Description:COOLING SYSTEMS FOR VEHICLES AND METHODS THEREOF

FIELD OF THE DISCLOSURE
[0001] This invention generally relates to a field of automotive cooling systems, and in particular, relates to a pulse width modulation (PWM) based multiple fan speed controller for optimizing cooling efficiency in vehicles.
BACKGROUND
[0002] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
[0003] Automotive cooling systems play a crucial role in maintaining optimal engine performance and preventing overheating. Traditional cooling fans in vehicles often operate at fixed speeds, either running at full power or turning off completely. This approach is inefficient, as it leads to unnecessary energy consumption, increased fuel usage, and excessive wear on fan components. In modern vehicles, engine temperature fluctuates based on driving conditions, load, and external environment. Fixed-speed fans are unable to adjust dynamically to these changes, which can result in inefficient cooling, either overcooling the engine (wasting energy) or undercooling it (leading to overheating and potential damage).
[0004] Moreover, many high-performance and larger-engine vehicles require multiple cooling fans. Without an intelligent control system, the fans may run out of sync, leading to inefficient power usage and ineffective cooling distribution. Additionally, sudden fan activations and high-speed operations cause mechanical stress, shortening the lifespan of cooling components of the automotive cooling systems.
[0005] According to a patent application “RU2718391C2” titled as “Vehicle cooling method” discloses an invention that relates to an engine cooling system. Disclosed are methods for evaluating cooling requirement of vehicle power transmission component and selecting operating mode of vehicle cooling system based on evaluation of requirements for cooling of power transmission component of vehicle and energy consumption by components of cooling system. Based on the selected operating mode, it is possible to simultaneously control the radiator fan speed, the coolant system pump output, opening degree of louvre of vehicle radiator grate and opening degree of ventilation holes connected to insulating casing of power transmission component, which allows to minimize parasitic losses during cooling with simultaneous satisfaction of requirements for vehicle cooling.
[0006] Therefore, with growing concerns over fuel efficiency, emissions regulations, and the need for sustainable automotive technologies, there is an increasing demand for a smarter cooling solution.
 
OBJECTIVES OF THE INVENTION
[0008] An objective of present invention is to dynamically adjust fan speeds based on real-time temperature data, ensuring optimal cooling efficiency.
[0009] Further, the objective of present invention is to reduce unnecessary power consumption, thereby improving fuel efficiency in commercial vehicles.
[0010] Furthermore, the objective of the present invention is to implement gradual speed transitions that minimize mechanical stress, reducing wear and tear on fan components.
[0011] Furthermore, the objective of the present invention is to synchronize multiple fans efficiently, ensuring balanced power distribution and improved airflow management.
[0012] Furthermore, the objective of the present invention is to provide precise and adaptive cooling control by using both temperature input and PWM cycle count for enhanced performance.
[0013] Furthermore, the objective of the present invention is to decrease long-term maintenance expenses by enhancing durability of the fan system.
[0014] Furthermore, the objective of the present invention is to enable seamless integration with vehicle systems for better diagnostics and control.
[0015] Furthermore, the objective of the present invention is to ensure scalability for use in various trucks, buses, and other commercial vehicles, maintaining vehicle safety and subsystem functionality.

