Multi-Port Valve for High-Low Temp Engine Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high/low temperature water cooling systems for combustion engines fail to address issues such as excessive air density leading to engine knocking and condensate freezing in cold ambient conditions, and prolonged warm-up times in diesel engines, as they lack arrangements to manage coolant flow effectively in these scenarios.
Innovation Solution
Incorporating a multi-port valve that interconnects the high and low temperature cooling circuits, allowing for coolant flow between them, and providing a bypass in the low temperature circuit to enable charge air heating and engine warm-up using hot coolant from the high temperature circuit, while optimizing coolant flow and energy consumption through control of the second coolant pump.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If coolant flow is reduced or cut off in the LT cooling circuit to prevent over-cooling in cold ambient conditions, then energy consumption is reduced, but charge air temperature drops below desirable values leading to engine knocking and condensate freezing
Solution Approach 1:
The patent merges the HT and LT cooling circuits by interconnecting them upstream and downstream of the coolant pump, allowing heat transfer between the circuits. This enables the LT circuit to receive hot coolant from the HT circuit during cold ambient conditions, preventing charge air temperature from dropping too low while avoiding excessive energy consumption by utilizing existing thermal energy in the system.
Solution Approach 2:
The multi-port valve acts as an intermediary control device that regulates coolant flow between the HT and LT circuits. It selectively opens or closes connections to enable or disable heat transfer pathways, allowing the system to adapt coolant distribution based on ambient temperature conditions without requiring complex active control mechanisms.
2Loss of time
If the thermostat is closed entirely during engine start-up to maximize heating speed, then engine warm-up time is reduced, but coolant heating relies solely on the engine itself resulting in prolonged warm-up times for diesel engines
Solution Approach 1:
The patent combines the heating functions of both cooling circuits during engine start-up. The LT circuit, which is typically used for charge air cooling, is repurposed to provide heated coolant to the HT circuit through the interconnection. This dual-circuit heating approach accelerates engine warm-up compared to relying solely on the engine's own heat generation.
Solution Approach 2:
The system uses its own thermal resources to accelerate warm-up. The LT circuit's hot coolant (from normal operation or ambient heat) is redirected to heat the HT circuit during start-up, enabling the system to serve itself rather than requiring external heat sources or extended engine running times.
3Loss of energy
If individual cooling strategies are adopted for HT and LT circuits to minimize heat energy loss, then fuel consumption is reduced, but the system cannot address cold ambient condition problems such as excessive air density and condensate freezing
Solution Approach 1:
The patent makes the cooling system multi-functional by enabling the LT circuit to serve dual purposes: charge air cooling during normal conditions and engine/charge air heating during cold ambient conditions. The interconnection and multi-port valve allow the same circuit to perform opposite thermal functions based on environmental requirements, enhancing system versatility without sacrificing energy efficiency.
Solution Approach 2:
The system dynamically adapts its thermal management strategy based on ambient temperature through the multi-port valve control. In cold conditions, the valve redirects coolant flow to provide heating; in normal conditions, it maintains separate cooling circuits for optimal energy efficiency. This dynamic reconfiguration allows the system to address both energy loss minimization and cold-weather adaptability requirements.
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
The solution effectively prevents engine knocking and condensate freezing by heating charge air and promoting engine warm-up, reducing engine wear and improving performance in cold conditions, while optimizing coolant flow and energy consumption across different operational modes.
Implementation Method 1
allowing for coolant flow between them... using hot coolant from the HT cooling circuit in the LT cooling circuit
Implementation Method 2
providing a bypass in the low temperature circuit to enable charge air heating... charge air heating in cold ambient conditions
Implementation Method 3
a second coolant pump... optimizing coolant flow and energy consumption through control of the second coolant pump
Data Source
Figure 1~2
Figure 3~4
Figure 5~9
AI summary
A high/low temperature water cooling system (1) for a combustion engine (3) comprises a high temperature (HT) cooling circuit (4) for cooling the engine (3) and a low temperature (LT) cooling circuit (11) for cooling a water cooled charge air cooler (WCCAC) (2) for charge air to the engine (3). The HT and LT cooling circuits (4, 11) are interconnected upstream and downstream a coolant pump (10) of the HT cooling circuit (4), the LT cooling circuit (11) having a pump (13) of its own. Further the LT cooling circuit (11) has a LT heat exchanger bypass (21) which is controlled by a multi port valve (18). Said valve (18) enables at least two different operational modes, a heat up mode, in which hot coolant from the HT cooling circuit (4) is used to heat the charge air in extremely cold ambient conditions, and a cooling mode, in which charge air is cooled in a traditional way.