Unified rotary flow control valve for internal combustion engine cooling system

• US 6,647,934 B2
• Filed: 10/01/2001
• Issued: 11/18/2003
• Est. Priority Date: 10/01/2001
• Status: Expired due to Fees

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Marsh, Gregory Alan, Valentine, Peter Loring
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): Trieu, Thai-Ba
• Application Number:
  US09/968,648
• Publication Number:
  US 20030079728A1
• Time in Patent Office: 778 Days
• Field of Search: 123/563, 123/41.44, 123/41.33, 123/41.31, 123/190.4, 605/99, 137/625.41, 137/625.46
• US Class Current: 123/41.33
• CPC Class Codes: F01P 11/029 Expansion reservoirs
• CPC Class Codes: F01P 2060/02 Intercooler
• CPC Class Codes: F01P 2060/04 Lubricant cooler
• CPC Class Codes: F01P 2060/12 Turbo charger
• 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 7/165 characterised by systems with two or more loops
• CPC Class Codes: F02B 29/0443 Layout of the coolant or refrigerant circuit
• CPC Class Codes: F02B 39/005 Cooling of pump drives
• CPC Class Codes: F16K 11/0856 having all the connecting conduits situated in more than one plane perpendicular to the axis of the plug
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10T 137/86823 Rotary valve
• CPC Class Codes: Y10T 137/86863 Rotary valve unit

Abstract

An enhanced split cooling system and method for a turbocharged internal combustion engine including a liquid cooled turbocharger 19 and an engine liquid coolant jacket 18, the system comprising a coolant pump 12 for pumping coolant from a coolant storage tank 16 in heat exchange relationship with the engine jacket 18 and turbocharger 19; an oil cooler 32 having coolant input and output lines; a valve assembly 74, 83 including a multi-port rotary valve actuated by a single actuator; a first coolant output line connected for conveying coolant from the engine to the valve assembly 74, 83; a radiator 22 connected via a second coolant line for receiving coolant from the valve assembly 74, 83 and having a coolant outflow line to return coolant to the coolant tank 16; an intercooler 28 operatively associated with the turbocharger 19 for passing the coolant in hear exchange relationship with compressed air in the turbocharger 19; a lube oil subcooler 46 coupled by a third coolant flow line to receive coolant from the radiator 22 and having a coolant outflow line selectively couplable through the valve assembly 74, 83 to the oil cooler 32 and the coolant tank 16; an intercooler subcooler 24 coupled by a fourth coolant flow line to receive coolant from the oil subcooler 46 and having a coolant outflow line selectively couplable through the valve assembly 74, 83 to the coolant tank 16 and the intercooler 28; and the valve assembly 74, 83 being independently operable for selectively directing coolant flow through the radiator 22 and subcoolers 46, 24 and the oil cooler 32 and intercooler 28 as a function of engine operating temperature.

Claims

1. A cooling system for a turbo-charged internal combustion engine for a locomotive or off highway vehicle, said system comprising:

(a) a coolant storage tank having an inlet and an outlet;

(b) a coolant pump associated with said tank operable to circulate coolant through said cooling system;

(c) an engine coolant jacket in heat transfer relationship with said engine having an inlet in fluid communication with said tank outlet and an outlet;

(d) a combustion air intercooler having an inlet;

(e) a radiator having an inlet and an outlet;

(f) a single rotary control valve connected in fluid communication with said coolant jacket outlet, said intercooler inlet, said radiator inlet, said radiator outlet, and said tank inlet and controllable to operate in a plurality of flow connection modes for selectively regulating a flow of coolant throughout said jacket, intercooler, radiator and tank, and thus a temperature of said engine under varying engine operating and environmental conditions;

(g) a liquid cooled turbo charger having an inlet in fluid communication with said tank outlet and an outlet;

(h) an intercooler subcooler having a coolant input and output;

(i) a lube oil cooler having a coolant input and output;

(j) a lube oil subcooler having a coolant input and output;

(k) wherein said single rotary control valve is further connected in fluid communication with said oil cooler inlet, said lube oil subcooler output, said intercooler subcooler inlet and said intercooler subcooler output and controllable to operate in a plurality of flow connection modes for selectively regulating a flow of coolant throughout said coolant jacket, turbo charger, intercooler, radiator, tank, oil cooler, oil subcooler, and intercooler subcooler and thus a temperature of the engine under varying engine operating and environmental conditions; and

(l) wherein said single rotary control valve comprises a first flow communication mode connecting said coolant jacket outlet and said turbo charger outlet to said radiator inlet, connecting said oil subcooler outlet to said oil cooler inlet, and connecting said intercooler subcooler outlet to said intercooler inlet;

a second flow communication mode connecting said coolant jacket outlet and said turbo charger outlet to said radiator inlet, said oil cooler inlet, and said intercooler inlet, connecting said oil subcooler outlet to said coolant tank inlet, and connecting said intercooler subcooler outlet to said coolant tank inlet; and

a third flow communication mode connecting said coolant jacket outlet to said intercooler inlet, said oil cooler inlet, and said coolant tank inlet, connecting said radiator input to said coolant tank inlet, connecting oil subcooler outlet to said coolant tank inlet, and connecting said intercooler subcooler outlet to said coolant tank inlet.

