Predictive Oil Cooling Circuit with Bypass Control
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Solution Overview
Problem
Existing oil flow control devices in vehicles, such as agricultural machines, suffer from inefficient cooling at low temperatures, leading to energy losses and potential malfunctions, and are often costly and inflexible in responding to temperature changes.
Innovation Solution
A predictive oil cooling arrangement with separate transmission and hydraulic oil cooling circuits, interconnected by a heat exchanger, uses bypass means and control means to manage oil flow based on temperature signals from sensors, ensuring optimal cooling capacity and protecting the cooler from excessive pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bypass valve is used to protect the cooler from excessive pressure, then the cooler is protected from bursting, but oil continues to flow through the cooler at low temperatures causing unwanted cooling and energy losses
Solution Approach 1:
The patent applies a thermostatically-controlled oil temperature regulator (OETR) that dynamically adjusts the bypass valve position based on oil temperature. The OETR has multiple intermediate positions that gradually open or close the bypass branch as temperature changes, enabling adaptive flow control that protects the cooler while preventing unwanted cooling at low temperatures.
Solution Approach 2:
The patent changes the physical state parameter (temperature) to control the bypass valve. The OETR responds to temperature changes by adjusting valve position, transitioning the system from a static pressure-based bypass control to a dynamic temperature-based control that optimizes both protection and energy efficiency.
2Loss of energy
If a thermostatically-controlled oil temperature regulator (OETR) is used to control oil flow, then oil warming is improved, but the OETR represents a large and expensive component with slow response
Solution Approach 1:
The patent segments the oil cooling system into two separate circuits: a first transmission oil cooling circuit and a second hydraulic oil cooling circuit. Each circuit has its own pump, tank, and temperature sensing means. This segmentation allows independent optimization of each circuit's thermal management without requiring a single large, complex OETR component.
Solution Approach 2:
The patent introduces a heat exchanger as an intermediary between the two separate oil cooling circuits. The heat exchanger enables thermal energy transfer between the circuits, allowing heat from the hydraulic oil to warm the transmission oil and vice versa, providing efficient temperature control without requiring a large OETR in each circuit.
3Reliability
If oil flows through the cooler at low temperatures, then the cooler provides continuous protection, but the constant cooling prevents efficient oil warming and causes valve malfunction and pump cavitation
Solution Approach 1:
The OETR dynamically adjusts the bypass valve position based on real-time temperature feedback, transitioning the system from static continuous cooling to dynamic conditional cooling. At low temperatures, the bypass is open allowing oil to bypass the cooler for efficient warming. As temperature increases, the bypass gradually closes to provide cooling when needed.
Solution Approach 2:
The system uses temperature as a control parameter to switch between different operating modes. The OETR monitors oil temperature and adjusts valve position accordingly, changing the flow regime from bypass-dominated at low temperatures to cooler-dominated at high temperatures, preventing valve malfunction and pump cavitation.
4Device complexity
If a single oil cooling circuit is used, then the system is simple, but the oil reacts sluggishly to temperature changes and switching response cannot be adapted to different operating conditions
Solution Approach 1:
The patent divides the oil cooling system into two separate circuits, each with its own pump and temperature sensing means. This segmentation allows each circuit to respond independently to temperature changes in its specific operating conditions, improving overall system adaptability while maintaining relatively simple individual circuit designs.
Solution Approach 2:
The heat exchanger serves multiple functions: it cools the transmission oil, warms the hydraulic oil, and enables thermal energy recovery between circuits. This multi-functionality allows the system to adapt to different operating conditions and temperature requirements of different hydraulic consumers without requiring complex separate cooling 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 solution enhances cooling efficiency, reduces the risk of cooler damage, and accelerates oil warming by dynamically adjusting oil flow through the cooler, thereby improving system performance and reducing energy losses.
Implementation Method 1
the two circuits being thermally interconnected by a heat exchanger through which both circuits flow separately
Data Source
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AI summary
The present invention relates to a device for controlling the flow through an oil cooler, comprising at least one oil tank (1) and at least one oil pump (7), a means (12) for determining the oil temperature, a cooling means (4) for cooling the oil, wherein said means (4) can be circumvented via a bypass (9), as well as an engine control unit (13). The device has a means (11), controllable via the engine control unit (13) by which the oil flow can be controlled via the means for cooling (4) and/or via the bypass (9). The device further comprises a means for predictively controlling the oil flow via the cooling means(4) and/or via the bypass (9).