Rear axle lubrication oil temperature control using exhaust heat recovery and a thermal battery

• US 10,408,333 B2
• Filed: 12/09/2015
• Issued: 09/10/2019
• Est. Priority Date: 12/09/2015
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Cole, Cary, Katragadda, Sunil, Bonkoski, Phillip, Bidner, David Karl, Levin, Michael, Buckman, Colby Jason, Demitroff, Danrich Henry, Karnik, Amey Y., Shaikh, Furqan
• Primary Examiner(s): Ruby, Travis C
• Application Number:
  US14/964,332
• Publication Number:
  US 20170167595A1
• Time in Patent Office: 1,371 Days
• CPC Class Codes: F16H 57/0417 Heat exchangers adapted or integrated in the gearing
• CPC Class Codes: F28D 20/0034 using liquid heat storage material
• CPC Class Codes: F28D 20/02 using latent heat
• CPC Class Codes: F28D 2021/0089 Oil coolers
• CPC Class Codes: F28D 21/0003 the heat being recuperated from exhaust gases F28D21/0014 takes precedence
• CPC Class Codes: F28F 27/02 for controlling the distribution of heat-exchange media between different channels static flow control means in header boxes F28F9/026; arrangements of guide plates or guide vanes F28F9/22, F28F25/12
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Methods and systems are provided for regulating the temperature of rear axle lubrication oil. In one example, a rear axle coolant system may include a coolant loop with a plurality of valves and sensors, regulating the coolant flow in heat exchange relationship with an exhaust gas heat recovery and storage system to deliver warm coolant to a rear axle heat exchanger to warm the rear axle lubrication oil. The method may regulate the components of the rear axle coolant system through a controller, receiving sensor input from the components of the coolant system.

Claims

1. A method, comprising;

responsive to a first condition, where the first condition includes a rear axle lubrication oil temperature that is above a threshold temperature and a thermal battery system outlet temperature that is less than an exhaust gas heat exchanger outlet temperature, recovering exhaust gas heat at an exhaust gas heat exchanger via coolant in a coolant loop and storing the recovered exhaust gas heat in a thermal battery system via the coolant; and

responsive to a second condition, where the rear axle lubrication oil temperature is below the threshold temperature in the second condition, transferring heat from the thermal battery system to rear axle lubrication oil via the coolant at a rear-axle heat exchanger, wherein the coolant in the coolant loop is maintained separate from engine coolant in an engine coolant system.

2. The method of claim 1, wherein the second condition further comprises a thermal battery system temperature equal to or greater than the rear axle lubrication oil temperature.

3. The method of claim 2, further comprising, responsive to a third condition, bypassing the thermal battery system and transferring heat from the exhaust gas heat exchanger to the rear axle lubrication oil via the rear-axle heat exchanger, wherein the third condition comprises the rear axle lubrication oil temperature below the threshold temperature and thermal battery system temperature below the rear axle lubrication oil temperature.

4. The method of claim 1, wherein during the second condition, when a pressure drop across the exhaust gas heat exchanger is greater than a threshold pressure, bypassing exhaust gas around the exhaust gas heat exchanger.

5. The method of claim 1, further comprising, responsive to a fourth condition including the rear axle lubrication oil temperature above a maximum threshold temperature and a thermal battery system temperature below the rear axle lubrication oil temperature, transferring heat from the rear axle lubrication oil to the thermal battery system by flowing coolant through the rear-axle heat exchanger and to the thermal battery system, and bypassing exhaust gas around the exhaust gas heat exchanger.

6. The method of claim 1, wherein the threshold temperature is a lower limit normal temperature for the rear axle lubrication oil, the lower limit normal temperature being less than a maximum temperature threshold of the rear axle lubrication oil, and wherein the rear axle lubrication oil temperature is less than the maximum temperature threshold.

7. The method of claim 1, further comprising performing a functionality assessment of a pump and valves associated with a coolant system of the rear axle lubrication oil.

8. The method of claim 7, further comprising, responsive to any one or combination of the pump and the valves not functioning, disabling the coolant system of the rear axle lubrication oil.

9. The method of claim 7, further comprising maintaining the coolant system of the rear axle lubrication oil in a default mode responsive to determining that the pump is functioning and that one or more of the valves are not functioning.

10. The method of claim 9, wherein the engine coolant is flowed through one or more coolant jackets of an engine.

11. A rear axle coolant system, comprising:

an exhaust heat recovery system to transfer heat from an engine exhaust system to a coolant in a coolant loop via an exhaust gas heat exchanger;

a rear-axle heat exchanger to transfer heat between the coolant and rear axle lubrication oil;

a thermal battery system positioned intermediate the exhaust heat recovery system and the rear-axle heat exchanger, the thermal battery system configured to store excess heat from the exhaust heat recovery system; and

a controller storing instructions executable to;

responsive to a first condition, where the first condition includes a rear axle lubrication oil temperature that is above a threshold temperature and a thermal battery system outlet temperature that is less than an exhaust gas heat exchanger outlet temperature, recover exhaust gas heat at the exhaust gas heat exchanger via the coolant in the coolant loop via the exhaust heat recovery system and store the recovered exhaust gas heat in the thermal battery system via the coolant and

responsive to a second condition, where the rear axle lubrication oil temperature is below the threshold temperature in the second condition, transfer heat from the thermal battery system to rear axle lubrication oil via the coolant at the rear-axle heat exchanger, wherein the coolant in the coolant loop is maintained separate from engine coolant in an engine coolant system.

12. The system of claim 11, wherein heat from the thermal battery system to the rear axle lubrication oil is transferred via the rear axle heat exchanger.

13. The system of claim 12, wherein, responsive to a third condition including rear axle lubrication oil temperature at an operating temperature and the thermal battery system below maximum heat storing capacity, the controller is configured to flow coolant through the exhaust heat recovery system to recover heat from exhaust gas and to flow the coolant to the thermal battery system to store heat energy from the coolant in the thermal battery system, and after flowing through the thermal battery system, to bypass the coolant around the rear-axle heat exchanger.

14. The system of claim 12, wherein, responsive to a fourth condition including rear axle lubrication oil temperature at an operating temperature and the thermal battery system at maximum heat storing capacity, the controller is configured to flow coolant through the exhaust heat recovery system while bypassing exhaust gas around the exhaust heat recovery system, bypassing the thermal battery system and the rear-axle heat exchanger.