Variable Coolant Flow Control via Multi-Position Valve
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Solution Overview
Problem
Vehicle thermal management systems face challenges with oversized mechanical coolant pumps due to high cooling demand sizing, leading to increased costs, and limited ability to balance heating and cooling needs across engine, transmission, and cabin due to non-variable coolant flow rates.
Innovation Solution
A vehicle thermal management system incorporating a mechanically driven coolant pump, bypass line, and multi-position valves that allow for adjustable coolant flow rates to heat exchangers and bypass, enabling efficient cooling and heating management without requiring electrical system redesign.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a mechanically driven coolant pump is used to meet high cooling demand, then cooling capability is improved, but device complexity and cost increase due to oversized pump design
Solution Approach 1:
The patent applies dynamics by making the coolant flow rate variable through a multi-position valve mechanism. The valve can be adjusted between fully open, partially open, and closed positions, allowing the system to adapt coolant flow dynamically based on thermal management needs. This resolves the contradiction by enabling a smaller pump to provide adequate cooling when needed while allowing reduced flow when cooling demand is lower, avoiding the need for an oversized pump.
Solution Approach 2:
The patent changes the parameter of coolant flow rate from fixed to variable through the multi-position valve. By allowing the flow rate parameter to be adjusted between multiple discrete values, the system can optimize pump sizing and reduce overall system complexity while maintaining the ability to meet high cooling demands when necessary.
2Device complexity
If non-variable coolant flow rates are used, then device complexity is reduced, but adaptability to balance heating and cooling needs across engine, transmission, and cabin is limited
Solution Approach 1:
The multi-position valve provides dynamic adaptability by offering multiple discrete flow rate positions (fully open, partially open, closed) without requiring complex continuous control mechanisms. This allows the system to adapt coolant distribution to balance heating and cooling needs across different components while maintaining relatively simple valve control architecture.
Solution Approach 2:
The patent segments the coolant flow control into multiple discrete positions rather than using continuous variable control. This segmentation approach provides sufficient thermal management adaptability for different operating conditions while keeping the valve control mechanism simple and avoiding excessive complexity.
3Temperature
If oversized mechanical coolant pumps are used, then cooling demand is met, but fuel economy deteriorates due to increased mechanical load
Solution Approach 1:
By implementing variable coolant flow control through the multi-position valve, the system allows the mechanically driven pump to operate at lower flow rates when full cooling capacity is not needed. This reduces the mechanical load on the pump and consequently decreases fuel consumption, while still maintaining the ability to meet cooling demands when the valve is positioned to allow maximum flow.
4Adaptability or versatility
If multi-position valves with adjustable flow rates are implemented, then thermal management adaptability is improved, but device complexity increases
Solution Approach 1:
The patent uses a multi-position valve that segments coolant flow control into multiple discrete positions rather than requiring continuous variable control. This provides adequate thermal management adaptability for different operating conditions while keeping the valve mechanism relatively simple in construction and operation.
Solution Approach 2:
The multi-position valve represents a cost-effective control mechanism that provides sufficient adaptability without the complexity and cost of electronic control systems with actuators and sensors. The mechanical valve design offers a simple, reliable solution for flow rate adjustment.
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 solution reduces vehicle costs by avoiding electrical system redesign and improves fuel economy by optimizing coolant flow, while enhancing transmission efficiency through auxiliary radiators and adjustable valve control.
Implementation Method 1
A vehicle thermal management system includes a mechanically driven coolant pump
Implementation Method 2
The radiator cools coolant flowing therethrough to prevent the engine from overheating
Implementation Method 3
The radiator typically includes a fan that blows ambient air through the radiator
Implementation Method 4
The heater core heats air from a vehicle cabin by transfer heat from coolant flowing through the heater core to cabin air flowing through the heater core
Implementation Method 5
The engine oil heater heats engine oil that is circulated through the engine
Implementation Method 6
The transmission oil heater heats transmission oil that is circulated through a transmission
Implementation Method 7
The condenser condenses gaseous refrigerant flowing coils in the condenser into liquid refrigerant by cooling the refrigerant
Data Source
AI summary
A system includes a coolant pump and a first rotary valve. The coolant pump is configured to be mechanically driven by an engine and to send coolant to an inlet of the engine. The first rotary valve is configured to receive coolant from an outlet of the engine and to send coolant to a first radiator and a heater core. The first rotary valve is adjustable to a zero flow position to prevent coolant flow to the first radiator and the heater core and thereby increase a rate at which the engine warms coolant flowing therethrough.