TECHNICAL FIELD
[001] The embodiments herein generally relate to engine performance testing, and more particularly, to a system and method for determining coolant flow in an engine.
BACKGROUND
[002] Continued proper flow of the cooling fluid through an engine is required to prevent permanent damage to the engine because of overheating. The flow is normally detected by a flow sensor and indirectly by a temperature sensor which indicates an over temperature condition when the flow is improper. Such indirect sensing leaves a built-in time lag which is undesirable particularly in diesel engine cooling systems and other heavy equipment, because by the time the temperature rise is indicated, the engine may have already been permanently damaged.
[003] When fouling of the engine cooling system occurs, the flow of cooling water through a strainer to the engine becomes reduced, or shuts off completely, leading to overheating and potential damage to or failure of the engine. The reduction of cooling water flow can also create a powerful vacuum in the pipes and hoses which carry water from the water intake port to the water pump and engine, resulting in the collapse or rupture of these pipes or hoses. Also, a pressure switch associated with the cooling system may provide a false pressure reading or may present a stand still pressure reading, due to vacuum in the flow path. To prevent these effects, the operator must be able to quickly ascertain whether impairment or failure of the cooling system has occurred, in order to restore cooling water flow through the engine promptly before overheating damage can result.
[004] The main reasons for the engine cooling system not working properly are: the pump belt slips, the pump belt is broken, the coolant is not replenished in time before driving, less water flow in the cooling circuit, trapped air which causes false reading of engine water pressure, ball valve position in circuit and the coolant is missing due to leakage of a certain part. Most of the faults are almost silent, and are unrecognizable.
[005] Engine cooling systems which incorporate a mechanism for directly determining proper flow therein have been previously suggested. However, such systems have not been satisfactory because the sensing mechanism could not reliably withstand the adverse conditions encountered in operating in the cooling fluid environment. In the cooling system the sensor is required to operate in a temperature range from 60º C to 90º C. The sensor must also withstand vibration forces of up to 25 G., while also withstanding any chemical deterioration such as might be encountered as a result of contact with the cooling fluid. Further, since particulate material can be present in the cooling system the sensor must not trap or be effected by such particulate material so as to give ineffective warnings. Researchers are still working on the control strategies of electronic water pumps, electronic fans and electronic thermostats under different loads, and the temperature of the coolant, the flow of each branch and the coolant in the cooling system, to optimize the coolant flow for the engine and thereby monitor and improve the engine performance.
[006] Therefore, there exists a need for a system and method for determining coolant flow in the engine, which obviates the aforementioned drawbacks.
OBJECTS
[007] The principal object of the embodiments herein is to provide a system for determining coolant flow in an engine.
[008] Another object of the embodiments herein is to provide a method for determining coolant flow in the engine.
[009] Another object of the embodiments herein is to provide the system which is configured to supply temperature and flow-controlled coolant in cooling jackets of the engine.
[0010] Another object of the embodiments herein is to provide the system which is configured to measure a coolant level in the coolant tank thereby prevent an engine seizure due to unavailability of coolant in the coolant tank.
[0011] Another object of the embodiments herein is to provide the system which is configured to prevent the engine seizure due to improper functioning of a pump.
[0012] Another object of the embodiments herein is to provide the system which is configured prevent the engine seizure in case of engine input valve is held in closed condition.
[0013] Another object of the embodiments herein is to provide the system which is configured to prevent the engine seizure due to strainer choke.
[0014] Another object of the embodiments herein is to provide the system which is configured to avoid false reading of pressure due to air trapping in coolant circulation path of an engine cooling.
[0015] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0016] The embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0017] FIG. 1 depicts a schematic view of a system for determining coolant flow in the engine, according to an embodiment as disclosed herein; and
[0018] FIG. 2 is a flowchart depicting a method for determining coolant flow in the engine, according to an embodiment as disclosed herein.

