Multi-Radiator Cooling Circuit With Pressure-Switched Flow Split
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Solution Overview
Problem
Existing cooling systems for fuel cell electric vehicles (FCEVs) struggle to manage high heat loads during high load conditions, often requiring complex and costly multiple radiator setups with increased energy consumption and failure risks, which are not suitable for heavy-duty commercial applications.
Innovation Solution
A cooling system with a main circuit line and an auxiliary circuit line, featuring a pressure valve that passively switches between states based on working pressure to distribute coolant flow between multiple heat exchangers, minimizing energy losses and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single radiator is used for cooling, then the system complexity is low, but the cooling capacity is insufficient during high load conditions
Solution Approach 1:
The cooling system is segmented into a main cooling circuit and an auxiliary cooling circuit, allowing independent operation of each circuit. The main circuit handles normal cooling requirements while the auxiliary circuit provides additional cooling capacity during high load conditions, resolving the contradiction between system simplicity and cooling performance.
Solution Approach 2:
The system dynamically switches between single-radiator operation and dual-radiator operation based on cooling demand. A control unit activates the auxiliary circuit and three-way valve only when high cooling capacity is required, allowing the system to adapt its complexity to actual needs rather than maintaining fixed high complexity.
2Temperature
If multiple radiators are used to increase cooling capacity, then the temperature management improves, but the system complexity and control requirements increase
Solution Approach 1:
A three-way valve acts as an intermediary component that automatically directs coolant flow between the main radiator and auxiliary radiator based on temperature sensor feedback. This intermediary mechanism simplifies control by using passive flow distribution rather than requiring active control of multiple valves.
Solution Approach 2:
The auxiliary cooling circuit includes its own pump and temperature sensor that autonomously monitor and regulate auxiliary radiator operation. This self-service capability reduces the burden on the main control system, allowing independent operation of the auxiliary circuit and simplifying overall control architecture.
3Temperature
If multiple radiators with complex control are used, then the cooling capacity increases, but the energy consumption and failure risk increase
Solution Approach 1:
The auxiliary cooling circuit operates partially only when high cooling capacity is required, rather than continuously. The control unit monitors temperature and activates the auxiliary pump and valve only during high load conditions, reducing energy consumption compared to having the auxiliary system always active.
Solution Approach 2:
The auxiliary pump is designed as a simple, reliable component that can be easily replaced if needed, rather than a complex high-efficiency pump. This approach prioritizes reliability and ease of maintenance over maximum efficiency, reducing failure risk and associated energy losses from system downtime.
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 effectively manages heat loads by adaptively distributing coolant flow without complex control strategies, reducing energy consumption and component failure risks, while maintaining reliable cooling performance.
Implementation Method 1
comprising a pump for pressurizing the main circuit line at a working pressure to generate a flow of coolant from the component towards the main heat exchanger
Implementation Method 2
The first auxiliary circuit line comprises a pressure valve that is passively operable by the pump adapting the working pressure in the main circuit line
Implementation Method 3
a main heat exchanger... a first auxiliary heat exchanger
Data Source
Figure 1
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AI summary
A commercial vehicle (10), comprising an electric drive unit (100) and a cooling system (200). The cooling system comprises a main circuit line (210) with a pump (212) for pressurizing the main circuit line at a working pressure. An auxiliary circuit line (220) extends from the main circuit line downstream of the pump towards a first auxiliary heat exchanger (221), and comprises a pressure valve (213) that is passively operable between a first state and a second state by the pump adapting the working pressure in the main circuit line. In response to a temperature of the electric drive unit exceeding a temperature threshold, the pump increases the working pressure for thereby operating the pressure valve to switch from the first state to the second state.