FLOW SCHEME FOR SWITCH PUMP WITH FOUR POSITIONS

A process for cooling a heat generating component of a vehicle including pumping a coolant fluid from a pump having a first impeller and a second impeller, the pump switchable from a chilling mode, a heating mode, an isolated state, and a linked state; and while the pump is in the chilling mode and the isolated state, pumping the coolant fluid with the first impeller through a first loop of a heater module, and a cabin heat exchanger, and pumping the coolant fluid with the second impeller through a second loop of a component heat exchanger and a chiller module.

FIELD

The field is generally related to a pump for switching flow to heat generating or absorbing components.

BACKGROUND

Pumps are known and commonly used to move fluids, such as coolant in a vehicle. One example is cooling systems with water pumps, which are used for the cooling of different electrical or mechanical components of a vehicle. In hybrid or purely electric vehicles, electrical components need to be cooled. Valves are used to ensure the distribution of the coolant throughout the cooling system. The valves each require an actuator with electrical control and a holder on a component of the vehicle, which results in high component costs.

In some vehicles, more than one cooling loop may be employed to cool heat generating components and to modulate the temperature of the driver cabin. Each loop requires a pump and a valve to direct flow through the appropriate loop.

It is an object of the present disclosure to employ a pump with an integrated valve that can control the flow from the pump through a plurality of outlets using a minimal set of components.

SUMMARY

This disclosure relates to a process for cooling a heat generating component of a vehicle including pumping a coolant fluid from a pump having a first impeller and a second impeller. The pump is switchable from a chilling mode, a heating mode, an isolated state, and a linked state. While the pump is in the chilling mode and the isolated state, pumping the coolant fluid with the first impeller through a first loop comprising a heater module, and a cabin heat exchanger, and pumping the coolant fluid with the second impeller through a second loop comprising a component heat exchanger and a chiller module.

This disclosure also relates to an apparatus for cooling a heat generating component of a vehicle. The apparatus has a first loop comprising a heater module and a cabin heat exchanger, and a second loop comprising a component heat exchanger and a chiller module. The apparatus also has a pump having a first impeller and a second impeller. The pump is switchable among four positions by a valve including combinations of a chilling mode, a heating mode, an isolated state, and a linked state. When the pump is in the linked state, the second impeller is in direct downstream communication with the first impeller. When the pump is in the isolated state, the first impeller pumps a coolant fluid through the first loop only and the second impeller pumps coolant fluid through the second loop only.

The disclosure also relates to a process for cooling a heat generating component of a vehicle. The process includes pumping a coolant fluid from a pump having a first impeller and a second impeller. The pump is switchable from a chilling mode, a heating mode, an isolated state, and a linked state. While the pump is in the chilling mode and the isolated state, pumping the coolant fluid with the first impeller through a first loop comprising a heater module, and a cabin heat exchanger. And pumping the coolant fluid with the second impeller through a second loop comprising a component heat exchanger and a chiller module. While the pump is in the chilling mode and the linked state, the first impeller pumps the coolant fluid to the second impeller and the second impeller pumps the coolant fluid through the first loop and the second loop.

DEFINITIONS

The term “communication” means that fluid flow is operatively permitted between enumerated components, which may be characterized as “fluid communication”. The term “communication” may also mean that data or signals are transmitted between enumerated components which may be characterized as “informational communication”.

The term “downstream communication” means that at least a portion of fluid flowing to the subject in downstream communication may operatively flow from the object with which it fluidly communicates.

The term “upstream communication” means that at least a portion of the fluid flowing from the subject in upstream communication may operatively flow to the object with which it fluidly communicates.

The term “direct communication” means that fluid flow from the upstream component enters the downstream component without passing through any other intervening vessel.

The term “indirect communication” means that fluid flow from the upstream component enters the downstream component after passing through an intervening vessel.

The term “bypass” means that the object is out of downstream communication with a bypassing subject at least to the extent of bypassing.

DETAILED DESCRIPTION

FIG.1depicts a system10for regulating the temperature of a heat generating component12of a vehicle. The heat generating component12may be a battery for powering a hybrid or an electrical vehicle. The system10can also be employed to modulate temperature in a driver cabin38. The system10may include a first loop14and a second loop16.

The system10includes a pump50having a first impeller52in a first impeller chamber53and a second impeller54in a second impeller chamber55. A mixing chamber59best seen inFIG.5separates the first and second impeller chambers. A valve19has a first end19ain the first impeller chamber and an opposed second end19bin the second impeller chamber. The first and second impellers52,54, their respective chambers53,55the mixing chamber59, and the valve19are inside a pump housing66. The first impeller and the second impeller are mounted on an axle68for co-rotation there about. The valve19is moveable by an actuator motor63(FIG.5) by a controller (not shown) to place the pump in one of four switch positions described in greater detail below.