DETAILED DESCRIPTION
[0019] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0020] The embodiments herein achieve a system for determining coolant flow in an engine. Further, the embodiments herein achieve a method for determining coolant flow in the engine. Furthermore, the embodiments herein achieve the system which is configured to supply temperature and flow-controlled coolant in cooling jackets of the engine. Moreover, the embodiments herein achieve the system which is configured to measure a coolant level in the coolant tank thereby prevent an engine seizure due to unavailability of coolant in the coolant tank. Additionally, the embodiments herein achieve the system which is configured to prevent the engine seizure due to improper functioning of a pump. The embodiments herein further achieve the system which is configured prevent the engine seizure in case of engine input valve is held in closed condition. Furthermore, the embodiments herein achieve the system which is configured to prevent the engine seizure due to strainer choke. Also, the embodiments herein achieve the system which is configured to avoid false reading of pressure due to air trapping in coolant circulation path of an engine cooling. Referring now to the drawings, and more particularly to Figs. 1 through 2, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0021] For the purpose of this description and ease of understanding, the system (100) is explained herein below with reference to an engine testing cycle of a diesel engine which includes a water cooling system. However, it is also within the scope of this invention to practice/implement the entire setup in a same manner or in a different manner or with omission of certain components or with any addition of certain components without otherwise deterring the intended function of the system (100) as can be deduced from the description and corresponding drawings.
[0022] FIG. 1 depicts a schematic view of a system for determining coolant flow in the engine, according to an embodiment as disclosed herein. In an embodiment, the system (100) for determining coolant flow in the engine (102) includes at least one flow sensor (104), an outlet (106) of a water pump (124), an inlet (110), a controller (112), a coolant tank (114), a coolant level sensor (116), a coolant temperature sensor (118), a heater (120), an auto-shut OFF valve (122), at least one temperature sensor (126), an outlet (128) of the engine (102), a heat exchanger (130), a first strainer (132a), a second strainer (132b), a third strainer (132c), a first ball valve (108a), a second ball valve (108b), at least one indicator (134) and a display unit (136).
[0023] The system (100) for determining coolant flow in the engine (102) includes the coolant tank (114) which is configured to store the coolant at a predetermined temperature. In an embodiment, the coolant is water. However, it is also within the scope of the invention to any type of coolant without otherwise deterring the intended function of determining coolant flow in the engine as can be deduced from the description and corresponding drawings. The coolant tank (114) is adapted to contain a predetermined quantity of coolant (water). The coolant tank (114) is further coupled with the coolant level sensor (116), the coolant temperature sensor (118) and the heater (120). The coolant level sensor (116) is configured to continuously measure and communicate a coolant level in the coolant tank (114) to the controller (112). If the coolant level in the coolant tank (114) drops below a predetermined quantity, the controller (112) opens the auto-shut OFF valve (122) through which the coolant from an additional coolant supply line (not shown) is received into the coolant tank (114). If the coolant level in the coolant tank (114) is normal, the controller (112) closes the auto-shut OFF valve (122) and prevent flow of the coolant from the additional coolant supply line (not shown) into the coolant tank (114). Further, the coolant temperature sensor (118) is configured to continuously measure and communicate a temperature of the coolant stored in the coolant tank (114) to the controller (112). If the temperature of the coolant in the coolant tank (114) drops below a predetermined value, the controller (112) activates the heater (120) to rise the temperature of the coolant in the coolant tank (114). If the temperature of the coolant in the coolant tank (114) is normal, the controller (112) deactivates the heater (120).
[0024] The system (100) for determining coolant flow in the engine (102) includes the flow sensor (104) which is installed between the outlet (106) of the pump (124) and the inlet (110) of the engine (102) of the coolant circulation path. The flow sensor (104) is configured to continuously measure and transmit at least one signal corresponding to a flow-rate of the coolant to the controller (112). If the flow-rate measured by the corresponding flow sensor (104) is less than a predetermined flow-rate, during the flow of coolant to the inlet (110) of the engine (102), the controller (112) shuts off the engine (102), thereby prevents the engine seizure. If the flow-rate measured by the flow sensor (104) is normal, then the controller (112) maintains the engine (102) in running condition. Further, the system (100) for determining coolant flow in the engine (102) includes a prime mover (not shown) which is adapted to initiate engine operation during the engine testing cycle. The prime mover is connected to engine (102) through propeller shafts and a clutch coupling. In an embodiment, the clutch coupling is at least an electromagnetic clutch coupling and magnetic clutch coupling. If the flow-rate measured by the flow sensor (104) is below the predetermined flow-rate, the controller (112) disengages the prime mover from the coupling, thereby preventing engine start. While if the flow-rate measured by the flow sensor (104) is normal, then the controller (112) actuates the coupling between the prime mover and the engine (102) thereby initiates engine start during the engine testing cycle. The flow sensor (104) is configured to generate at least two inputs which are transferred through at least two relays (not shown). For example, the flow sensor may be connected to two relays, where a first relay is used for engine loading and unloading, and buzzer indication, when engine is in running condition and a second relay is used for engine prime mover magnetic clutch engage and disengage function. In an embodiment, the controlling voltage of 24-volt dc is used for relay function. If the coolant flow rate in