WO2020145921A2

WO2020145921A2 - A smart thermal management module for engine cooling

Info

Publication number: WO2020145921A2
Application number: PCT/TR2019/051090
Authority: WO
Inventors: Faruk UNLUASLAN
Original assignee: Kirpart Otomotiv Parcalari Sanayi Ve Ticaret A.S
Priority date: 2019-01-10
Filing date: 2019-12-17
Publication date: 2020-07-16
Also published as: WO2020145921A3; TR201900313A2

Abstract

This invention relates to a smart thermal management module (1) which autonomously controls the flow ratio between the bypass circuitry and radiator circuitry according to the temperature value measured by a temperature sensor (20) located within the module, as independently from the engine control unit (ECU).

Description

A SMART THERMAL MANAGEMENT MODULE FOR ENGINE COOLING Technical Field

The invention relates a smart thermal management module for engine cooling.

Especially, present invention relates to an electromechanical thermostat which autonomously controls the flow ratio between the bypass channel and radiator channel according to the temperature value measured by a temperature sensor located within the thermostat, as independently from engine control unit.

Prior Art

In today’s technology, it is not possible that the chemical energy within the fuel is converted totally to useable energy. Consequently, during combustions, the temperature of both combustion chamber and related parts rises to extreme temperature values which could damage all motor system irreversibly. So, it is crucial to remove the access heat accumulated over both engine and engine parts. Removing of this excess heat is provided by engine cooling system.

All engine cooling systems aim to ensure that engine operates in appropriate temperature range of work. A cooling system generally comprises engine channels, radiator channel, a thermostat assembly and circulation (water) pump. The main task within a cooling system is belong to the thermostat assembly. Thermostat assembly determines whether the temperature of the engine coolant flowing through engine channels is within appropriate temperature range of work for engine or not. If the coolant temperature is above the appropriate temperature range of work, thermostat assembly directs the coolant as flowing through the heat exchange circuitry (radiator channel, engine channels, thermostat assembly, circulation pump) to be cooled and so, reduces or totally prevents the coolant flow through bypass circuitry (engine channels, thermostat assembly, circulation pump). Vice versa, if the coolant temperature falls below the appropriate temperature range of work, thermostat assembly reduces or totally prevents the coolant flow through the heat exchange circuitry and so, allows the coolant circulation through the bypass circuitry again. It means the thermostat assembly decides the coolant flow ratio between two coolant circulation circuitries (by-pass circuitry and heat exchange circuitry) according to the engine coolant temperature value.

There are different type thermostat assemblies respect to the way controlling the valve structure such as thermal expansion valve, electrically controlled thermal expansion valve, electrically controlled valve. Conventional thermostat assemblies have a thermo-actuator with expandable material such as wax, for sensing the coolant temperature. When the temperature of the coolant passing throughout thermostat interior space increases, the expandable material within the heat sensitive reservoir causes the piston to move forward, by expanding within the reservoir. Consequently, motion of the piston allows motion of the valve structure guided by the thermo-actuator. This type thermostat assembly provides self-determined (independent) operation. However, the reaction rate of the conventional thermostat assembly towards temperature change is quite slow due to the time require for expansion.

There are also map-controlled engine cooling systems using externally-sourced heater within thermo actuator of thermostat assembly. These heaters provide the wax compound within the heat sensitive part of thermo-actuator to warm externally according to estimated engine conditions by engine control unit during a trip. Engine designers who know the engine working conditions well could estimate the cooling necessities of an engine during operation. Consequently, they define cooling maps according to the possible cases of engine. However, although the map-controlled engine cooling systems show a great performance by ensuring engine in the appropriate temperature range of work, they need more organization. The thermo-actuators used in map-controlled system has an externally-sourced heater in their core portions. So, production process of these thermal element is very complicated and costs more than production process of the wax-based thermal elements used in conventional thermostat assemblies. Besides, likewise in the conventional thermostat assembly, the reaction rate of this type thermostat assembly towards temperature changes is also slow due to the time require for expansion.

Electrically controlled valves are controlled by an electric current passing generally through a winding adapted to produce a magnetic flux for controlling opening or closing of thermostat assembly. In the absence of current, this type valves remain generally in predetermined position. Permanent feeding of current is required for maintaining the valve in its other positions. Here, since the electric current determining the valve position is provided by engine control unit with respect to estimated engine conditions, this type thermostat assembly cannot provide independent operation.

Therefore, there is a need for an engine cooling system which, having high reaction rate towards temperature changes, provides independent operation, and a thermostat assembly therefore.

The document US2018058304 is to be considered the closest invention in prior art. Basically a three- way valve, a flow regulator controlled by a control unit is defined and a proportion of flow through the by-pass and radiator is to be controlled by control unit. However, here, it is not mentioned about independent operation. As a result, there is a require for a compact thermal management module which, having high reaction rate towards temperature changes, operates independently from engine control unit.