 
SUMMARY
[0017] According to an aspect, the present embodiments discloses a cooling system for a vehicle. The cooling system comprises at least one sensor configured to detect a temperature value of one or more components of the vehicle. The cooling system further comprises at least one control unit communicatively coupled to the at least one sensor. The at least one control unit is configured to receive the detected temperature value from the at least one sensor. The at least one control unit is further configured to compare the received temperature value with a predefined threshold value. The at least one control unit is further configured to generate a pulse width modulation (PWM) signal if the received temperature value exceeds the predefined threshold value. Further, the at least one control unit is configured to determine a PWM cycle count to determine an optimal fan duty cycle for one or more fans. The optimal duty cycle is adjustable between 15% and 95%. Thereafter, the at least one control unit is configured to adjust speed of the one or more fans based at least on the determined optimal fan duty cycle to regulate cooling performance.
[0018] In some embodiments, the at least one control unit is further configured to detect an open circuit condition. The one or more fans are turned off when the open circuit condition is detected. The open circuit condition corresponds to an absence of a detected temperature value from the at least one sensor.
[0019] In some embodiments, the at least one control unit is further configured to adjust the fan duty cycle based at least on the PWM cycle count. If the PWM cycle count is 1, fan 1 duty cycle corresponds to 15% to 95% and fan 2 duty cycle corresponds to 15% to 90%, and if the PWM cycle count is 2, the fan 1 duty cycle corresponds to 15% to 90% and the fan 2 duty cycle corresponds to 15% to 95%.
[0020] In some embodiments, one or more additional fans is integrated into the cooling system.
[0021] In some embodiments, the at least one sensor corresponds to a temperature sensor.
[0022] In some embodiments, the one or more components of the vehicle comprises at least of an engine, a radiator, a battery, and a compressor.
[0023] In some embodiments, the predefined temperature value corresponds to 350 C.
[0024] In some embodiments, the one or more fans operate at variable speed.
[0025] In some embodiments, the at least one control unit is further configured to determine a state of the one or more fans.
[0026] According to an aspect, the present embodiments discloses a method. The method comprising steps of detecting, via at least one sensor, a temperature value of one or more components of a vehicle. The method further comprising steps of receiving, via at least one control unit, the detected temperature value from the at least one sensor. The method further comprising steps of comparing, via the at least one control unit, the received temperature value with a predefined threshold value. Further, the method comprising steps of generating, via the at least one control unit, a pulse width modulation (PWM) signal if the received temperature value exceeds the predefined threshold value. Further, the method comprising steps of determining, via the at least one control unit, a PWM cycle count to determine an optimal fan duty cycle for one or more fans, wherein the optimal duty cycle is adjustable between 15% and 95%. Thereafter, the method comprising steps of adjusting, via the at least one control unit, speed of the one or more fans based at least on the determined optimal fan duty cycle to regulate cooling performance.
 
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The accompanying drawings illustrate various embodiments of systems, methods, and embodiments of various other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. It may be that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another, and vice versa. Furthermore, elements may not be drawn to scale. Non-limiting and non-exhaustive descriptions are described with reference to the following drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles.
[0028] FIG. 1 illustrates a block diagram of a cooling system for a vehicle, in accordance to an embodiment of the present invention;
[0029] FIG. 2 illustrates a flowchart showing a method for operating the cooling system, in accordance to an embodiment of the present invention; and
[0030] FIG. 3 illustrates another flowchart showing the method for operating the cooling system, in accordance to an embodiment of the present invention.
 
