Method of flowing coolant through exhaust heat recovery system after engine shutoff

• US 10,677,545 B2
• Filed: 10/12/2016
• Issued: 06/09/2020
• Est. Priority Date: 10/12/2016
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Bonkoski, Phillip, Bidner, David Karl, Cole, W. Cary, Russell, Jeremy L., Rollinger, John
• Primary Examiner(s): Gimie, Mahmoud
• Assistant Examiner(s): Campbell, Joshua
• Application Number:
  US15/291,965
• Publication Number:
  US 20180100711A1
• Time in Patent Office: 1,336 Days
• CPC Class Codes: F01P 2011/205 using heat-accumulators
• CPC Class Codes: F01P 2031/30 Cooling after the engine is stopped
• CPC Class Codes: F01P 2050/24 Hybrid vehicles
• CPC Class Codes: F01P 2060/045 for transmissions
• CPC Class Codes: F01P 2060/16 Outlet manifold
• CPC Class Codes: F01P 3/20 Cooling circuits not specific to a single part of engine or machine F01P3/22 takes precedence
• CPC Class Codes: F01P 7/04 by varying pump speed, e.g. by changing pump-drive gear ratio
• CPC Class Codes: F01P 7/165 characterised by systems with two or more loops
• CPC Class Codes: F02G 5/02 Profiting from waste heat of exhaust gases
• CPC Class Codes: F16H 57/0412 Cooling or heating; Control of temperature
• CPC Class Codes: F16H 57/0413 Controlled cooling or heating of lubricant; Temperature control therefor
• CPC Class Codes: F16H 57/0417 Heat exchangers adapted or integrated in the gearing
• CPC Class Codes: F16H 57/0435 Pressure control for supplying lubricant; Circuits or valves therefor
• CPC Class Codes: F16H 57/0475 Engine and gearing, i.e. joint lubrication or cooling or heating thereof electric machines and gearing F16H57/0476
• CPC Class Codes: F16H 57/0483 Axle or inter-axle differentials
• CPC Class Codes: F28D 15/00 Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies F28D17/00, F28D19/00, F28D20/00 take precedence
• CPC Class Codes: F28D 20/0034 using liquid heat storage material
• CPC Class Codes: F28D 20/02 using latent heat
• CPC Class Codes: F28D 2021/008 for vehicles
• CPC Class Codes: F28D 2021/0089 Oil coolers
• CPC Class Codes: F28D 2021/0094 : for recooling the engine coolant
• CPC Class Codes: F28D 21/0003 : the heat being recuperated from exhaust gases F28D21/0014 takes precedence
• CPC Class Codes: F28F 2250/08 : Fluid driving means, e.g. pumps, fans
• 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: Y02E 60/14 : Thermal energy storage
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Methods and systems are provided for adjusting a flow of coolant through a coolant system including a rear axle heat exchanger. In one example, a method may include flowing coolant through the coolant system while an engine is not operating. In another example, a method may include increasing a flow of coolant to the rear axle heat exchanger while the engine is not operating when a rear axle oil temperature exceeds a threshold temperature.

Claims

1. A method, comprising:

cooling a rear axle heat exchanger (RAHX) at a rear axle of a vehicle by flowing a coolant, comprising water and maintained separate from an engine coolant, through a coolant system while an engine is not operating, while adjusting a flow rate of the coolant through the RAHX in response to a rear axle oil temperature of rear axle oil exchanged between only the RAHX and the rear axle via first and second oil lines, the coolant and the rear axle oil maintained separate from each other within the RAHX without mixing, by, responsive to a first condition, concurrently adjusting a first three-way valve and a second three-way valve to control a flow of coolant from the first three-way valve to a thermal storage vessel (TSV) and to control a flow of coolant from the second three-way valve to the RAHX, where the first three-way valve is adjustable to bypass the flow of coolant around the TSV to the second three-way valve, and where the second three-way valve is adjustable to bypass the flow of coolant around the RAHX to a coolant line coupled to an outlet of the RAHX, and, responsive to a second condition, adjusting only one of the first three-way valve or the second three-way valve.