Objectives and Short Description of the Invention

The aim of the present invention is to present a smart thermal management module which provides fast and independent temperature control of engine channels according to the temperature sensed by a temperature sensor located within the module.

Another aim of the present invention is to present an electromechanical thermostat assembly providing self-determined operation independent from engine control unit.

Another aim of the present invention is to present a smart thermal management module which is all in one structure.

Description of the Figures

In figure 1 , an engine cooling system diagram showing the location of the present smart thermal management module within the system is given.

In figure 2, an embodiment of the present thermal management module which, having one inlet-two outlets, includes temperature sensor within its inlet is shown.

In figure 3, an embodiment of the present thermal management module which, having two inlets-one outlet, includes temperature sensor within its outlet is shown.

Reference Numerals

1. Thermal management module

20. Temperature sensor

30. Thermal control unit

40. Electrical motor

50. Gear stage

60. Valve

E. Engine

Wo. Water outlet

Wi. Water inlet

WP. Water pump

R. Radiator Ch. Hydraulic connection

Ce. Electrical connection

P. Power unit

ECU. Engine Control Unit

Detailed Description of the Invention

Electrically controlled valves were emerged to eliminate the disadvantage (slow response rate) of conventional thermal expansion valves. However, although the electrically controlled valves have fast response time, they cannot operate autonomously unlike the thermal expansion valves. They are controlled by engine control unite (ECU) via signals transmitted through cables. So, electrically controlled valves are complicated and dependent structures.

The present invention provides a thermal management module (1) having a valve (60) structure controlled via a motor according to the temperature sensed by a sensor located within the module. So, present valve (60) operates autonomously according to the temperature changes of engine coolant. Besides, present thermal management module (1) provides non-complicated structure by having all in one structure.

The present thermal management module (1) comprises a body, a valve (60) structure located within mentioned body, an electrical motor (40) moving mentioned valve (60) structure, at least one temperature sensor (20) located at inlet or outlet of the module, a thermal control unit (30) controlling mentioned electrical motor (40) according to the temperature sensed by mentioned temperature sensor (20), a gear stage (50) increasing the torque generated by said electrical motor (40) until the torque value is enough for the motion of the valve (60) structure.

Mentioned temperature sensor (20) is a component to sense the coolant temperature. It is possible to use any type temperature sensor (20) such as NTC, PTC, thermocouple etc. In this preferred embodiment of the present invention, NTC is used as temperature sensor (20).

A diagram showing the position of the present smart thermal management module (1) within engine cooling system is given in Figure 1. In this embodiment of the present invention, mentioned body has one inlet-two outlets (inlet, bypass outlet and radiator outlet) and said temperature sensor (20) is located at the inlet.

As shown in Figure 2, the temperature sensor (20) located at the inlet senses the temperature of the coolant around valve (60) structure and the coolant coming from water inlet (Wi). The temperature values of water inlet (Wi) coolant and coolant around valve (60) structure are transmitted to mentioned thermal control unit (30). Said thermal control unit (30) is powered by a power unit (P) via power inlets V+ and V-. Also, there is another inlet for the control and feedback signal between engine control unit (ECU) and the present smart thermal management module (1). This signal provides the communication of the present module with the engine control unit (ECU). The data of the engine coolant temperature is transmitted to engine control unit (ECU) through this channel or set value of the coolant temperature is transmitted from engine control unit (ECU) to module. In this figure electrical connection (Ce) and hydraulic connection (Ch) are shown with separated lines. The dashed lines represent the electrical connection (Ce) whereas the continuous lines represent hydraulic connection (Ch). The thermal control unit (30) generates electrical signal by evaluating these transmitted temperature values from temperature sensor (20) and the position of the valve (60) structure. The generated electric signal is transmitted to electric motor (40). Thus, electric motor (40) generates mechanical energy (torque) according to the electric signal transmitted by the thermal control unit (30). The generated mechanical energy is transmitted to the valve (60) structure via mentioned gear stage (50). Said gear stage (50) is adjusted so as to increase the torque until the proper torque value required for motion of the valve (60) structure is obtained. As a result, the valve (60) structure is moved to the desired position and so, the desired position of the valve (60) structure determines the actual flow ratio between bypass circuitry and radiator circuitry according to the water inlet (W) and radiator (R) outlet temperatures sensed by the temperature sensor (20). If the temperature value sensed by temperature sensor (20) is greater than the desired temperature value of the coolant, the thermal control unit (30) allows more valve (60) opening. Thus, it is provided that the coolant is cooled much more by increasing the amount of the coolant going to radiator (R) via radiator outlet. If the temperature value sensed by temperature sensor (20) is less than the desired temperature value of the coolant, the thermal control unit (30) allows less valve (60) opening. Thus, it is provided that the coolant is less cooled by increasing the amount of the coolant going to water outlet (Wo) via bypass outlet.

