Vehicle Cooling System Segmentation for Overload Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cooling systems for internal combustion engines, particularly in vehicles with power boost capabilities, are prone to overload during brief high-power operations, risking engine damage due to insufficient cooling capacity.
Innovation Solution
The cooling system is enhanced by dividing the charge air cooler into high-temperature and low-temperature stages, with an additional cooling circuit, allowing for increased efficiency and capacity without requiring larger coolers, and incorporating separate coolant pumps for independent operation of each circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cooling system uses a single high-temperature circuit for the internal combustion engine, then the engine can be cooled effectively under normal operating conditions, but the system becomes overloaded and risks damaging the engine during brief high-power operations
Solution Approach 1:
The cooling system is divided into two independent circuits: a high-temperature circuit for the internal combustion engine and a low-temperature circuit for the charge air cooler and oil cooler. This segmentation allows each circuit to operate independently with appropriate temperature ranges, preventing overload of the high-temperature circuit during high-power operations while maintaining effective cooling of all components.
2Productivity
If the charge air cooler is cooled using the high-temperature circuit, then the engine can be cooled effectively, but the cooling efficiency of the high-temperature circuit decreases and the system cannot handle brief overload conditions
Solution Approach 1:
The charge air cooler is assigned to the low-temperature circuit separate from the high-temperature circuit. This allows the high-temperature circuit to maintain optimal temperature control for the engine while the low-temperature circuit handles the charge air cooling, enabling the system to achieve higher cooling capacity during overload conditions.
Solution Approach 2:
The system changes the temperature parameter distribution by operating the high-temperature circuit at higher temperatures (90-110°C) for the engine and the low-temperature circuit at lower temperatures (45-90°C) for the charge air cooler, optimizing cooling efficiency for each component's specific requirements.
3Productivity
If the cooling system components are arranged to maximize cooling efficiency, then the cooling capacity increases, but the vehicle space available for installing cooling components is insufficient
Solution Approach 1:
By segmenting the cooling system into two independent circuits with separate coolers, the design allows for optimized component arrangement within limited vehicle space. The high-temperature cooler and low-temperature cooler can be positioned to maximize cooling capacity while fitting within the available space constraints of the vehicle.
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 configuration prevents engine overheating during high-power operations, reduces oil heating time after a cold start, and allows for stricter exhaust gas regulation compliance by optimizing cooling capacity within limited vehicle space.
Implementation Method 1
The charge air cooler (22) is divided into a high-temperature stage (46) and a low-temperature stage (44)
Implementation Method 2
an oil cooler (24) for transmission fluid are cooled in the low-temperature circuit
Implementation Method 3
a cooler (26) in this circuit
Implementation Method 4
The coolant of the low-temperature circuit is conveyed to the low-temperature stage of the charge air cooler by a coolant pump
Data Source
AI summary
The invention relates to a cooling system for an internal combustion engine on a vehicle, preferably for an agricultural or industrial commercial vehicle. The cooling system includes a high temperature circuit and a low-temperature circuit. The high temperature circuit cools the internal combustion engine and includes at least a first cooler. The low temperature circuit cools a charge air cooler and, optionally, an oil cooler and includes at least one second cooler. The charge air cooler has at least two parts or stages. In the direction of flow of coolant in the low temperature circuit, the second cooler is connected downstream of a first part of the charge air cooler, the oil cooler and a second part of the charge air cooler. Alternatively or additionally, a further cooling circuit cools the charge air cooler and includes at least one cooler.