Powertrain Thermal Management with Variable Flow Valves
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Solution Overview
Problem
Conventional coolant systems for automobile powertrains face inefficiencies due to excessive coolant flow under normal conditions and inadequate heat management across varying operating conditions, leading to parasitic energy losses and inefficient use of heat energy.
Innovation Solution
A thermal management system incorporating a coolant pump, first and second control valves, a radiator, a heater core, and a transmission oil heat exchanger, which allows for controlled coolant flow and heat energy distribution to optimize engine and transmission temperatures, utilizing variable flow valves and multiple operating states of the second control valve to direct coolant flow effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high flow rate coolant pump is used to provide high coolant flow under severe conditions, then engine overheating is prevented, but parasitic energy losses increase under normal operating conditions
Solution Approach 1:
The system employs a variable speed coolant pump that dynamically adjusts its operating speed based on real-time thermal conditions. The pump can operate at high speeds during severe conditions to prevent overheating, and at reduced speeds during normal conditions to minimize parasitic energy losses. This dynamic adaptation resolves the contradiction between ensuring adequate cooling capacity and reducing energy consumption during normal operation.
Solution Approach 2:
The system changes the operational parameters of the coolant pump by implementing multiple operating speed levels. Rather than using a single fixed high flow rate, the pump operates at variable flow rates matched to the actual cooling demand. This parameter adjustment allows the system to maintain reliability when needed while reducing energy losses during normal operation.
2Temperature
If coolant flow is increased to maintain proper component temperatures under severe operating conditions, then component temperatures are controlled, but system efficiency decreases due to excessive flow under normal conditions
Solution Approach 1:
The thermal management system dynamically adjusts coolant flow rates based on real-time monitoring of component temperatures and operating conditions. During severe conditions, the system increases coolant flow to maintain proper component temperatures. During normal conditions, it reduces flow to the minimum necessary level, thereby maintaining temperature control while maximizing system efficiency.
Solution Approach 2:
The system incorporates temperature sensors and control logic that enable it to automatically self-regulate coolant flow based on actual thermal conditions. This self-service capability allows the system to optimize its own performance by adjusting flow rates to match demand, eliminating the need for excessive flow and improving overall efficiency.
3Device complexity
If conventional coolant systems are used, then simple structure is maintained, but heat energy utilization is inefficient
Solution Approach 1:
The system recovers waste heat energy from the coolant that would otherwise be discarded to the environment. By incorporating heat exchangers and thermal management components, the system captures and utilizes this waste heat for beneficial purposes such as heating the transmission fluid or warming the engine during cold starts, thereby reducing energy loss while adding only moderate complexity to the system.
Solution Approach 2:
The coolant system is designed to perform multiple functions beyond simple cooling. The same coolant circuit serves both cooling purposes and heat recovery purposes, and the thermal management system can adapt its operation based on whether the engine needs cooling or heating. This multi-functionality improves heat energy utilization without requiring completely separate systems.
4Temperature
If coolant flow is increased during cold start conditions, then proper temperature of internal components is achieved, but parasitic energy losses increase
Solution Approach 1:
The system implements preliminary heating action during cold start conditions by directing coolant flow through the heater core to warm the engine components before full operation begins. This preliminary action reduces the time and energy needed to reach optimal operating temperatures, thereby minimizing parasitic losses associated with extended warm-up periods while still achieving proper component temperatures.
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 system enhances the controllability and efficiency of heat energy management, reducing parasitic losses and optimizing powertrain performance across a range of operating conditions by strategically directing coolant flow and heat exchange, thereby improving overall powertrain efficiency.
Implementation Method 1
a coolant pump that provides fluid, such as an engine coolant, to a plurality of engine and transmission components
Implementation Method 2
much of the thermal energy in the circulating coolant is dissipated to the air by a heat exchanger, such as a radiator
Implementation Method 3
The transmission oil heat exchanger exchanges heat energy between the coolant and a transmission oil
Implementation Method 4
The heater core has an inlet and an outlet
Data Source
AI summary
A vehicle powertrain thermal management system for distributing thermal energy to vehicle powertrain components, including an engine and a transmission. The system for managing heat energy includes a coolant pump, a first control valve, a second control valve, a radiator, a heater core, and a transmission oil heat exchanger. The first control valve has an inlet that is in fluid communication with the engine coolant outlet. The first control valve also has a first control valve outlet. The second control valve has a first inlet, a second inlet, a first outlet, a second outlet and a third outlet. Heat energy produced by the engine is transferred to the radiator through control of the first control valve and to at least one of the heater core, and the transmission oil heat exchanger through the control of the second control valve.