In another embodiment of the present invention, body has two inlets-one outlet (bypass inlet and radiator inlet and outlet) and said temperature sensor (20) is located at the outlet. The temperature sensor (20) located at the outlet senses the temperatures of the coolant going to water outlet (Wo) and of the coolant of radiator (R) inlet. As shown in Figure 3, the temperature values of water outlet (Wo) and radiator (R) inlet coolants are transmitted to the thermal control unit (30). Here, the thermal control unit (30) is also powered by a power unit (P) via power inlets V+ and V-. Also, there is another inlet for the control and feedback signal between engine control unit (ECU) and the present smart thermal management module (1). This signal provides the communication of the present module with the engine control unit (ECU). The data of the engine coolant temperature is transmitted to engine control unit (ECU) through this channel or set value of the coolant temperature is transmitted from engine control unit (ECU) to module. In this figure electrical connection (Ce) and hydraulic connection (Ch) are also shown with separated lines. The dashed lines represent the electrical connection (Ce) whereas the continuous lines represent hydraulic connection (Ch). The thermal control unit (30) generates electrical signal by evaluating these transmitted temperature values and the position of the valve (60) structure. The generated electric signal is transmitted to electric motor (40). Thus, electric motor (40) generates mechanical energy according to the electric signal transmitted by the thermal control unit (30). The generated mechanical energy is transmitted to the valve (60) structure via mentioned gear stage (50). Said gear stage (50) is adjusted so as to increase the torque until the proper torque value required for motion of the valve (60) structure is obtained. As a result, the valve (60) structure is moved to the desired position and so, the desired position of the valve (60) structure determines the actual flow ratio between bypass circuitry and radiator circuitry according to the water outlet (Wo) temperature sensed by the temperature sensor (20). If the temperature value sensed by temperature sensor (20) is greater than the desired temperature value of the coolant, the thermal control unit (30) allows more valve (60) opening. Thus, it is provided that the coolant is cooled much more by increasing the amount of the coolant coming from radiator (R) via radiator inlet. If the temperature value sensed by temperature sensor (20) is less than the desired temperature value of the coolant, the thermal control unit (30) allows less valve (60) opening. Thus, it is provided that the coolant is less cooled by increasing the amount of the coolant coming from water inlet (Wi) via bypass inlet.

In one preferred embodiment of the present invention, thermal control unit (30) has also another electrical connection (Ce) allowing input of a second temperature sensor (20) which is located at proper position on chassis as sensing the temperature of outdoor environment. In this situation, the environment temperature is also evaluated by the thermal control unit (30) during generating electric signal.

Claims

1. A smart thermal management module (1) which, comprising a body, a valve (60) structure located within mentioned body, autonomously controls the flow ratio between the bypass channel and radiator channel, as independently from engine control unit (ECU) and characterized by; for provides autonomous temperature control of coolant;

comprising at least one temperature sensor (20) located within said body,

a thermal control unit (30) which generates electrical signal to control the proportion of flow by adjusting the position of the valve (60) structure, by evaluating the temperature sensed by mentioned temperature sensor (20),

an electrical motor (40) which generates mechanical energy with respect to the electrical signal transmitted by mentioned thermal control unit (30),

a gear stage (50) which increases the mechanical energy obtained from mentioned electrical motor (40) until the torque value is enough for motion of the valve (60) structure.

2. A smart thermal management module (1) according to claim 1 , and characterized in that, in one preferred embodiment of the invention, body has one inlet-two outlets, temperature sensor (20) is located at the inlet and valve (60) is located at the outlet between radiator (R) and water outlet (Wo) so as to control the proportional flow through these outlets.

3. A smart thermal management module (1) according to claim 1 , and characterized in that, in one preferred embodiment of the invention, body has one outlet-two inlets and temperature sensor (20) is located at the outlet and valve (60) is located at the inlet between radiator (R) and water inlet (Wi) so as to control the proportional flow from these inlets.

4. A smart thermal management module (1) according to one of the prior claims, and characterized in that, in one preferred embodiment of present invention, there is an electrical connection (Ce) between thermal control unit (30) and engine control unit (ECU) to transmit the engine coolant temperature to engine control unit (ECU) and to receive set temperature from engine control unit (ECU) or, just to one of them.

5. A smart thermal management module (1) according to one of the prior claims, and characterized in that, in one preferred embodiment of the present invention, thermal control unit (30) has an electrical connection (Ce) allowing input of second temperature sensor (20) which is located at proper position on chassis as sensing the temperature of outdoor environment.