Thermal management system for a vehicle
A vehicle thermal management system includes an exhaust gas cooler configured to receive exhaust gas from the engine and to cool the exhaust gas before it is recirculated back into the engine. A valve is located downstream from the exhaust gas cooler, and is operable to control the amount of exhaust gas passing through the exhaust gas cooler. Intake air mixes with the exhaust gas downstream from the first valve. The mixed gas is then cooled by a mixed gas cooler before it enters the engine intake manifold. A coolant is circulated through the mixed gas cooler and a heat exchanger. The mixed gas rejects heat to the coolant via the mixed gas cooler, and the coolant rejects heat to the ambient air via the heat exchanger.
1. A thermal management system for a vehicle including an engine, the system comprising:
an exhaust gas cooler configured to receive exhaust gas from the engine and to cool the exhaust gas as it passes through the exhaust gas cooler;
a first valve downstream from the exhaust gas cooler operable to control the amount of exhaust gas passing through the exhaust gas cooler;
an air intake system for receiving intake air for the engine, the intake system including a compressor operable to compress the intake air, the intake system being disposed to facilitate mixing of the intake air and the exhaust gas after the intake air is compressed and the exhaust gas has passed through the exhaust gas cooler, thereby forming a mixed gas;
a mixed gas cooler downstream from the first valve and the compressor for cooling the mixed gas as it passes through the mixed gas cooler;
a first pump operable to pump a first coolant through the mixed gas cooler, thereby facilitating heat transfer from the mixed gas to the first coolant;
a first heat exchanger in fluid communication with the mixed gas cooler for transferring heat from the first coolant to ambient air;
a radiator in fluid communication with the engine and the exhaust gas cooler;
a second pump operable to pump a second coolant through the radiator, the engine, and the exhaust gas cooler, thereby facilitating heat transfer from the engine and the exhaust gas to the second coolant, and from the second coolant to the ambient air via the radiator;
a first fan operable to move the ambient air across the first heat exchanger;
a first sensor for sensing a temperature of the mixed gas after it passes through the mixed gas cooler, and for outputting a signal related to the sensed temperature of the mixed gas;
a control system operatively connected to the sensors, the first fan and the first pump, and including at least one controller, the control system being configured to operate the first fan and the first pump to maintain the sensed temperature of the mixed gas within a first temperature range; and
a second valve disposed between an outlet of the mixed gas cooler and an inlet of the exhaust gas cooler, the second valve being in communication with the control system and operable to direct at least some of the first coolant to the inlet of the exhaust gas cooler, and at least some of the first coolant to an inlet of the first heat exchanger.
2. The thermal management system of claim 1 , wherein the control system is configured with a control structure for optimizing the speed of the first pump and the speed of the first fan based at least in part on the sensed temperature of the first coolant, the optimized speeds providing a maximized heat transfer between the first coolant and the ambient air via the first heat exchanger for a minimized combined power input into the first pump and the first fan, for a respective amount of heat transfer.
3. The thermal management system of claim 1 , further comprising:
a flow sensor for sensing the flow of exhaust gas through the first valve, and for outputting a signal related to the sensed flow to the control system, and
wherein the control system is configured with a control structure for optimizing the speed of the first pump and the speed of the first fan based at least in part on the sensed flow of the exhaust gas, the optimized speeds providing a maximized heat transfer between the first coolant and the ambient air via the first heat exchanger for a minimized power input into the first pump and the first fan, for a respective amount of heat transfer.
4. The thermal management system of claim 1 , further comprising:
a second heat exchanger for providing additional heat transfer between the first coolant and the ambient air, the second heat exchanger being configured to receive the first coolant leaving the exhaust gas cooler; and
a second fan in communication with the control system and operable to move the ambient air across the second heat exchanger.
5. The thermal management system of claim 4 , wherein the second heat exchanger is disposed between an outlet of the exhaust gas cooler and an inlet of the first heat exchanger.
6. The thermal management system of claim 4 , wherein the second heat exchanger is disposed between an outlet of the exhaust gas cooler and an inlet of the first pump.
7. A thermal management system for a vehicle including an engine, the system comprising:
an exhaust gas cooler configured to receive exhaust gas from the engine and to cool the exhaust gas as it passes through the exhaust gas cooler;
a first valve operable to control the amount of exhaust gas passing through the exhaust gas cooler;
an air intake system for receiving intake air for the engine, the intake system including a compressor operable to compress the intake air, the intake system being disposed to facilitate mixing of the intake air and the exhaust gas after the intake air is compressed and the exhaust gas has passed through the exhaust gas cooler, thereby forming a mixed gas;
a mixed gas cooler downstream from the first valve and the compressor for cooling the mixed gas as it passes through the mixed gas cooler;
a first heat exchanger in fluid communication with the mixed gas cooler for transferring heat from a coolant to ambient air;
a pump operable to pump the coolant through the mixed gas cooler and the exhaust gas cooler, thereby facilitating respective heat transfer from the mixed gas and the exhaust gas to the coolant;
a first fan operable to move the ambient air across the first heat exchanger;
a first sensor for sensing a temperature of the mixed gas after it passes through the mixed gas cooler, and for outputting a signal related to the sensed temperature of the mixed gas;
a second sensor for sensing a temperature of the coolant, and for outputting a signal related to the sensed temperature of the coolant; and
a control system operatively connected to the sensors, the first fan, and the pump and including at least one controller, the control system being configured to operate the first fan and the pump to maintain the sensed temperature of the mixed gas within a first temperature range.
