Thermal Management Unit for Vehicle Powertrain Oil Temperature Control
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Solution Overview
Problem
Vehicle powertrains face challenges in efficiently regulating the temperature of fluids like coolant and transmission oil, leading to reduced fuel economy due to high viscosity at low temperatures, which requires increased energy for circulation and can result in prolonged warm-up times, compromising overall efficiency.
Innovation Solution
A thermal management unit integrating a valve system with a temperature-responsive element, such as a wax motor, and a pressure relief valve, which selectively routes fluid through a transmission oil heater or cooler to maintain optimal temperature, and includes a shunt flow path to bypass heat exchangers when pressure thresholds are exceeded, ensuring efficient heat transfer and pressure management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If transmission oil is circulated through the powertrain at low temperatures, then the powertrain can operate, but the high viscosity of cold oil increases energy consumption and reduces fuel economy
Solution Approach 1:
The transmission oil heater pre-heats the transmission oil before it enters the powertrain by transferring heat from the coolant. This preliminary heating action reduces the oil's viscosity before circulation, thereby decreasing energy consumption and improving fuel economy while ensuring reliable operation.
Solution Approach 2:
The system changes the temperature parameter of the transmission oil from cold to warm by passing it through the heater assembly. This parameter change transforms the oil's physical properties, reducing viscosity and enabling efficient circulation without excessive energy consumption.
2Temperature
If a separate heater assembly is used to warm transmission oil, then the oil can be heated effectively, but the number of interconnections and system complexity increases
Solution Approach 1:
The heater assembly is integrated directly into the thermal management unit, merging the heating function with the existing coolant flow paths and thermal management components. This integration eliminates the need for separate heating systems and reduces the number of interconnections, thereby simplifying the overall system while maintaining effective transmission oil heating.
3Ease of manufacture
If the thermal management unit integrates valve and heat exchanger components, then installation is simplified, but the internal flow path complexity increases
Solution Approach 1:
The thermal management unit is designed with distinct functional zones including separate valve assemblies, heater sections, and coolant flow paths. This segmentation allows each component to be independently designed and manufactured with optimized flow paths, while the overall integrated structure simplifies installation. The modular segmentation reduces internal complexity by organizing flow paths into discrete, manageable sections.
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 rapid warm-up of transmission oil, reduces fuel consumption by optimizing fluid viscosity, and protects heat exchangers from excessive pressure, thereby enhancing the overall efficiency and longevity of the vehicle powertrain.
Implementation Method 1
a sensing element configured to operate the valve in response to the temperature of oil passing over the sensing element, and in some particular embodiments the sensing element is a wax motor
Implementation Method 2
an integrated transmission oil heater having a fluid inlet manifold, a fluid outlet manifold, and a plurality of flow structures extending between the fluid inlet manifold and the fluid outlet manifold
Implementation Method 3
A pressure relief valve is arranged along the shunt flow path to block the flow of oil along the shunt flow path when the pressure differential between the first fluid port and the end of the shunt flow path is below a threshold, and to allow flow of oil along the shunt flow path when the pressure differential exceeds that threshold
Data Source
AI summary
A thermal management unit for a vehicle powertrain includes an integrated oil heater, a control valve, and a pressure relief valve. A remote oil cooler is connected to fluid ports of the thermal management unit. Transmission oil is received into the thermal management unit and is directed to one or both of the transmission oil heater and the transmission oil cooler. A portion of the flow of oil can be internally bypassed through the pressure relief valve to maintain the pressure of the oil below a threshold. The flow of oil is directed through the control valve after having been heated and/or cooled, and the proportions of oil being directed through the oil heater and the oil cooler are determined by the temperature of the oil in the control valve.