Automated Vehicle Coolant Charging Control
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Solution Overview
Problem
The conventional method for charging coolant in a vehicle's cooling system is inefficient, leading to insufficient coolant injection, potential engine damage, and excessive labor costs due to manual operation and reliance on operator skill, with issues exacerbated by the need for prolonged idle times and inadequate coolant distribution to components like the EGR cooler and heater core.
Innovation Solution
A diagnostic apparatus is used to automate the coolant charging process by determining connection and starting a coolant charging mode, controlling the EGR device, engine RPM, and electric thermostat to ensure efficient coolant distribution and temperature regulation, reducing manual intervention and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual coolant charging is performed by operator, then flexibility in operation is maintained, but injection performance deviates according to operator skill and labor cost increases
Solution Approach 1:
The system performs self-diagnosis and self-regulation during coolant charging. The control unit automatically monitors coolant temperature, regulates water pump speed, and determines when charging is complete based on pre-set conditions, eliminating the need for continuous manual observation while ensuring consistent performance.
Solution Approach 2:
The patent replaces manual mechanical operation with an automated electronic control system. The control unit uses sensors to detect coolant temperature and flow conditions, then automatically adjusts water pump operation and monitors charging completion, substituting human judgment and manual control with electronic automation.
2Productivity
If engine is idled at high RPM to shorten charging time, then charging efficiency improves, but engine damage risk increases due to overheating
Solution Approach 1:
The water pump speed is dynamically adjusted based on real-time coolant temperature feedback. The control unit increases pump speed to accelerate coolant circulation and temperature rise during charging, then automatically reduces speed when the thermostat opens or temperature reaches safe levels, creating a dynamic response that optimizes charging speed while preventing overheating damage.
Solution Approach 2:
The system uses coolant temperature sensors to provide continuous feedback to the control unit. This feedback loop allows the control unit to monitor temperature trends and automatically adjust water pump operation, increasing speed when cooling is needed and reducing it when the thermostat opens, thereby preventing overheating while maintaining charging efficiency.
3Reliability
If vehicle is left idle for long time during coolant charging, then complete coolant injection is achieved, but charging time becomes excessively long exceeding one hour
Solution Approach 1:
The control unit is pre-programmed with the complete charging procedure and decision logic. It automatically executes the charging sequence, monitors temperature conditions, determines when the thermostat opens, and identifies charging completion based on pre-set criteria, eliminating the need for prolonged idle waiting while ensuring complete coolant distribution.
Solution Approach 2:
The water pump operates continuously at optimized speeds throughout the charging process, maintaining constant coolant circulation. The control unit ensures uninterrupted coolant flow through the system, preventing air pockets and ensuring complete filling of all cooling channels, including the EGR cooler and heater core, without requiring extended idle periods.
4Temperature
If thermostat remains closed during initial coolant injection, then coolant temperature increases, but sufficient coolant cannot be injected into EGR cooler and heater core
Solution Approach 1:
The water pump speed is dynamically controlled based on thermostat status and coolant temperature. When the thermostat is closed, the pump operates at higher speed to force coolant through the bypass path to the EGR cooler and heater core. When the thermostat opens, the pump speed is automatically reduced, allowing natural circulation and preventing overheating, thus resolving the contradiction between temperature control and component cooling.
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 automated process ensures reliable and efficient coolant injection, reducing engine damage risks, shortening charging time, and improving convenience by eliminating skill-dependent variations in coolant injection performance.
Implementation Method 1
a radiator 30 for performing a cooling operation by receiving the coolant discharged from the engine 10 and heat-exchanging with the outside air
Implementation Method 2
since the thermostat is opened only when the coolant temperature is equal to or greater than a certain temperature (e.g., 80°C)
Implementation Method 3
a water pump 70 for pushing coolant into an engine of the vehicle 10
Implementation Method 4
some of the coolant supplied to the engine 10 reaches the thermostat housing 50 through the bypass 90. As such, some of the coolant is transferred to an exhaust gas recirculation (EGR) cooler 100
Implementation Method 5
some of the coolant supplied to the engine 10 reaches the thermostat housing 50 through the bypass 90. As such, some of the coolant is transferred to an exhaust gas recirculation (EGR) cooler 100 and a heater core 110 for heating the vehicle
Data Source
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AI summary
A method for charging coolant in a cooling system for a vehicle may include determining a vehicle-diagnostic apparatus connection that determines whether a diagnostic apparatus configured for charging coolant has been connected to a vehicle; starting a coolant charging mode for charging the coolant by the diagnostic apparatus; and determining whether a coolant charging mode release condition has been satisfied after starting the coolant charging mode.