the coolant circulation path is lower than a predetermine value then the flow sensor output signal is zero i.e. the first relay does not receive any signal from the flow sensor and the first relay is in OFF condition. The first relay thereby transmits a signal with the help of NO and NC points to the controller (112) and activates the buzzer for unloading the engine, meanwhile, if the coolant flow rate is ok as per requirement then the flow sensor output signal is high whereby the first relay is in ON condition, and the engine continues to run and there is no activation of alarm or buzzer indication. Also, if the coolant flow rate in the coolant circulation path is not ok then flow sensor output signal is zero whereby the second relay is in OFF condition and the clutch is not engage with the prime mover and the engine does not start. However, if coolant flow rate in the coolant circulation path is ok, then the flow sensor output signal is high and the second relay is in ON condition whereby the clutch engages with the prime mover and the engine is ignited.
[0025] The system (100) for determining coolant flow in the engine (102) includes the first ball valve (108a) which is mounted between the cooling tank (114) and the pump (124) and the second ball valve (108b) mounted between the pump (124) and the engine (102). In an embodiment, the first and second ball valves (108a and 108b) are configured to be operated by one of manually and automatically. The first and second ball valves (108a and 108b) are provided in communication with the controller (112).
[0026] The system (100) for determining coolant flow in the engine (102) includes the pump (124) which is connected between the coolant tank (114) and the engine (102). The pump (124) is configured to circulate the temperature and the flow controlled coolant in the coolant circulation path. In an embodiment, the pump (124) is at least a centrifugal pump. Further, the system (100) includes a vacuum pump (138) is used for draining the coolant inside the engine after completion of the test cycle.
[0027] The system (100) for determining coolant flow in the engine (102) includes the at least one temperature sensor (126) which is connected towards the outlet (128) of the engine (102). The temperature sensor (126) is configured to continuously measure and communicate a temperature corresponding to coolant temperature at the outlet (128) of the engine (102) to the controller (112). If the coolant temperature at the outlet (128) of the engine (102) is normal, the controller (112) maintains the engine (102) in ON condition. If the coolant temperature at the outlet (128) of the engine (102) is high, the controller (112) and shuts the engine (102) to an OFF condition, thereby prevents overheating of the engine.
[0028] The system (100) for determining coolant flow in the engine (102) includes the heat exchanger (130) which is connected between the engine (102) and the coolant tank (114). The heat exchanger (130) is configured to maintain the coolant at a predetermined temperature by rejecting the excess heat through coolant circulation. Further, the system (100) for determining coolant flow in the engine (102) includes the first strainer (132a) connected to an inlet (not shown) of said coolant tank (114), the second strainer (132b) connected between the coolant tank (114) and the pump (124) and the third strainer (132c) connected between the engine (102) and the heat exchanger (130). The first, second and third strainers (132a, 132b and 132c) are adapted to prevent entry of any unwanted particles into said system (100).
[0029] The system (100) for determining coolant flow in the engine (102) includes the at least one indicator (134) which is adapted to indicate at least one fault in the system (100). The fault condition in the system includes but not limited to at least one of, low flow-rate of the coolant, insufficient coolant due to unavailability of coolant in the coolant tank, improper-functioning of the pump (124), choking of the strainer, false reading of pressure due air trapped in the coolant circulation path, and closed condition of the ball valve (108). In an embodiment, the indicator (134) is at least a buzzer and an alarm. Further, the system (100) for determining coolant flow in the engine (102) includes the display unit (136) which is configured to display current status of the system (100). The current status of the system (100) includes but not limited to at least one of engine running condition, said coolant temperature, and said coolant flow-rate.
[0030] The system (100) for determining coolant flow in the engine (102) includes the controller (112). The controller (112) is provided in communication with the coolant level sensor (116), the coolant temperature sensor (118), the heater (120), the auto-shut OFF valve (122), the pump (124), the at least one temperature sensor (126), the engine (102), the heat exchanger (130), the first ball valve (108a), the second ball valve (108b), the at least one indicator (134), and the display unit (136). In an embodiment, the controller (112) is at least an electronic control unit of a vehicle. However, it is also within the scope of the invention to provide integrated or separate control unit for the engine without otherwise deterring the intended function of determining coolant flow in the engine as can be deduced from the description and corresponding drawings.
[0031] FIG. 2 is a flowchart depicting a method for determining coolant flow in the engine, according to an embodiment as disclosed herein. The method (200) for determining coolant flow in an engine (102), said method (200) includes installing at least one flow sensor (104) between an outlet (106) of a water pump (124) and an inlet (110) of said engine (102) of a coolant circulation path, said flow sensor (104) configured to continuously measure and transmit at least one signal corresponding to a flow-rate of said coolant to a controller (or electronic control unit) (112) (At step 202). The controller (112) is configured to maintain said engine (102) in ON condition, upon determining said flow-rate of said coolant is normal (or standard) in said coolant circulation path, and maintain said engine (102) in OFF condition, upon determining said flow-rate of said coolant is low in said coolant circulation path.
[0032] The technical advantages of the embodiments discussed herein include prevention of engine damage, prevention of engine seizure, inexpensive and easy to fabricate, and early detection of faults in the cooling system.
[0033] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

