Multivariable Thermal Management Controller for Powertrain Flow Optimization
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Solution Overview
Problem
Current thermal management systems face limitations in making optimal control decisions due to individual component constraints and cross-purpose outcomes, leading to suboptimal performance in complex systems with multiple interrelated actuators, particularly in applications like vehicle powertrains where coolant temperature management is critical.
Innovation Solution
A thermal management system utilizing a physics-based model and multivariable control approach, where sensors monitor input parameters, actuators adjust fluid flow, and a controller processes these inputs through flow and thermal models to minimize errors and optimize actuator positions, considering physical limitations and performance factors to achieve desired temperature states across the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If single input single output controllers are used to control each actuator independently, then individual actuator control is simplified, but system-level control effectiveness deteriorates due to cross-purpose outcomes and lack of coordination between actuators
Solution Approach 1:
The patent merges multiple single-input single-output controllers into a unified multivariable controller that processes multiple inputs and controls multiple actuators simultaneously. This allows the controller to consider cross-purpose outcomes and coordinate actuator positions system-wide, resolving the contradiction between simplified individual control and effective system-level control.
Solution Approach 2:
The controller is designed with universal functionality to handle multiple control objectives and actuator types simultaneously. It can process various sensor inputs and generate coordinated control signals for different actuators, enabling it to address both individual actuator needs and system-level requirements through a single multi-functional control unit.
2Ease of operation
If actuators are positioned to fully open or closed states, then actuator positioning is simplified, but the ability to achieve further position changes and respond to control requests deteriorates
Solution Approach 1:
The patent implements dynamic actuator positioning where actuators can operate continuously across their full range of motion rather than being restricted to fixed discrete positions. The multivariable controller dynamically adjusts actuator positions based on real-time system conditions and control requests, enabling both simplified positioning control and continuous adaptability to changing requirements.
3Adaptability or versatility
If coolant is directed to multiple continuously varying uses simultaneously, then system versatility is improved, but conflicts and unintended effects between uses increase
Solution Approach 1:
The patent applies local quality by directing coolant flow with different characteristics to different system components based on their specific thermal requirements. The multivariable controller independently adjusts flow rates and temperatures for each coolant destination, allowing versatile multi-use coolant distribution while preventing conflicts through localized flow optimization for each application.
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 enables more flexible and effective control of thermal systems, optimizing powertrain thermal performance, balancing multiple flow requests, and ensuring efficient operation by positioning actuators to achieve desired temperatures with minimal pump flow, thus overcoming individual component constraints and cross-purposes.
Implementation Method 1
process an actuator state through a flow model of the thermal system to obtain an existing flow in the fluid conduits
Implementation Method 2
process the existing flow through a thermal model of the thermal system to determine an input that reduces an error between a desired parameter state and the input parameter state
Implementation Method 3
A sensor is disposed to monitor an input parameter state of the thermal system
Implementation Method 4
An actuator is configured to vary a flow in the fluid conduits
Data Source
AI summary
Systems and methods are provided for management of a thermal system. A system for thermal management includes a thermal system with fluid conduits. A sensor is disposed to monitor an input parameter state of the thermal system. An actuator is configured to vary a flow in the fluid conduits. A controller is configured to receive a signal representative of the input parameter state; process an actuator state through a flow model of the thermal system to obtain an existing flow in the fluid conduits; process the existing flow through a thermal model of the thermal system to determine an input that reduces an error between a desired parameter state and the input parameter state; process the input through an inverse flow model to convert the input to a desired actuator state; and position the actuator in the desired actuator state.