DETAILED DESCRIPTION
[0032] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
[0033] Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the preferred, systems and methods are now described. Embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which example embodiments are shown. Embodiments of the claims may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.
[0034] FIG. 1 illustrates a block diagram of a cooling system (100) for a vehicle, in accordance to an embodiment of the present invention.
[0035] In some embodiments, the cooling system (100) in the vehicle is configured to regulate temperature of one or more components of the vehicle to prevent overheating. The cooling system (100) is configured to transfer excess heat from the one or more components to surrounding air or a coolant fluid. The one or more components of the vehicle comprises at least of an engine, a radiator, a battery, and a compressor. The vehicle comprises a truck or a bus. In some embodiments, the cooling system (100) is configured to optimize cooling of the one or more components of the vehicle by adjusting speed of one or more fans (114). In the cooling system (100), the one or more fans (114) work in sync with each other.
[0036] In some embodiments, the cooling system (100) comprises at least one sensor (102), a filter and regulator circuit (104), at least one control unit (106), a pulse-width modulation (PWM) driver (108), a resistance (110), a motor controller (112), and the one or more fans (114).
[0037] In some embodiments, the cooling system (100) is powered by a battery. The battery is configured to provide power to the cooling system (100) and the one or more components of the cooling system (100). The battery power passes through the filter and regulator circuit (104). The filter and regulator circuit (104) is configured to ensure a stable voltage supply for the intelligent controller (106) and the PWM driver (108). The filter and regulator circuit (104) is further configured to stabilize the power supply from the battery to prevent voltage fluctuations.
[0038] In some embodiments, the at least one sensor (102) is configured to detect a temperature value of the one or more components of the vehicle. The at least one sensor (102) corresponds to a temperature sensor. The cooling system (100) further comprises at least one control unit (106). The at least one control unit (106) is communicatively coupled to the at least one sensor (102). The at least control unit is configured to receive the detected temperature value from the at least one sensor (102). In some embodiments, the detected temperature value is transmitted from the at least one sensor (102) to the control unit via a controller area network (CAN) bus. A CAN TX is configured to transmit the detected temperature value. Further, a CAN RX is configured to receive the detected temperature value.
[0039] In some embodiments, the at least one control unit (106) is configured to determine a state of the one or more fans (114) based at least on the received temperature value. The at least one control unit (106) corresponds to an intelligent controller. In some embodiments, the at least one control unit (106) is configured to compare the received temperature value with a predefined threshold value. The predefined threshold value corresponds to a temperature above which the cooling system (100) activates to regulate thermal conditions of the one or more components of the vehicle. The predefined threshold value corresponds to 350 C. The received temperature value is compared with the predefined threshold value to determine if cooling of the one or more components is required. Based at least on the comparison, the at least control unit determines the state of the one or more fans (114).
[0040] In some embodiments, the at least one control unit (106) is further configured to generate a PWM signal via the PWM driver (108), if the received temperature value exceeds the predefined threshold value. The PWM signal regulates speed of the one or more fans (114). Generation of the PWM signal ensures that the cooling system (100) responds dynamically to change in the received temperature value rather than operating at a fixed speed.
[0041] In some embodiments, the resistance (110) corresponds to a pull-up resistor. The cooling system (1000 comprises two resistances (110). The resistance (110) is configured to ensure that the generated PWM signal remains at a valid logic level. The valid logic level corresponds to a signal voltage that is interpreted as either a high voltage or a low voltage in a digital circuit. The high voltage is represented as (1), and the low voltage is represented as (0). The resistance (110) is further configured to stabilize the PWM signal and reduce electrical noise.
[0042] In some embodiments, the at least one control unit (106) is further configured to determine a PWM cycle count to determine an optimal fan duty cycle for one or more fans (114). The optimal duty cycle is adjustable between 15% and 95%. In some embodiments, the at least one control unit (106) is further configured to adjust the fan duty cycle based at least on the PWM cycle count. In some embodiments, the high temperature value increases the PWM duty cycle. The increased PWM duty cycle makes the one or more fans (114) moves faster for enhanced cooling. Further, the low temperature value decreases the PWM duty cycle. The decreased PWM duty cycle makes the one or more fans (114) moves slower to conserve power.
[0043] In some embodiments, if the PWM cycle count is 1, fan 1 duty cycle corresponds to 15% to 95% and fan 2 duty cycle corresponds to 15% to 90%. Further, if the PWM cycle count is 2, the fan 1 duty cycle corresponds to 15% to 90% and the fan 2 duty cycle corresponds to 15% to 95%.
[0044] In some embodiments, the at least one control unit (106) is further configured to detect an open circuit condition. The one or more fans (114) are turned off when the open circuit condition is detected. The open circuit condition corresponds to an absence of a detected temperature value from the at least one sensor (102). In the open circuit condition, no temperature value is received from the at least one sensor (102).
[0045] In some embodiments, the at least one control unit (106) is further configured to adjust speed of the one or more fans (114) based at least on the determined optimal fan duty cycle to regulate cooling performance. The one or more fans (114) operate at variable speeds. The cooling system (100) is configured to operate with the variable speeds of the one or more fans (114). The cooling system (100) is configured to allow gradual cooling adjustments rather than sudden on/off switching.