The first impeller chamber53has a first fluid inlet44, a first outlet60and a second outlet62. The second impeller chamber55has a second fluid inlet30aand a third fluid inlet30bwhich may be located in the mixing chamber59shown inFIG.5. As described in greater detail below, when the pump is in an isolated state, the second impeller chamber55receives fluid from the second fluid inlet30a. When the pump is in a linked state, the second impeller chamber55receives fluid from both the second and third fluid inlets30a,30b. An outlet of the mixing chamber directly communicates with the second impeller chamber55. The second impeller chamber55has a third outlet56and a fourth outlet58. A jumper line64connects the second fluid outlet62to the third fluid inlet30bThe pump50pumps a coolant fluid through the first loop14and the second loop16.

The first loop14comprises a heater module32and a cabin heat exchanger36. The second loop16comprises a chiller module18and a component heat exchanger22.

The pump50is switchable between four positions of a combination of two modes and two states by positioning of valve19. The two modes are chilling and recirculation or heating. Recirculation is a form of heating using waste heat from the batteries. For the sake of convenience, we will refer to the recirculation mode as the heating mode. The position of valve19bdetermines whether the pump is in the chilling or heating mode. The two states are isolated and linked which are selected by the position of19aof the valve.FIG.1shows the pump50in the first position of the chilling mode and the isolated state.FIG.2shows the pump50in the second position of the chilling mode and the linked state.FIG.3shows the pump50in the third position of the heating mode and the isolated state.FIG.4shows the pump50in the fourth position of the heating mode and the linked state. These combinations of modes and states will now be discussed.

FIG.1shows that when the pump is in the first switch position of the chilling mode and the isolated state, coolant fluid is received in the first impeller chamber53from the first fluid inlet44. Valve end19aopens an outlet60and closes an outlet62. The valve end19bopens an outlet56and closes an outlet58. The coolant fluid is pumped by the first impeller52through the outlet60through line39of the first loop14into the heater module32and then to the cabin heat exchanger36in a cabin38of a vehicle. The first loop14, thus, is in direct downstream communication with the first impeller chamber53. When the pump is in the isolated state, the heater module32will be off or on based on whether there is a request to cool or warm the cabin respectively.

Also, when in the first switch position, the second impeller chamber55receives fluid from the inlet30avia mixing chamber59. The second impeller54pumps coolant fluid through the outlet56and line25through the second loop16to the chiller module18. The chiller module18can be in an on state or an off state depending on the temperature of the heat generating component12. When the heat generating component needs cooling, the chiller module18will be in the on state. The second loop16, thus, is in direct downstream communication with the second impeller chamber54. The coolant fluid flows through line26through a junction24, through a second sensor20, and then into the heat exchanger22to possibly cool the heat generating component12.

When on, the chiller module18cools the coolant fluid by means of a device such as a Peltier electric device. A Peltier electric device applies a current through a junction connecting two metals to absorb heat at the junction to balance the difference in the chemical potential of the two metals to produce a cooling effect. Coolant fluid exiting the heat exchanger22is directed through line28to an inlet30aof the second impeller chamber55. Thus, when the pump50is in the first switch position, the chilling mode and the isolated state, the first loop14is isolated from the second loop16. Thus, the chiller module18and the heater module32are operated independently based on the needs of the battery and the cabin temperature respectively. However, the first and second loops do communicate, minorly due to fluid expansion and contraction through line17.

FIG.2shows the pump50in the second switch position in the heating mode and the linked state. The valve end19aopens outlet62and closes outlet60. The valve end19bopens outlet56and closes outlet58. The first impeller chamber53receives fluid through the first fluid inlet44and pumps the coolant fluid through outlet62, through fluid jumper line64, into the third fluid inlet30bof the mixing chamber59, then into the second impeller chamber55. The mixing chamber59also receives fluid from the second fluid inlet30a. The second impeller54pumps the coolant fluid out through outlet56and through line25into the chiller unit18. The chiller unit will be on if the heat generating component12needs cooling. The coolant fluid is conveyed through line26through junction24where the coolant is split into two streams. A first stream flows minorly through line26based on flow resistance through the second sensor into the heat exchanger22to possibly cool the heat generating component12. A second stream flows through line17to the heater module32, which is off or on based on whether the cabin air temperature is above or below the desired temperature respectively. The coolant then flows through the first sensor34into the cabin heat exchanger36to possibly cool the air in the cabin38and then returns through line42to the inlet44of the first impeller chamber53.

FIG.3shows the pump50in the third switch position in the heating mode and the isolated state. The valve end19aopens outlet60and closes outlet62. The valve end19bopens outlet58and closes outlet56. The first impeller52receives fluid through the first inlet44and pumps the coolant fluid through outlet60and line17to the heat exchanger32which is on or off based on the temperature of the cabin38. When on, the heat exchanger32heats the coolant fluid by a device such as a Seebeck device which operates on the reverse principle as a Peltier electrical device described above for the chiller module18. The heated coolant flow through line40, through the first sensor34, into the cabin heat exchanger36to possibly warm the air in the cabin38. The second impeller54pumps the coolant fluid through outlet58and lines27and26directly to the heat exchanger22bypassing the chiller module18which is off. The coolant fluid is conveyed by line28back to the second impeller chamber54. Loops1and2are isolated and the coolant fluid flows independently through them. However, loops1and2do minorly communicate through line17due to fluid expansion and contraction keeping the loops1and2in equilibrium.

