Engine cooling system for a vehicle
An engine cooling system for a vehicle, and method of operation, includes both an engine driven main coolant pump that may be disengaged by a clutch and an electrically driven auxiliary coolant pump, where each can be used separately or they can be used together to control the amount of coolant flow through the engine cooling system.
1. An engine cooling system for a vehicle having an internal combustion engine comprising:
a main coolant pump having an inlet and an outlet configured to pump a coolant into the internal combustion engine;
a torque transfer assembly driven by the engine and operatively engaging the main coolant pump to transfer torque from the internal combustion engine to the main coolant pump;
a clutch connected between the main coolant pump and the torque transfer assembly and operable to selectively disengage the main coolant pump from the torque transfer assembly;
a thermostat having a thermostat outlet connected to the inlet of the main coolant pump, a first inlet and a second inlet, the thermostat operable to selectively prevent coolant flow from the first inlet to the thermostat outlet;
a radiator configured to receive the coolant from the internal combustion engine and direct the coolant to the first inlet;
a heater core located in a HVAC module; and
an electrically driven auxiliary coolant pump configured such that the coolant flowing through the auxiliary coolant pump and the heater core is directed into the second inlet of the thermostat.
2. The engine cooling system of claim 1 wherein the main coolant pump has a first pumping capacity and the auxiliary coolant pump has a second pumping capacity that is less than the first pumping capacity.
3. The engine cooling system of claim 1 including an electric motor configured to drive the auxiliary coolant pump.
4. The engine cooling system of claim 3 including a controller operatively engaging the clutch and the electric motor and operable to selectively cause the clutch to engage and disengage and the motor to start and stop.
5. The engine cooling system of claim 1 wherein the torque transfer assembly is a belt and pulley system configured to be driven by the internal combustion engine.
6. A method of operating an engine cooling system in a vehicle having an internal combustion engine, the method comprising the steps of:
(a) determining if no coolant flow is required during operation of the engine;
(b) disengaging a main pump clutch to prevent a torque produced by the engine to drive a main coolant pump and ceasing operation of an auxiliary pump motor to deactivate an auxiliary coolant pump, if the determination is made that no coolant flow is required;
(c) determining if a minimum coolant flow is required in the engine cooling system;
(d) disengaging the main pump clutch to prevent the torque produced by the engine to drive the main coolant pump and activating the auxiliary pump motor to drive the auxiliary coolant pump, if the determination is made that the minimum coolant flow is required in the engine cooling system;
(e) determining if a maximum coolant flow is required in the engine cooling system during operation of the engine;
(f) engaging the main pump clutch to cause the engine to drive the main coolant pump and activating the auxiliary pump motor to drive the auxiliary coolant pump, if the determination is made that the maximum coolant flow is required in the engine cooling system;
(g) determining if a normal coolant flow is required in the engine cooling system during operation of the engine, the normal coolant flow being a greater coolant flow than the minimum coolant flow and less coolant flow than the maximum coolant flow; and
(h) engaging the main pump clutch to cause the engine to drive the main coolant pump and ceasing operation of the auxiliary pump motor to deactivate the auxiliary coolant pump, if the determination is made that the normal coolant flow is required in the engine cooling system.
7. The method of claim 6 wherein step (a) is further defined by a metal temperature being less than a predetermined threshold temperature and a HVAC system not requiring coolant flow through a heater core.
8. The method of claim 6 including step (i): adjusting a thermostat set point based on vehicle operating conditions.
9. The method of claim 6 wherein step (c) is further defined by minimum coolant flow being required when a metal temperature is below localized coolant boiling conditions and a climate control coolant flow request is below a predetermined level of climate control coolant flow.
10. The method of claim 6 wherein step (e) is further defined by maximum coolant flow being required when a climate control coolant flow request is at a maximum level of climate control coolant flow.
11. The method of claim 6 wherein step (e) is further defined by maximum coolant flow being required when a coolant temperature in the engine is at a boiling point and the internal combustion engine is operating below a predetermined low engine speed.
12. The method of claim 6 wherein step (g) is further defined by normal coolant flow being required when a coolant temperature is high enough that a thermostat is open and an engine fan is activated to improve cooling in a radiator.
13. The method of claim 6 including:
(i) detecting if a high vehicle acceleration event is occurring while the main pump clutch is engaged; and
(j) disengaging the main pump clutch and activating the auxiliary pump motor for a predetermined time period if the high vehicle acceleration event is detected while the main pump clutch is engaged.
14. The method of claim 6 including:
(i) detecting an engine auto-stop condition while the vehicle is operating and the main pump clutch is engaged; and
(j) disengaging the main pump clutch and activating the auxiliary pump motor during the engine auto-stop condition if the vehicle is operating and the main pump clutch is engaged.