Vehicle Cooling System EGR Cooler Flow Control
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Solution Overview
Problem
The existing cooling systems for vehicles, which use a mechanical wax-type thermostat, face limitations in controlling the flow rate of cooling water through an EGR cooler due to the restrictive placement of the EGR cooler, leading to deteriorated controllability of other valves and inefficient engine warm-up.
Innovation Solution
A cooling system with water temperature sensors at the engine inlet and outlet, and a flow rate control valve that manages the flow rate by opening and closing ports in specific sections to control the flow rate of cooling water through the EGR cooler, oil heat exchanger, and heater core, optimizing the engine warm-up process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the EGR cooler is located close to the engine outlet to ensure the engine-outlet cooling water temperature is the same as the cooling water temperature flowing into the EGR cooler, then the temperature measurement accuracy is improved, but the controllability of other valves used for controlling cooling water deteriorates
Solution Approach 1:
The patent divides the cooling water flow control into multiple independent sections using separate control valves (first control valve for EGR cooler, second control valve for heater core, third control valve for radiator). This segmentation allows each valve to operate independently without interfering with others, resolving the controllability issue while maintaining accurate temperature measurement through the strategically placed outlet temperature sensor.
2Use of energy by moving object
If the cooling water flow rate through the EGR cooler is increased to improve heat exchange efficiency, then the fuel efficiency is improved through better exhaust heat recovery, but the EGR cooler may overheat and exceed the boiling temperature of cooling water
Solution Approach 1:
The patent implements a feedback control system where the controller continuously monitors the outlet cooling water temperature from the EGR cooler and adjusts the opening degree of the first control valve accordingly. When the temperature approaches the boiling point, the controller reduces the flow rate through the EGR cooler, preventing overheating while maximizing heat recovery efficiency under normal conditions.
Solution Approach 2:
The system dynamically changes the flow rate parameter through the EGR cooler based on real-time temperature conditions. By adjusting the opening degree of the first control valve, the system optimizes the balance between heat exchange efficiency and temperature control, ensuring the EGR cooler operates within safe temperature limits while maintaining high fuel efficiency.
3Use of energy by moving object
If the engine warm-up process is accelerated by controlling cooling water flow rate, then the fuel efficiency is improved through reduced engine friction and heat loss, but the system complexity increases due to multiple sensors and control valves
Solution Approach 1:
The patent designs the control system to perform multiple functions using the same components. The controller manages not only the EGR cooler flow control for warm-up optimization but also prevents overheating, regulates temperature for EGR operation, and coordinates with other control valves for overall cooling system management. This multi-functionality justifies the added complexity by providing comprehensive control and protection.
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 improves fuel efficiency by rapidly warming up the engine through exhaust heat recovery, reducing engine friction and heat loss, while preventing overheating of the EGR cooler.
Implementation Method 1
exhaust heat recovery
Implementation Method 2
heat exchange between the exhaust gas and the cooling water in the EGR cooler
Implementation Method 3
cooling water flow rate flowing through the EGR cooler
Data Source
AI summary
A cooling system for a vehicle and a control method thereof improves fuel efficiency through quick warm-up of an engine by controlling a flow rate of cooling water passing through an EGR cooler. In the cooling system and control method cooling water with an increased temperature through flow stagnation control is first supplied to an oil heat exchanger side. Heat energy generated from the engine is used to rapidly raise a cooling water temperature and an oil temperature. A warm-up characteristic is improved through the exhaust heat recovery function by heat exchange between exhaust gas and the cooling water in the EGR cooler.