Active Piston Pressurization for Engine Cooling Circuit
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Solution Overview
Problem
Conventional cooling systems for internal combustion engines rely on indirect and slow pressurization, which is not controllable and dependent on the coolant circulation pump and engine heat, making it inefficient, especially at cold engine starts.
Innovation Solution
A direct pressurization system using an auxiliary pressurization assembly with a cylinder and piston, actuator, and electronic control unit, independent of the coolant circulation pump, to control pressure in the cooling circuit, allowing for faster and more controlled pressurization, and including a three-way valve for coolant management and pressure regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If indirect pressurization through expansion tank is used, then the system structure is simple, but the pressurization speed is slow and uncontrollable
Solution Approach 1:
The invention extracts the pressurization function from the passive expansion tank system and implements it through an active piston-cylinder assembly. The piston is directly coupled to the cooling circuit, allowing active control of pressurization speed and pressure levels, thereby resolving the contradiction between simple structure and controllable pressurization speed.
Solution Approach 2:
The invention replaces the passive mechanical expansion tank system with an active mechanically-controlled piston-cylinder system. The piston's displacement is controlled by a control unit that receives signals from pressure sensors, enabling precise control of pressurization speed and pressure, thus overcoming the limitations of indirect pressurization.
2Ease of operation
If indirect pressurization through expansion tank is used, then the system is passive, but the pressurization is not controllable
Solution Approach 1:
The invention implements a feedback control system where pressure sensors continuously monitor the pressure in the cooling circuit and the piston-cylinder assembly. The control unit receives these pressure signals and adjusts the piston's displacement accordingly, enabling precise control of pressure levels and resolving the contradiction between passive operation and controllable pressurization.
Solution Approach 2:
The invention introduces dynamic control to the pressurization system through the piston-cylinder assembly. The piston's position and displacement are actively controlled based on real-time pressure feedback, transforming the passive system into a dynamic one that can precisely regulate pressure according to operating conditions.
3Reliability
If indirect pressurization is used, then the system depends on coolant circulation pump and engine heat, but pressurization cannot be achieved at cold engine starts
Solution Approach 1:
The invention enables preliminary pressurization of the cooling circuit before the engine reaches operating temperature. The piston-cylinder assembly can actively pressurize the circuit at cold starts, ensuring proper pressure levels are established in advance, thereby improving reliability and adaptability across different operating conditions.
Solution Approach 2:
The piston-cylinder assembly serves multiple functions: it provides active pressurization, controls pressure levels, and can operate independently of engine heat or coolant circulation pump status. This multi-functionality resolves the contradiction by enabling reliable pressurization across all operating conditions, including cold starts.
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 efficient and controlled pressurization of the cooling circuit, independent of engine activation, ensuring proper pressurization at cold starts and minimizing pressure peaks, with the ability to refill and adjust coolant levels based on operating conditions.
Implementation Method 1
the displacement of the piston varies the pressure inside the cooling circuit itself
Implementation Method 2
the piston is provided of an elastic buffer to minimize pressure peaks in the cooling circuit
Data Source
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AI summary
Cooling circuit of an internal combustion engine (ICE) comprising a pump (P) to circulate cooling coolant, a radiator (R) suitable to disperse heat produced by the internal combustion engine in the ambient, at least a first pipe (P1) to convey coolant from the internal combustion engine towards the radiator and at least another pipes (P2) connecting the radiator with the pump, the circuit further comprising a cylinder (C)/piston (P) assembly (CPA) defining a chamber (CH) suitable to be hydraulically connected with said second pipe (P2), an actuator (a) connected to said piston in order to control its displacement in said cylinder, by varying said chamber volume, a pressure sensor (PR) in hydraulic communication with said chamber and an electronic control unit (ECU) coupled with said pressure sensor and with said actuator and configured to control said actuator in order to maintain a pressure measured by said pressure sensor above a predetermined threshold.