2. The cooling system of claim 1, wherein said rotary control valve further comprises:

(a) a cylinder having openings connected to said turbocharger outlet, said coolant jacket outlet, said intercooler inlet, said radiator inlet, said radiator outlet, and said coolant tank inlet;

(b) a rotor disposed within said cylinder and having a plurality of sets of openings formed therein said rotor operable to be moved to a plurality of positions within said cylinder;

(c) a first of said positions aligning said openings in said cylinder with a first set of opening in said rotor to form said first flow communication mode;

(d) a second of said positions aligning said openings in said cylinder with a second set of opening in said rotor to form said second flow communication mode; and

(e) a third of said positions aligning said openings in said cylinder with a third set of openings in said rotor to form said third flow communication mode.

3. A control valve for regulating flow of coolant throughout a cooling system for a turbo-charged internal combustions engine for a locomotive or off highway vehicle, said control valve comprising:

(a) a cylinder having openings in fluid communication with a coolant jacket, intercooler, radiator, and coolant tank;

(b) a rotor disposed within said cylinder and having a plurality of sets of openings formed therein said rotor operable to be rotated to a plurality of positions within said cylinder for regulating coolant flow between said control valve and said coolant jacket, said intercooler, said radiator and said coolant tank;

(c) a first of said positions aligning said openings in said cylinder with a first set of openings in said rotor to form a first flow connection mode;

(d) a second of said positions aligning said openings in said cylinder with a second set of openings in said rotor to form a second flow connection mode; and

(e) a third of said positions aligning said openings in said cylinder with a third set of openings in said rotor to form a third flow connection mode.

4. The control valve of claim 3 wherein said first flow connection mode is formed by connecting an outlet for said coolant jacket in fluid communication with an inlet of said radiator, and connecting an outlet of said radiator in fluid communication with an inlet of said intercooler.

5. The control valve of claim 3 wherein said second flow connection mode is formed by connecting said coolant jacket outlet in fluid communication with said radiator inlet, and connecting said radiator outlet in fluid communication with an inlet to said coolant tank.

6. The control valve of claim 3 wherein said third flow connection mode is formed by connecting said coolant jacket outlet in fluid communication with said intercooler inlet and said coolant tank inlet, and connecting said radiator inlet and outlet in fluid communication with said coolant tank inlet.

7. An enhanced split cooling system for a turbocharged internal combustion engine including a liquid cooled turbocharger and an engine liquid coolant jacket, said system comprising:

(a) a coolant pump for pumping coolant from a coolant storage tank into heat exchange relationship with said engine jacket and said turbocharger;

(b) an oil cooler;

(c) an oil subcooler;

(d) a radiator;

(e) an intercooler operatively associated with said turbocharger for passing coolant in heat exchange relationship with compressed air in said turbocharger;

(f) an intercooler subcooler having an input and an output;

(g) a valve assembly actuated by an actuator wherein said valve assembly is in fluid communication with said coolant jacket, said turbo charger, said oil cooler, said oil subcooler, said intercooler, said intercooler subcooler, said radiator, said tank and independently operable for selectively directing coolant flow through said coolant jacket, turbo charger, oil cooler, oil subcooler, intercooler, intercooler subcooler, radiator, and tank under varying engine operating environmental conditions; and

(h) wherein said valve assembly is operable in a mode wherein coolant flows from said engine and flows to said radiator, said oil cooler, and said intercooler, flows from said oil subcooler to said tank, and flows from said intercooler subcooler to said tank.

8. The system as set forth in claim 7 wherein aid valve assembly is operable in a first mode wherein coolant flows from said engine and flows to said radiator, said oil cooler, and said intercooler, flows from said oil subcooler to said tank, and flows from said intercooler subcooler to said tank.

9. The system as set forth in claim 7 wherein said oil cooler is a plate type heat exchanger.

10. The system as set forth in claim 7 wherein said radiator, said oil subcooler and said intercooler subcooler are horizontally disposed in parallel relationship.

11. The system as set forth in claim 7 wherein said oil cooler is a plate type heat exchanger and wherein said radiator, said oil subcooler and said intercooler subcooler are horizontally displaced in parallel relationship.

