Variable-Speed Coolant Pump Control for Engine Thermal Management
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Solution Overview
Problem
Existing coolant systems for internal combustion engines are complex and expensive, as they require additional flow control valves and sensors to manage coolant flow efficiently, and typically operate at higher pump speeds than needed to ensure minimum flow requirements, leading to suboptimal energy consumption.
Innovation Solution
A variable-speed coolant pump system with a pump controller that dynamically determines the restriction state of the coolant loop, maps flow rate requests to corresponding pump speeds, and adjusts pump operation to meet the lowest necessary speed for all heat-transfer nodes, thereby optimizing energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional coolant systems use additional flow control valves and sensors to manage coolant flow efficiently, then flow control precision is improved, but device complexity increases
Solution Approach 1:
The patent removes flow control valves and flow rate sensors from the system, retaining only the coolant pump and thermostat. Flow control is achieved through the thermostat's on/off operation rather than through dedicated flow control components, thereby reducing device complexity while maintaining flow management capability
Solution Approach 2:
The thermostat serves multiple functions: it acts as both a temperature control device and a flow rate control device. By switching between on and off states, it simultaneously regulates temperature and controls coolant flow rate to different heat transfer nodes, eliminating the need for separate flow control valves
2Reliability
If coolant pumps operate at higher speeds to ensure minimum flow requirements are met, then flow reliability is improved, but energy consumption increases
Solution Approach 1:
The coolant pump operates dynamically with variable speed rather than at a fixed high speed. The pump controller continuously adjusts the pump speed based on real-time feedback about coolant flow rates and temperature conditions, allowing the system to maintain reliable flow when needed while reducing energy consumption during lower-demand periods
Solution Approach 2:
The system implements a feedback control mechanism where sensors monitor coolant flow rates and temperature, and this information is fed back to the pump controller. The controller uses this feedback to adjust pump speed automatically, ensuring minimum flow requirements are met while avoiding unnecessary high-speed operation that would waste energy
3Measurement precision
If variable-speed pump control uses complex control strategies to accurately manage flow rates, then flow control accuracy is improved, but control complexity increases
Solution Approach 1:
The control approach segments the coolant distribution system into distinct thermal zones with individual heat transfer nodes. Each node's flow requirements are calculated independently based on its specific thermal needs, and the pump controller manages each zone separately, simplifying the overall control strategy while maintaining accurate flow distribution
Solution Approach 2:
The system changes operational parameters dynamically by adjusting pump speed based on calculated flow rate requirements for each heat transfer node. Rather than using complex control logic, the system varies the pump speed parameter in response to changing thermal demands, achieving accurate flow control through parameter adaptation rather than control complexity
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 approach allows for accurate control of coolant flow rates, reducing energy consumption by operating the pump at the lowest required speed, which is adaptable to various coolant loop configurations and changes in flow restrictions, enhancing fuel economy and simplifying pump control design.
Implementation Method 1
a variable-speed coolant pump for providing a coolant flow to a plurality of heat-transfer nodes coupled in a coolant loop with the pump
Implementation Method 2
identifies a restriction state in which the coolant loop is configured
Data Source
AI summary
A cooling system for an internal combustion engine in a vehicle comprises a variable-speed coolant pump for providing a coolant flow to a plurality of heat-transfer nodes coupled in a coolant loop with the pump. Each node generates a flow rate request based on an operating state of the node. The coolant loop is configurable to a plurality of restriction states. A pump controller receives the flow rate requests, maps each respective flow request to a pump flow rate that would produce the respective pump flow rate request, selects a largest mapped pump flow rate, identifies a restriction state in which the coolant loop is configured, selects a pump speed in response to the selected flow rate and the identified restriction state, and commands operation of the pump to produce the selected pump speed.