Modular Coolant Flow Inserts for Flexible Vehicle Cooling
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Solution Overview
Problem
Current cooling systems for vehicles and stationary systems face challenges in optimizing energy efficiency and compliance with future emissions standards, particularly in reducing energy consumption for coolant pumps and warm-up phases after engine startup.
Innovation Solution
A modular cooling system design featuring interchangeable inserts that adjust coolant flow, allowing for flexible configuration and reduced power consumption by optimizing the flow cross-section, enabling the system to adapt to different cooling requirements and legal standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional cooling system with fixed coolant flow paths is used, then the system structure is simple, but the system cannot adapt to different cooling requirements and cannot reduce pump energy consumption
Solution Approach 1:
The cooling system is segmented into multiple coolant volume regions (first, second, third, fourth regions) with separate controllable flow paths. Each region can be independently managed through dedicated control valves, allowing selective cooling of different components based on thermal requirements without requiring a completely complex reconfiguration of the entire system.
Solution Approach 2:
The system employs dynamically adjustable flow paths through control valves (first, second, third, fourth control valves) that can modify coolant distribution in real-time. This dynamic capability allows the system to adapt to varying thermal loads and operational conditions while maintaining a relatively simple base structure that only becomes complex when adaptability is activated.
2Use of energy by moving object
If coolant flow is optimized to reduce pump power consumption, then energy efficiency improves, but the system loses flexibility in distributing coolant to different components
Solution Approach 1:
Control valves are strategically positioned to dynamically adjust coolant flow distribution. The first control valve regulates flow to the first coolant volume region, the second control valve manages flow to the second region, the third control valve controls flow through the third region, and the fourth control valve manages flow through the fourth region. This dynamic control enables the system to optimize pump power consumption by directing coolant flow only to regions requiring cooling, while preserving full flexibility to distribute coolant to any combination of components as needed.
Solution Approach 2:
The system changes flow parameters (volume flow rate, pressure) through controlled adjustment of valve openings. By modifying these parameters dynamically, the system can reduce pump power consumption during low-demand periods while maintaining the capability to provide full coolant distribution flexibility when thermal conditions require it.
3Reliability
If separate cooling circuits are provided for different components, then cooling performance is optimized, but production costs and component count increase
Solution Approach 1:
The system merges multiple cooling circuit functions into a single integrated cooling system with shared coolant supply and return lines. Instead of providing completely separate cooling circuits for each component, the invention combines them into one system with internal flow management through control valves and designated coolant volume regions, achieving optimized cooling performance while reducing production costs associated with multiple independent circuits.
Solution Approach 2:
The single cooling system is designed with multi-functionality to serve multiple components (engine, cylinder head, intercooler, EGR cooler) through a unified architecture. The system can selectively direct coolant to different components or regions based on operational needs, providing the cooling performance of separate circuits while avoiding the increased production costs and component count that would result from truly separate systems.
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 reduces production and component costs while enhancing flexibility to meet market and legal requirements, lowering coolant pump power consumption by optimizing flow, and improving thermal management efficiency.
Implementation Method 1
The receiving device is designed to selectively receive or omit an interchangeable insert for blocking, limiting and/or adjusting a coolant volume flow through the direct fluid connection
Implementation Method 2
a drive device with at least one cooling channel through which the coolant can flow for cooling the drive device
Implementation Method 3
a first coolant volume region which is arranged downstream of the at least one cooling channel for collecting the coolant from the at least one cooling channel and has a plurality of outlets for distributing the coolant
Implementation Method 4
a second coolant volume area, which is arranged downstream of the first coolant volume area, the coolant distributed by the first coolant volume area at least partially collects and has an outlet for recirculating the coolant
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a cooling system (10) for conducting a coolant for vehicles or stationary plant. The cooling system (10) has a holding device (36) which is arranged in a direct fluid connection between a first coolant volume region (K1) and a second coolant volume region (K2) and is designed for, selectively, the holding or the omission of a changeable insert (38) for blocking, limiting and/or setting a coolant volumetric flow through the direct fluid connection. The cooling system (10) allows a needs-based, flexible configuration of the cooling system (10) to be created by varying only one component (i.e. the changeable insert (38)), in which configuration different cooling system components can be combined as desired to meet requirements.