Vehicle Thermal Management System with Dynamic Flow Control
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Solution Overview
Problem
Conventional thermal management systems for vehicles are limited in their ability to optimally distribute heat between components, leading to inefficiencies in fuel economy, performance, and emissions, and require specific hardware designs for each vehicle application, increasing design complexity and costs.
Innovation Solution
A thermal management system with a split cooling layout and a controller that dynamically adjusts coolant flow between multiple heat exchangers and a bypass conduit, using sensors to prioritize heat distribution based on loss functions and component capabilities, allowing for flexible heat arbitration and common component use across different vehicle platforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional thermal management systems are used, then the system structure is simple, but the ability to optimally distribute heat between components is limited
Solution Approach 1:
The thermal management system is divided into multiple independent cooling circuits, each serving specific components (engine, transmission, differential). This segmentation allows independent control of coolant flow to each component, enabling optimal heat distribution flexibility without requiring complete system redesign.
Solution Approach 2:
The system employs electronically controlled valves and a variable-speed coolant pump that can dynamically adjust coolant flow distribution in real-time based on thermal demands of different components. This dynamic control enables the system to adapt to varying operating conditions while maintaining a relatively simple fixed hardware architecture.
2Use of energy by moving object
If conventional thermal management systems are used, then the hardware design is standardized, but fuel economy and emissions optimization are insufficient
Solution Approach 1:
The system incorporates temperature sensors throughout the thermal management network and uses an electronic control module that receives sensor signals and adjusts coolant flow distribution accordingly. This closed-loop feedback control enables real-time optimization of heat distribution to maximize fuel economy and minimize emissions based on actual thermal conditions.
Solution Approach 2:
The system can change operational parameters such as coolant flow rate, coolant temperature, and valve positions to optimize thermal management for different driving conditions. By dynamically adjusting these parameters, the system improves fuel economy and emissions performance without requiring complex hardware redesigns.
3Adaptability or versatility
If separate cooling circuits for each component are used, then heat distribution control is improved, but system complexity increases
Solution Approach 1:
The coolant pump serves multiple functions by being able to direct coolant flow to different circuits as needed. The electronically controlled valves act as universal flow distribution elements that can route coolant to any required component. This multi-functionality reduces the need for dedicated pumps and valves for each circuit, thereby reducing overall system complexity while maintaining independent control capability.
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 enables precise control over heat distribution, improving fuel economy, emissions, and performance by optimizing heat delivery to components that benefit most, while reducing design complexity and costs through the use of common components.
Implementation Method 1
a first heat exchanger having a coolant inlet in communication with the engine coolant outlet and a coolant outlet in communication with an inlet of the coolant pump
Implementation Method 2
a second heat exchanger having a coolant inlet in communication with a first of the plurality of valve coolant outlets and a coolant outlet in communication with the pump coolant inlet
Implementation Method 3
a third heat exchanger having a coolant inlet in communication with a second of the plurality of valve coolant outlets and a coolant outlet in communication with the pump coolant inlet
Implementation Method 4
A radiator may transfer heat from the vehicle to ambient air
Implementation Method 5
A coolant pump may propel cooling fluid through coolant passages in the engine block, the transmission case and sump, and to a radiator or other heat exchanger
Implementation Method 6
some vehicle may include vents that expel hot air and amplify convective cooling within the engine bay
Data Source
AI summary
A vehicle thermal management system includes an engine, a coolant pump, a first heat exchanger, a first valve in communication with the first heat exchanger, a second valve having a plurality of outlets, a second heat exchanger in communication with a first of the plurality of outlets, a third heat exchanger in communication with a second of the plurality of outlets, a bypass fluid conduit in communication with a third of the plurality of outlets, and a controller that determines a first potential benefit based upon a loss function of the second heat exchanger, determines a second potential benefit based upon a loss function of the third heat exchanger, compares the first potential to the second potential, and proportionally distributes flow between the first heat exchanger, the second heat exchanger, the third heat exchanger, and the bypass fluid conduit based upon the comparison.