8. The thermal management system of claim 7 , wherein the control system is configured with a control structure for optimizing the speed of the pump and the speed of the first fan based at least in part on the sensed temperature of the coolant, the optimized speeds providing a maximized heat transfer between the coolant and the ambient air via the first heat exchanger for a minimized combined power input into the pump and the first fan, for a respective amount of heat transfer.
9. The thermal management system of claim 7 , further comprising a second valve disposed between the pump and an inlet of the mixed gas cooler, the second valve being in communication with the control system and operable to direct at least some of the coolant to the inlet of the mixed gas cooler, and at least some of the coolant to an inlet of the exhaust gas cooler.
10. The thermal management system of claim 7 , farther comprising:
a second heat exchanger in fluid communication with the first heat exchanger and the mixed gas cooler for transferring heat from the coolant to the ambient air; and
a second valve disposed between the pump and an inlet of the second heat exchanger, the second valve being in communication with the control system and operable to direct at least some of the coolant to an inlet of the second heat exchanger, and at least some of the coolant to an inlet of the exhaust gas cooler.
11. The thermal management system of claim 7 , further comprising a second valve disposed between an outlet of the mixed gas cooler and an inlet of the exhaust gas cooler, the second valve being in communication with the control system and operable to direct at least some of the coolant to the inlet of the exhaust gas cooler, and at least some of the coolant to an inlet of the first heat exchanger.
12. The thermal management system of claim 11 , further comprising:
a second heat exchanger for providing additional heat transfer between the coolant and the ambient air, the second heat exchanger being configured to receive the coolant leaving the exhaust gas cooler; and
a second fan in communication with the control system and operable to move the ambient air across the second heat exchanger.
13. The thermal management system of claim 12 , wherein the second heat exchanger is disposed between an outlet of the exhaust gas cooler and an inlet of the first heat exchanger.
14. The thermal management system of claim 12 , wherein the second heat exchanger is disposed between an outlet of the exhaust gas cooler and an inlet of the pump.
15. The thermal management system of claim 12 , wherein the control structure includes optimized speeds for the pump and the second fan, the optimized speeds for the pump and the second fan providing a maximized heat transfer between the coolant and the ambient air via the second heat exchanger for a minimized power input into the pump and the second fan, for a respective amount of heat transfer.
16. The thermal management system of claim 7 , further comprising:
a second heat exchanger in fluid communication with the exhaust gas cooler for transferring heat from the first coolant to the ambient air; and
a second valve disposed between the mixed gas cooler and the exhaust gas cooler, the second valve being in communication with the control system and operable to direct at least some of the first coolant to an inlet of the first heat exchanger, and at least some of the first coolant to an inlet of the exhaust gas cooler.
17. The thermal management system of claim 7 , further comprising:
a second heat exchanger in fluid communication with the exhaust gas cooler for transferring heat from the first coolant to the ambient air; and
a second valve disposed between the mixed gas cooler and the second heat exchanger, the second valve being in communication with the control system and operable to direct at least some of the first coolant to an inlet of the first heat exchanger, and at least some of the first coolant to an inlet of the second heat exchanger.
18. A thermal management system for a vehicle including an engine, the system comprising:
an exhaust gas cooler configured to receive exhaust gas from the engine and to cool the exhaust gas as it passes through the exhaust gas cooler;
a first valve downstream from the exhaust gas cooler operable to control the amount of exhaust gas passing through the exhaust gas cooler;
an air intake system for receiving intake air for the engine, the intake system including a compressor operable to compress the intake air, the intake system being disposed to facilitate mixing of the intake air and the exhaust gas after the intake air is compressed and the exhaust gas has passed through the exhaust gas cooler, thereby forming a mixed gas;
a mixed gas cooler downstream from the first valve and the compressor for cooling the mixed gas as it passes through the mixed gas cooler;
a first pump operable to pump a first coolant through the mixed gas cooler, thereby facilitating heat transfer from the mixed gas to the first coolant;
a first heat exchanger in fluid communication with the mixed gas cooler for transferring heat from the first coolant to ambient air;
a radiator in fluid communication with the engine and the exhaust gas cooler;
a second pump operable to pump a second coolant through the radiator, the engine, and the exhaust gas cooler, thereby facilitating heat transfer from the engine and the exhaust gas to the second coolant, and from the second coolant to the ambient air via the radiator;
a first fan operable to move the ambient air across the first heat exchanger;
a first sensor for sensing a temperature of the mixed gas after it passes through the mixed gas cooler, and for outputting a signal related to the sensed temperature of the mixed gas;
a control system operatively connected to the sensors, the first fan and the first pump, and including at least one controller, the control system being configured to operate the first fan and the first pump to maintain the sensed temperature of the mixed gas within a first temperature range; and
a second valve disposed between the first pump and an inlet of the mixed gas cooler, the second valve being in communication with the control system and operable to direct at least some of the first coolant to the inlet of the mixed gas cooler, and at least some of the first coolant to an inlet of the exhaust gas cooler.
19. The thermal management system of claim 18 , wherein the control system is configured with a control structure for optimizing the speed of the first pump and the speed of the first fan based at least in part on the sensed temperature of the first coolant, the optimized speeds providing a maximized heat transfer between the first coolant and the ambient air via the first heat exchanger for a minimized combined power input into the first pump and the first fan, for a respective amount of heat transfer.
20. The thermal management system of claim 18 , farther comprising:
a flow sensor for sensing the flow of exhaust gas through the first valve, and for outputting a signal related to the sensed flow to the control system, and
wherein the control system is configured with a control structure for optimizing the speed of the first pump and the speed of the first fan based at least in part on the sensed flow of the exhaust gas, the optimized speeds providing a maximized heat transfer between the first coolant and the ambient air via the first heat exchanger for a minimized power input into the first pump and the first fan, for a respective amount of heat transfer.