2. The method of claim 1, wherein adjusting the flow rate of the coolant through the RAHX includes:

responsive to the rear axle oil temperature being greater than a first threshold temperature, maintaining or increasing a flow rate of the coolant from an exhaust gas heat exchanger (EGHX) through the RAHX; and

responsive to the rear axle oil temperature being less than the first threshold temperature, decreasing the flow rate of the coolant from the EGHX through the RAHX.

3. The method of claim 2, further comprising adjusting a flow rate of the coolant from the EGHX through the TSV fluidly coupled with the coolant system in response to a temperature of the TSV.

4. The method of claim 3, wherein adjusting a flow rate of the coolant through the TSV includes maintaining or increasing the flow rate of the coolant from the EGHX through the TSV while the temperature of the TSV is less than both of a second threshold temperature and a third threshold temperature.

5. The method of claim 4, wherein adjusting the flow rate of the coolant through the TSV includes decreasing the flow rate of the coolant from the EGHX through the TSV while the temperature of the TSV is greater than either of the second threshold temperature or the third threshold temperature.

6. The method of claim 5, wherein the second threshold temperature corresponds to a desired storage temperature of the TSV, and wherein the third threshold temperature corresponds to a fluid outlet temperature of the EGHX fluidly coupled with the coolant system, the EGHX fluidly coupled with the TSV via the first three-way valve and fluidly coupled with the RAHX via the second three-way valve.

7. The method of claim 6, wherein cooling the RAHX by flowing the coolant through the coolant system while the engine is not operating includes decreasing the rear axle oil temperature by maintaining or increasing a coolant pumping rate of a coolant pump fluidly coupled with the coolant system while an amount of time since engine shutoff is less than a threshold amount of time, and wherein the coolant flowing through the coolant system is maintained separate from an engine coolant system comprising a radiator.

8. The method of claim 7, wherein adjusting the flow rate of the coolant through the RAHX includes maintaining or increasing the coolant pumping rate of the coolant pump while the fluid outlet temperature of the EGHX is greater than a fourth threshold temperature, wherein the coolant pump and the coolant system are not fluidly coupled with the engine.

9. The method of claim 8, wherein adjusting the flow rate of the coolant through the RAHX includes decreasing the coolant pumping rate of the coolant pump while the amount of time since engine shutoff is greater than the threshold amount of time and the fluid outlet temperature of the EGHX is less than the fourth threshold temperature.

10. A method for a coolant system of a vehicle, comprising:

in response to vehicle engine shutoff, flowing a coolant, comprising water and maintained separate from a vehicle engine coolant, through coolant lines fluidly coupling an exhaust gas heat exchanger (EGHX) to each of a rear axle heat exchanger (RAHX) at a rear axle of the vehicle and a thermal storage vessel (TSV);

cooling the RAHX by adjusting a flow rate of the coolant from the EGHX through the RAHX in response to a rear axle oil temperature of rear axle oil exchanged directly between the RAHX and the rear axle via first and second oil lines, the coolant and the rear axle oil maintained separate from each other within the RAHX without mixing, and, responsive to a first condition, concurrently adjusting a first three-way valve and a second three-way valve to control a flow of coolant from the first three-way valve to the TSV and to control a flow of coolant from the second three-way valve to the RAHX, where the first three-way valve is adjustable to bypass the flow of coolant around the TSV to the second three-way valve, and where the second three-way valve is adjustable to bypass the flow of coolant around the RAHX to a coolant line coupled to an outlet of the RAHX, and, responsive to a second condition, adjusting only one of the first three-way valve or the second three-way valve; and

heating the TSV by adjusting a flow rate of the coolant from the EGHX through the TSV in response to a temperature of the TSV.

11. The method of claim 10, wherein flowing the coolant through the coolant lines includes at least flowing the coolant through the first three-way valve fluidly coupling the EGHX to the TSV and flowing the coolant through the second three-way valve fluidly coupling the EGHX to the RAHX, and further includes maintaining the coolant separate from a vehicle engine.

12. The method of claim 11, wherein cooling the RAHX by adjusting the flow rate of the coolant from the EGHX through the RAHX in response to the rear axle oil temperature includes maintaining or increasing the flow rate of the coolant from the EGHX through the RAHX while the rear axle oil temperature is above a first threshold temperature and decreasing the flow rate of the coolant from the EGHX through the RAHX while the rear axle oil temperature is below the first threshold temperature, and wherein the first and second three-way valves and the RAHX are not fluidly coupled with the vehicle engine.