[0046] In some embodiments, the motor controller (112) is configured to regulate the speed of the one or more fans (114) in the vehicle. The motor controller (112) is configured to receive the PWM signal from the at least one control unit (106). The motor controller (112) is further configured to adjust the power supplied to a motor of the one or more fans (114). In some embodiments, the cooling system (100) is scalable. If required, one or more additional fans can be integrated into the cooling system (100).
[0047] FIG. 2 illustrates a flowchart showing a method for operating the cooling system, in accordance to an embodiment of the present invention.
[0048] At operation 202, the at least one sensor (102) is configured to detect a temperature value of the one or more components of the vehicle. The at least one sensor (102) is placed in proximity to the one or more components of the cooling system (100). The one or more components of the vehicle comprises at least of the engine, the radiator, the battery, and the compressor. The at least one sensor (102) is configured to continuously detect the temperature value of the one or more components of the vehicle.
[0049] At operation 204, the at least one control unit (106) is configured to detect the open circuit condition. The one or more fans (114) are turned off when the open circuit condition is detected. The open circuit condition corresponds to an absence of the detected temperature value from the at least one sensor (102).
[0050] At operation 206, the at least one control unit (106) is configured to determine the PWM cycle count to determine the optimal fan duty cycle for the one or more fans (114). The optimal duty cycle is adjustable between 15% and 95%. In some embodiments, the at least one control unit (106) is further configured to adjust the fan duty cycle based at least on the PWM cycle count. In some embodiments, the high temperature value increases the PWM duty cycle. The increased PWM duty cycle makes the one or more fans (114) moves faster for enhanced cooling. Further, the low temperature value decreases the PWM duty cycle. The decreased PWM duty cycle makes the one or more fans (114) moves slower to conserve power.
[0051] At operation 208, the at least one control unit (106) is configured to adjust the fan duty cycle based at least on the PWM cycle count. In some embodiments, the PWM cycle count is 1. Fan 1 duty cycle corresponding to the PWM cycle count 1 corresponds to 15% to 95% and fan 2 duty cycle corresponds to 15% to 90%.
[0052] At operation 210, the at least one control unit (106) is configured to adjust the fan duty cycle based at least on the PWM cycle count. In some embodiments, the PWM cycle count is 2. Fan 1 duty cycle corresponding to the PWM cycle count 2 corresponds to 15% to 90% and fan 2 duty cycle corresponds to 15% to 95%.
[0053] FIG. 3 illustrates another flowchart showing the method for operating the cooling system, in accordance to an embodiment of the present invention.
[0054] At operation 302, the at least one sensor (102) is configured to detect a temperature value of the one or more components of the vehicle. The at least one sensor (102) is placed in proximity to the one or more components of the cooling system (100). The one or more components of the vehicle comprises at least of the engine, the radiator, the battery, and the compressor. The at least one sensor (102) is configured to continuously detect the temperature value of the one or more components of the vehicle.
[0055] At operation 304, the at least one control unit (106) is configured to receive the detected temperature value from the at least one sensor (102). The at least one control unit (106) is communicatively coupled to the at least one sensor (102). The detected temperature value is transmitted from the at least one sensor (102) to the control unit via the CAN bus. The CAN RX is configured to receive the detected temperature value from the at least one sensor (102).
[0056] At operation 306, the at least one control unit (106) is further configured to compare the received temperature value with the predefined threshold value. The predefined threshold value corresponds the temperature above which the cooling system (100) activates to regulate thermal conditions of the one or more components of the vehicle. The predefined threshold value corresponds to 350 C. The received temperature value is compared with the predefined threshold value to determine if cooling of the one or more components is required. Based at least on the comparison, the at least control unit determines the state of the one or more fans (114).
[0057] At operation 308, the at least one control unit (106) is configured to generate the PWM signal if the received temperature value exceeds the predefined threshold value. The PWM signal regulates speed of the one or more fans (114). Generation of the PWM signal ensures that the cooling system (100) responds dynamically to change in the received temperature value rather than operating at a fixed speed.
[0058] At operation 310, the at least one control unit (106) is configured to determine the PWM cycle count to determine the optimal fan duty cycle for the one or more fans (114). The optimal duty cycle is adjustable between 15% and 95%. In some embodiments, the at least one control unit (106) is further configured to adjust the fan duty cycle based at least on the PWM cycle count. In some embodiments, the high temperature value increases the PWM duty cycle. The increased PWM duty cycle makes the one or more fans (114) moves faster for enhanced cooling. Further, the low temperature value decreases the PWM duty cycle. The decreased PWM duty cycle makes the one or more fans (114) moves slower to conserve power.
[0059] At operation 312, the at least one control unit (106) is configured to adjust the speed of the one or more fans (114) based at least on the determined optimal fan duty cycle to regulate the cooling performance. The one or more fans (114) operate at variable speeds. The cooling system (100) is configured to operate with the variable speeds of the one or more fans (114). The cooling system (100) is configured to allow gradual cooling adjustments rather than sudden on/off switching.
[0060] It should be noted that the cooling system in any case could undergo numerous modifications and variants, all of which are covered by the same innovative concept; moreover, all of the details can be replaced by technically equivalent elements. In practice, the components used, as well as the numbers, shapes, and sizes of the components can be of any kind according to the technical requirements. The scope of protection of the invention is therefore defined by the attached claims.