12. The system of claim 7 wherein said valve assembly is a four-port rotary valve.

13. The system of claim 7 where said valve assembly is a three-port rotary valve assembly.

14. An enhanced split cooling system for a turbocharged internal combustion engine including a liquid cooled turbocharger and an engine liquid coolant jacket, said system comprising:

(a) a coolant pump for pumping coolant from a coolant storage tank into heat exchange relationship with said engine jacket and said turbocharger;

(b) an oil cooler;

(c) an oil subcooler;

(d) a radiator;

(e) an intercooler operatively associated with said turbocharger for passing coolant in heat exchange relationship with compressed air in said turbocharger;

(f) an intercooler subcooler having an input and an output;

(g) a valve assembly actuated by an actuator wherein said valve assembly is in fluid communication with said coolant jacket, said turbo charger, said oil cooler, said oil subcooler, said intercooler, said intercooler subcooler, said radiator, said tank and independently operable for selectively directing coolant flow through said coolant jacket, turbo charger, oil cooler, oil subcooler, intercooler, intercooler subcooler, radiator, and tank under varying engine operating environmental conditions; and

(h) wherein said valve assembly is operable in a mode wherein coolant flows from said engine and flows to said intercooler, said oil cooler, said tank, flows from said radiator to said tank, flows from said oil subcooler to said tank, and flows from said intercooler subcooler to said tank.

15. An enhanced split cooling system for a turbocharged internal combustion engine including a liquid cooled turbocharger and an engine liquid coolant jacket, said system comprising:

(a) coolant pump for pumping coolant from a coolant storage tank into heat exchange relationship with said engine jacket and said turbocharger;

(b) an oil cooler;

(c) an oil subcooler;

(d) a radiator;

(e) an intercooler operatively associated with said turbocharger for passing coolant in heat exchange relationship with compressed air in said turbocharger;

(f) an intercooler subcooler having an input and an output;

(g) a valve assembly actuated by an actuator wherein said valve assembly is in fluid communication with said coolant jacket, said turbo charger, said oil cooler, said oil subcooler, said intercooler, said intercooler subcooler, said radiator, said tank and independently operable for selectively directing coolant flow through said coolant jacket, turbo charger, oil cooler, oil subcooler, intercooler, intercooler subcooler, radiator, and tank under varying engine operating environmental conditions; and

(h) wherein said valve assembly is a five-port rotary valve.

16. A control valve for regulating flow of coolant throughout a cooling system for an enhanced turbo-charged internal combustions engine for a locomotive or off highway vehicle, said control valve comprising:

(a) a cylinder having openings in fluid communication with to a turbocharger, a coolant jacket, an intercooler, a radiator, and a coolant tank;

(b) a rotor disposed within said cylinder and having a plurality of sets of openings formed therein said rotor operable to be rotated to a plurality of positions within said cylinder;

(c) a first of said positions aligning said openings in said cylinder with a first set of openings in said rotor to form a first flow communication mode;

(d) a second of said positions aligning said openings in said cylinder with a second set of openings in said rotor to form a second flow communication mode; and

(e) a third of said positions aligning said openings in said cylinder with a third set of openings in said rotor to form a third flow communication mode.

17. The control valve of claim 16 wherein said first flow connection mode is formed by connecting an outlet for said coolant jacket and an outlet for said turbo charger to an inlet for said radiator, connecting an outlet for said oil subcooler to and inlet for said oil cooler, and connecting an outlet for said intercooler subcooler to an inlet for said intercooler inlet.

18. The control valve of claim 16 wherein said second flow connection mode is formed by connecting an outlet for said coolant jacket and said turbo charger outlet to said radiator inlet, said oil cooler inlet, and said intercooler inlet, connecting said oil subcooler outlet to said coolant tank inlet, and connecting said intercooler subcooler outlet to said coolant tank inlet.

19. The control valve of claim 16 wherein said third flow connection mode is formed by connecting said coolant jacket outlet and said turbo charger outlet to said intercooler inlet, said oil cooler inlet, and said coolant tank inlet, connecting said radiator input to said coolant tank inlet, connecting oil subcooler outlet to said coolant tank inlet, and connecting said intercooler subcooler outlet to said coolant tank inlet.

20. A method for controlling cooling of an internal combustion engine for a locomotive or off highway vehicle having a number of engine components receiving and discharging engine coolant via a single control valve assembly having a plurality of flow connection modes, the method comprising:

(a) providing fluid flow connections between said engine and a cooling system comprising a coolant storage tank, a coolant pump, a radiator, and an intercooler;

(b) connecting said control valve into said fluid flow connections to selectively open and block flow through the connections;

(c) flowing a coolant from said cooling tank to a liquid coolant jacket of said engine;

(d) flowing said coolant from said coolant jacket to a rotary valve assembly;

(e) determining the relationship between an engine temperature operating range and the fluid flow connection mode of said valve assembly;

(f) sensing the temperature of the engine; and

(g) configuring said valve assembly to the selected fluid flow connection mode for controlling the cooling said engine.

21. The method of claim 20 wherein said engine further comprises a liquid cooled turbo charger and said cooling system further comprises an intercooler subcooler, a lube oil cooler and a lube oil subcooler.

22. The method of claim 20 wherein determining a temperature control operating mode further comprises selecting a mode that flows said coolant through said rotary valve assembly to said radiator when heat rejection requirements are greatest.

23. The method of claim 20 wherein determining a temperature control operating mode further comprises selecting a mode that minimizes a risk of damage to said engine during operation.

24. The method of claim 20 wherein determining a temperature control operating mode further comprises selecting a mode that is a cost effective operating mode.