13. The method of claim 12, wherein heating the TSV by adjusting the flow rate of the coolant from the EGHX through the TSV in response to the temperature of the TSV includes comparing the temperature of the TSV to both of a second threshold temperature and an EGHX fluid outlet temperature, and maintaining or increasing the flow rate of the coolant from the EGHX through the TSV while the temperature of the TSV is less than both of the second threshold temperature and the EGHX fluid outlet temperature, and decreasing the flow rate of the coolant from the EGHX through the TSV while the temperature of the TSV is greater than one of the second threshold temperature and the EGHX fluid outlet temperature.

14. The method of claim 13, further comprising not flowing the coolant through the coolant lines and not flowing the coolant from the EGHX through the RAHX and the TSV while an amount of time after the vehicle engine shutoff is greater than a threshold amount of time, and not flowing the coolant through the coolant lines and not flowing the coolant from the EGHX through the RAHX and the TSV while the EGHX fluid outlet temperature is less than a third threshold temperature and the rear axle oil temperature is less than the first threshold temperature.

15. A method for a rear axle coolant system of an engine, comprising:

during engine operation;

responsive to a first condition, recovering exhaust gas heat at an exhaust gas heat exchanger (EGHX) via a coolant comprising water in a coolant loop maintained separate from an engine coolant and storing the recovered exhaust gas heat in a thermal storage vessel (TSV); and

responsive to a second condition, transferring heat from the TSV to rear axle lubrication oil via a rear axle heat exchanger (RAHX) at a rear axle, the rear axle lubrication oil maintained separate from the coolant and exchanged directly between the RAHX and the rear axle via first and second oil lines; and

during engine non-operation;

responsive to a third condition, concurrently adjusting a first three-way valve and a second three-way valve to control a flow of coolant from the first three-way valve to the TSV and to control a flow of coolant from the second three-way valve to the RAHX, where the first three-way valve is adjustable to bypass the flow of coolant around the TSV to the second three-way valve, and where the second three-way valve is adjustable to bypass the flow of coolant around the RAHX to a coolant line coupled to an outlet of the RAHX;

responsive to a fourth condition, adjusting only one of the first three-way valve or the second three-way valve;

responsive to a temperature of the rear axle lubrication oil, adjusting a flow of the coolant from the EGHX to the RAHX;

responsive to a temperature of the TSV, adjusting a flow of the coolant from the EGHX to the TSV; and

responsive to a temperature of the EGHX, adjusting a flow rate of the coolant through the coolant loop.

16. The method of claim 15, wherein the first condition comprises the temperature of the rear axle lubrication oil being above a first threshold temperature, and wherein the second condition comprises the temperature of the rear axle lubrication oil being below the first threshold temperature, while the temperature of the TSV is equal to or greater than the rear axle lubrication oil temperature.

17. The method of claim 16, wherein adjusting the flow of the coolant from the EGHX to the RAHX includes actuating the second three-way valve, wherein adjusting the flow of the coolant from the EGHX to the TSV includes actuating the first three-way valve, and wherein adjusting the flow rate of the coolant through the coolant loop includes adjusting a pump rate of a coolant pump fluidly coupled with the coolant loop.

18. The method of claim 17, wherein actuating the second three-way valve includes not adjusting an amount of opening of a coolant inlet of the second three-way valve downstream of the EGHX and the TSV and upstream of the RAHX while adjusting an amount of opening of at least one coolant outlet of the second three-way valve downstream of the EGHX and the TSV and upstream of the RAHX, and wherein actuating the first three-way valve includes not adjusting an amount of opening of a coolant inlet of the first three-way valve upstream of the RAHX and the TSV and downstream of the EGHX while adjusting an amount of opening of at least one coolant outlet of the first three-way valve upstream of the RAHX and the TSV and downstream of the EGHX.

19. The method of claim 18, wherein, during the engine non-operation, the coolant is pumped through the coolant pump until the temperature of the rear axle lubrication oil and the temperature of the EGHX are each below a boiling temperature of the coolant.

20. The method of claim 19, wherein a vehicle including the engine is a hybrid-electric vehicle, and wherein engine non-operation is defined as a condition in which an electric motor of the vehicle is not energized and the vehicle is not in motion.