Dated this 20th Day of February, 2025
Ishita Rustagi (IN-PA/4097)
Agent for Applicant
, Claims:CLAIMS
WE CLAIM:
1. A cooling system (100) for a vehicle comprising:
at least one sensor (102) configured to detect a temperature value of one or more components of the vehicle;
at least one control unit (106) communicatively coupled to the at least one sensor (102), wherein the at least one control unit (106) is configured to:
receive the detected temperature value from the at least one sensor (102);
compare the received temperature value with a predefined threshold value;
generate a pulse width modulation (PWM) signal if the received temperature value exceeds the predefined threshold value;
determine a PWM cycle count to determine an optimal fan duty cycle for one or more fans (114), wherein the optimal duty cycle is adjustable between 15% and 95%; and
adjust speed of the one or more fans (114) based at least on the determined optimal fan duty cycle to regulate cooling performance.

2. The cooling system (100) as claimed in claim 1, wherein the at least one control unit (106) is further configured to detect an open circuit condition, and wherein the one or more fans (114) are turned off when the open circuit condition is detected, and wherein the open circuit condition corresponds to an absence of a detected temperature value from the at least one sensor (102).

3. The cooling system (100) as claimed in claim 1, wherein the at least one control unit (106) is further configured to adjust the fan duty cycle based at least on the PWM cycle count, and wherein if the PWM cycle count is 1, fan 1 duty cycle corresponds to 15% to 95% and fan 2 duty cycle corresponds to 15% to 90%, and if the PWM cycle count is 2, the fan 1 duty cycle corresponds to 15% to 90% and the fan 2 duty cycle corresponds to 15% to 95%.

4. The cooling system (100) as claimed in claim 1, wherein one or more additional fans is integrated into the cooling system (100).

5. The cooling system (100) as claimed in claim 1, wherein the at least one sensor (102) corresponds to a temperature sensor.

6. The cooling system (100) as claimed in claim 1, wherein the one or more components of the vehicle comprises at least of an engine, a radiator, a battery, and a compressor.

7. The cooling system (100) as claimed in claim 1, wherein the predefined temperature value corresponds to 350 C.

8. The cooling system (100) as claimed in claim 1, wherein the one or more fans (114) operate at a variable speed.

9. The cooling system (100) as claimed in claim 1, wherein the at least one control unit (106) is further configured to determine a state of the one or more fans (114).

10. A method comprising:
detecting, via at least one sensor (102), a temperature value of one or more components of a vehicle;
receiving, via at least one control unit (106), the detected temperature value from the at least one sensor (102);
comparing, via the at least one control unit (106), the received temperature value with a predefined threshold value;
generating, via the at least one control unit (106), a pulse width modulation (PWM) signal if the received temperature value exceeds the predefined threshold value;
determining, via the at least one control unit (106), a PWM cycle count to determine an optimal fan duty cycle for one or more fans (114), wherein the optimal duty cycle is adjustable between 15% and 95%; and
adjusting, via the at least one control unit (106), speed of the one or more fans (114) based at least on the determined optimal fan duty cycle to regulate cooling performance.

Dated this 20th Day of February, 2025
Ishita Rustagi (IN-PA/4097)
Agent for Applicant