FIG.4shows the pump in the fourth switch position of the heating mode and the linked state. The valve end19aopens outlet62and closes outlet60. The valve end19bopens outlet58and closes outlet56. The first impeller chamber53receives fluid from the first fluid inlet44. The first fluid impeller52pumps coolant fluid through outlet62, through fluid jumper line64, into the mixing chamber59via the third fluid inlet30b, and then into the second impeller chamber55. The second impeller54pumps the coolant fluid through outlet58and lines27and26directly to the heat exchanger22bypassing the chiller module18which is off. The coolant fluid is conveyed by line28back to the second impeller chamber55.

The second sensor20senses the temperature of coolant in line26entering the component heat exchanger22. The sensor20sends a signal to a controller70for signaling the pump to operate in the heating mode and to turn the chiller module18off. The first sensor20may send a signal directly to the pump50or the chiller module18.

FIG.5illustrates an example of a pump50for pumping the coolant in a vehicle. As can be appreciated, the pump50may also be used in non-vehicle applications. The pump50is an integration of a pump50and a valve19positioned by an actuator motor63for switching between four flow paths. The pump50includes the first impeller52(FIGS.6-9) in the first impeller chamber53, the second impeller54(FIGS.6-9) in the second impeller chamber55, the mixing chamber59between the two impeller chambers, the fluid jumper line64connecting the first impeller chamber53to the mixing chamber59and an electric motor75that engages the shaft68and causes it to rotate about its axis.

FIGS.6A and6Bshow the pump in the first switch position of the chilling mode and the isolated state ofFIG.1. The first impeller chamber53receives coolant fluid from inlet44, and outlets60and62extend along lines 180° from one another. Inlet44is best seen inFIG.5, but its flow is indicated by the lead line44. The first impeller52has numerous spaced arcuate vanes79that push the coolant fluid from the first impeller chamber53when the impeller52is rotated about the shaft68. The first valve end19ahas a first circular wall80with a first opening82that is in alignment with the outlet60to open outlet60. A solid wall portion of the first circular wall80closes the outlet62.

FIG.6Bshows a cross-sectional view of the second impeller chamber55that receives coolant fluid from inlet30a. Inlet30ais best seen inFIG.5but its flow is indicted by the led line for30a. The second impeller chamber55has the outlets56and58disposed 90° from one another. The second valve end19bhas a second circular wall81with a second opening83and a third opening84. The second circular wall81of the valve end19bis connected to the first circular wall80of the first valve end19aand rotates together therewith about a centrally disposed axis in response to the actuator motor63. The third opening84is in alignment with the outlet56to open outlet56. The second opening83is in alignment with the wall of the pump. A solid portion of the wall81is in alignment with outlet58to close outlet58. The second impeller54also has arcuate vanes86that when the second impeller54is rotated about shaft68cause the coolant to flow through opening56.

FIGS.7A and7Bshow the pump in the second switch position in the warming mode and the isolated state ofFIG.2. The valve19has been rotated 180° clockwise from the first switch position placing the first opening82into alignment with outlet62and a solid wall portion in alignment with outlet60. Thus, outlet62is open and outlet60is closed. Coolant fluid is pumped from the first impeller chamber53through the jumper line64into inlet30bof the second impeller chamber55shown inFIG.7Bvia the mixing chamber59only shown inFIG.5.

FIG.7Bshows the second impeller chamber55receives fluid from both inlets30aand30b. Inlet30aofFIG.7A, and inlet30bis best seen inFIG.5but its flow is indicated by the lead line for30a,30b, inFIG.7B. The third opening84is in alignment with the outlet56but a solid wall portion of the wall81is in alignment with outlet58. Thus, fluid is pumped from the second impeller chamber55through open outlet56only because outlet58is closed.

FIGS.8A and8Bshow the pump in the third switch position in the heating mode and the isolated state ofFIG.3. As shown inFIG.8A, the first impeller chamber53receives coolant fluid from inlet44. The valve19has been rotated 90° clockwise from the first switch position but still has opening82in alignment with outlet60and a solid wall portion is in alignment with opening62. Thus, outlet60is open and outlet62is closed.

FIG.8Bshows the third opening84is in alignment with the outlet58but a solid wall portion of the wall81is in alignment with outlet56. Thus, fluid is pumped from the second impeller chamber through open outlet58only while the outlet56is closed.

FIGS.9A and9Bshow the pump in the fourth switch position of the heating mode and the linked state ofFIG.4. As shown inFIG.9A, the first impeller chamber53receives coolant fluid from inlet44. The first valve opening82is in alignment with the fluid outlet62, but a solid wall portion of the wall80is in alignment with outlet60. Thus, outlet62is open and outlet60is closed.

FIG.9Bshows the second opening83is in alignment with the outlet58but a solid wall portion of the wall81is in alignment with outlet56. Thus, fluid is pumped from the second impeller chamber through open outlet58only.

The disclosure sets for a process and apparatus that can control temperature of a heat generating component and a vehicle cabin by means of a pump with two impellers coaxially mounted on an axle without requiring separate valves and the additional fluid lines and controls appurtenant thereto.