Throttle Loss Recovery Electronics Thermal Management
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Solution Overview
Problem
Existing throttle loss recovery systems face inefficiencies in managing excess electrical energy, leading to potential overheating and electrical noise, especially under elevated temperatures near the vehicle's engine compartment, where dissipating excess energy as heat exacerbates existing temperature issues.
Innovation Solution
A throttle loss recovery system that includes a turbine assembly generating electrical energy from a bypass fluid flow, with an electronics module thermally coupled to the fluid flow to dissipate excess energy effectively, using either ambient air or colder air downstream of the turbine, and dynamically adjusting heat generation to maintain desired temperatures and prevent icing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If excess electrical energy is dissipated by short-circuiting generator stator coils, then electrical power output is regulated, but current ripple and electrical noise are generated that can be detrimental to other electrical components
Solution Approach 1:
The harmful dissipation function is extracted from the generator electronics and transferred to a separate resistive load (heating element, motor, or lighting system) that can handle the excess energy without generating electrical noise or current ripple. This isolates the noise-sensitive generator circuitry from the energy dissipation process.
Solution Approach 2:
An intermediary electrical load is introduced between the generator and the short-circuiting path. This intermediary load acts as a mediator that converts excess electrical energy into useful work or heat without creating harmful electrical transients, thereby protecting other electrical components from noise and ripple.
2Power
If excess electrical energy is short-circuiting to regulate power output, then electrical power is controlled, but relatively high current is generated that produces excess heat
Solution Approach 1:
The excess electrical energy that would otherwise be wasted as harmful heat through short-circuiting is converted into useful thermal energy by driving electrical loads such as heating elements, motor resistances, or lighting systems. This transforms a harmful byproduct into a potentially useful output.
Solution Approach 2:
The system changes the operational parameters of electrical loads dynamically based on excess energy availability. By adjusting load resistance or power consumption characteristics, the system optimizes heat generation to match thermal management requirements while regulating generator output.
3Power
If heat is dissipated under the hood of a vehicle to manage excess electrical energy, then electrical power is regulated, but component overheating is exacerbated in already elevated temperature environments
Solution Approach 1:
The control system dynamically adjusts the amount of excess energy dissipated as heat based on real-time temperature sensors and thermal management requirements. By modulating the dissipation parameter, the system regulates electrical power output while preventing excessive heat accumulation in confined under-hood spaces.
Solution Approach 2:
The heat dissipation system operates dynamically rather than statically, continuously adapting its power consumption characteristics based on thermal conditions, vehicle speed, ambient temperature, and cooling system capacity to optimize both electrical regulation and thermal management.
4Loss of energy
If turbine assembly generates electrical energy from bypass fluid flow, then energy loss from throttling is recovered, but excess energy must be dissipated which creates thermal management challenges
Solution Approach 1:
The turbine assembly system serves multiple functions simultaneously: it recovers energy from bypass flow to offset throttling losses, regulates generator power output by controlling excess energy dissipation, and contributes to thermal management of the engine bay. This multi-functionality resolves the contradiction by making the heat dissipation a useful feature rather than a problem.
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 efficiently dissipates excess electrical energy without overheating, reduces the risk of icing, and improves turbine efficiency by using thermal communication to manage intake air temperatures, thereby enhancing overall engine performance and component reliability.
Implementation Method 1
A throttle loss recovery system includes a turbine assembly (124) that generates electrical energy in response to a bypass fluid flow (114)
Implementation Method 2
the recovered electrical energy may exceed the demands of the vehicle electrical system, in which case, the excess electrical energy must be dissipated
Implementation Method 3
at least a portion of the electronics assembly is in fluid communication with the bypass portion of the fluid flow
Data Source
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AI summary
Systems and methods are provided for managing temperatures associated with a throttle loss recovery system. One exemplary system includes a flow control assembly (102) for recovering energy from a fluid bypassing a flow control valve (106) based on an orientation of the flow control valve (106), a conduit providing fluid communication with the flow control assembly (102) for the portion of the fluid flow (112) bypassing the flow control valve (106), and an electronics assembly (136) including an electronics module (130) coupled to the flow control assembly (102). At least a portion of the electronics assembly (136) is in fluid communication with the portion of the fluid flow (112) bypassing the flow control valve (106), thereby allowing for heat transfer between the electronics assembly (136) and the fluid bypassing the flow control valve (106).