and mapping, then measurement precision is improved, but device complexity and ease of manufacture deteriorate
Solution Approach 1:
The patent introduces temperature sensors as intermediary measurement devices that indirectly measure flow ratio through thermal principles. Instead of using complex flow meters directly in the fluid path, temperature sensors measure temperature differences caused by mixing, which then serve as proxies for flow ratio calculation, achieving precise measurement without adding complex flow measurement hardware.
Solution Approach 2:
The patent replaces mechanical flow meters with a thermal-based measurement system using temperature sensors. The flow ratio is determined through thermal field measurements and calculations rather than direct mechanical flow measurement, substituting a simpler thermal sensing system for complex mechanical flow measurement devices.
3Adaptability or versatility
If complex networks of flow diverting valves and pumps are used, then adaptability is improved, but device complexity and packaging space deteriorate
Solution Approach 1:
The patent makes the existing mixing valve universal by enabling it to perform adaptive flow control through software-based map updates rather than requiring multiple specialized valves and pumps. The single mixing valve can adapt to different flow requirements by adjusting its operation based on self-calibrated map data, eliminating the need for a complex network of flow-diverting devices.
Solution Approach 2:
The system implements feedback control where temperature sensor measurements are continuously compared with map predictions, and the map is automatically updated based on the differences. This feedback mechanism enables the existing valve to adaptively control flow without requiring additional flow-diverting valves or pumps, achieving adaptability through intelligent control rather than mechanical complexity.
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
Enables robust and accurate control of thermal management systems in vehicles, maintaining performance while simplifying the system architecture and reducing the need for extensive recalibration.
Implementation Method 1
obtain the temperatures of the at least two incoming flows and the temperature of at least one outlet flow 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) for the same mixing valve position; and update the map (312) with the obtained flow ratio.