Segmented Cooling Module for Engine Electronics
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Solution Overview
Problem
Existing solutions for protecting electronic components from high temperatures in diesel engine EGR systems, such as liquid cooled internal chambers and double-walled enclosures, are either expensive or insufficiently effective in managing heat loads.
Innovation Solution
A cooling module composed of thermally conductive panels with integral tubular coolant passages, forming an enclosure with open sides and ceiling to provide active and passive cooling, shielding electronic components from engine-generated heat through conduction, convection, and radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooled internal chambers are used to protect electronic components, then temperature protection is improved, but manufacturing cost increases
Solution Approach 1:
The cooling module is divided into multiple separate panels (front panel, rear panel, first side panel, second side panel) that are joined together to form an enclosure. This segmentation allows for easier manufacturing and assembly compared to a monolithic liquid-cooled chamber, reducing manufacturing cost while maintaining temperature protection functionality.
Solution Approach 2:
A coolant passage is introduced as an intermediary element that circulates coolant through the panels to provide active cooling. This separate coolant circulation system allows temperature protection without requiring complex integrated liquid-cooled chambers, simplifying manufacturing.
2Temperature
If double-walled enclosures are used to enclose temperature sensitive electronics, then temperature protection is improved, but device complexity increases
Solution Approach 1:
The enclosure is constructed from multiple discrete panels joined at edges, creating a simplified double-walled structure with coolant passages between panels. This segmented approach reduces assembly complexity compared to traditional double-walled enclosures while maintaining thermal protection.
Solution Approach 2:
The panels serve multiple functions: they form the structural enclosure, provide thermal shielding, and contain the coolant passages for active cooling. This multi-functionality reduces the need for separate components, simplifying the overall device complexity.
3Use of energy by moving object
If panels with integral coolant passages are used, then active cooling capability is improved, but manufacturing complexity increases
Solution Approach 1:
The coolant passages are formed as integral features of individual panels rather than requiring complex internal chamber construction. This segmentation allows each panel to be manufactured separately with embedded coolant channels, reducing overall manufacturing complexity while providing effective active cooling.
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
Effectively reduces temperatures of electronic components exposed to engine heat loads exceeding 700°F, preventing damage by actively cooling and passively radiating heat away from the components.
Implementation Method 1
a plurality of thermally conductive panels, and at least one panel includes an integral tubular coolant passage
Implementation Method 2
at least one panel includes an integral tubular coolant passage
Implementation Method 3
The floor and at least one side wall are substantially open to avoid the trapping of heat
Implementation Method 4
at least one side wall are substantially open to avoid the trapping of heat
Data Source
AI summary
A multi-paneled cooling module adapted to be mounted to an engine exterior protects electronic components such as sensors and associated wiring from heat loads of the engine and/or other heat generating engine devices. The module is formed of wall and ceiling panels having a relatively high thermal conductivity, such as aluminum. The cooling module, which includes strategically situated integral coolant passages within several of its panels, is adapted to protect all enclosed electronic components, including electronic pressure sensors, an EGR valve, and all associated wiring and wiring harnesses. For example, the sensors, harnesses, and valve components associated with and proximal to an EGR venturi may be fully protected from overheating, in spite of exposure of those components to massive heat loads generated by the venturi. Finally, the cooling module may incorporate additional cooling accommodation for hydraulic oil cooling if, for example, the EGR valve is hydraulically actuated.