Stacked Valve Assembly With Single-Actuator Cooling Circuit Switching
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Solution Overview
Problem
Existing fluid valves for liquid cooling in electrified vehicles are bulky, expensive, and require multiple actuators and control signal cables, limiting their versatility and increasing complexity due to the need for custom arrangements for each application.
Innovation Solution
A stacked valve assembly that uses a single actuator to operate multiple valves through a modular, vertically or horizontally stacked geometry, allowing for various combinations of valve positions and fluidic isolation between valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standard multi-way ball valves are used to meet increased cooling complexity needs, then cooling coverage is improved, but device complexity and cost increase due to requiring multiple actuators and control cables for each valve
Solution Approach 1:
Multiple valve bodies are stacked together to form a single integrated valve assembly, where a single actuator controls multiple valves through shared rotational movement. The valve bodies are arranged in stacks with fluid ports aligned, allowing one actuator to simultaneously control the switching of multiple valves, thereby reducing the total number of actuators and control cables required.
Solution Approach 2:
The stacked valve assembly provides multi-functionality by enabling a single actuator to control multiple valves for different cooling circuits (battery cooling, motor cooling, power electronics cooling, etc.). The universal design allows the same valve assembly structure to serve multiple thermal management functions through configurable fluid port connections.
2Reliability
If standard multi-way ball valves are manufactured as single units to maintain fluid-tight seals, then sealing reliability is improved, but manufacturing cost and production complexity increase
Solution Approach 1:
The valve assembly is segmented into multiple individual valve bodies that are manufactured separately and then stacked together. Each valve body can be manufactured as a standard component with its own sealing, allowing for modular production. The segmentation enables standardized manufacturing processes to be applied to each valve body independently, reducing overall manufacturing cost and complexity while maintaining sealing integrity through the stacking arrangement.
3Ease of operation
If multiple actuators are used to control each valve individually, then valve control precision is improved, but device complexity and space requirements increase
Solution Approach 1:
Multiple valve control functions are merged into a single actuator system. The actuator rotates a drive member that is mechanically connected to multiple valve bodies in the stack, allowing simultaneous control of multiple valves through one actuator. This merging reduces device complexity by eliminating the need for multiple separate actuators and their associated control cables, while still achieving precise control over each valve's switching state.
Data Source
AI summary
An apparatus and method of stacked valves that selectively move the stacked valves into various switched positions using a single actuator. A first valve of the valve stack is movable into one or more switched positions by an actuator that drives the first valve in a first or a second direction for a first or a second distance. Second and third valves of the valve stack are selectively movable into one or more switched positions by motion transfer stages. The motion transfer stages selectively transfer the first or second direction and the first or second distance movements of the first valve to the second and third valves that place the second and third valves into one of the switched positions.