We claim,

1. A system (100) for determining coolant flow in an engine (102), said system (100) comprising:
at least one flow sensor (104) connected between an outlet (106) of a pump (124) and an inlet (110) of said engine (102) of a coolant circulation path, said flow sensor (104) configured to continuously measure and transmit at least one signal corresponding to a flow-rate of said coolant to a controller (or electronic control unit) (112),
wherein,
said controller (112) configured to maintain said engine (102) in ON condition, upon determining said flow-rate of said coolant is normal (or standard) in said coolant circulation path, and maintain said engine (102) in OFF condition, upon determining said flow-rate of said coolant is low in said coolant circulation path.

2. The system (100) as claimed in claim1, wherein said system (100) includes a coolant tank (114) which is coupled with a coolant level sensor (116), a coolant temperature sensor (118) and a heater (120),
wherein,
said coolant tank (114) is configured to store coolant under a predetermined temperature, said coolant temperature sensor (118) is configured to continuously measure and communicate a temperature of said coolant stored in said coolant tank (114) to said controller (112), said controller (112) is configured to perform one of switch ON and OFF said heater (120), upon determining said temperature of said coolant in said coolant tank (114) is low and standard, respectively; and
said coolant level sensor (116) is configured to continuously measure and communicate a coolant level in said coolant tank (114) to said controller (112), said controller (112) is configured to perform one of open and block additional coolant supply line, upon determining said coolant level in said coolant tank (114) is low and standard, respectively.

3. The system (100) as claimed in claim 2, wherein said system (100) includes an auto-shut OFF valve (122) connected to said additional coolant supply line of said coolant tank (114), said auto-shut OFF valve (122) is operated by said controller to be in one of open and block condition, upon determining said coolant level in said coolant tank (114) is low and standard, respectively.

4. The system (100) as claimed in claim 1, wherein said system (100) includes a pump (124) connected between said coolant tank (114) and said engine (102), said pump (124) is configured to circulate said temperature controlled coolant in said coolant circulation path, said pump (124) is at least a centrifugal pump.

5. The system (100) as claimed in claim 1, wherein said system (100) includes at least one temperature sensor (126) connected towards an outlet (128) of said engine (102), said temperature sensor (126) configured to continuously measure and communicate a temperature corresponding to coolant temperature at said outlet (128) of said engine (102) to said controller (112), said controller (112) configured to:
maintain said engine (102) in ON condition, upon determining said temperature of said coolant at said engine outlet (128) is normal (or standard), and maintain said engine (102) in OFF condition, upon determining said temperature of said coolant at said engine outlet (128) is high.

6. The system (100) as claimed in claim 1, wherein system (100) includes a heat exchanger (130) connected between said engine (102) and said coolant tank (114), said heat exchanger (130) is configured to maintain said coolant at a predetermined temperature.

7. The system (100) as claimed in claim 1, wherein said system (100) includes:
a first strainer (132a) connected to an inlet (108) of said coolant tank (114);
a second strainer (132b) connected between said coolant tank (114) and said pump (124); and
a third strainer (132c) connected between said engine (102) and said heat exchanger (130),
wherein,
said first, second and third strainers (132a, 132b and 132c) are adapted to prevent entry of any unwanted particles into said system (100).

8. The system (100) as claimed in claim 1, wherein system (100) includes:
a first ball valve (108a) mounted between said cooling tank (114) and said pump (124); and
a second ball valve (108b) mounted between said pump (124) and said engine (102),
wherein,
said ball valve (108) is configured to be operated by one of manually and automatically, said ball valve (108) is provided in communication with said controller (112).

9. The system (100) as claimed in claim 1, wherein said system (100) includes:
at least one indicator (134) adapted to indicate at least one fault in said system (100), said fault condition includes at least one of, low flow-rate of said coolant, insufficient coolant due to unavailability of coolant in said coolant tank, improper-functioning of said pump (124), choking of said strainer, false reading of pressure due air trapped in said coolant circulation path, and closed condition of ball valve (108), said wherein said indicator is at least a buzzer and an alarm; and
a display unit (136) configured to display current status of said system (100), said current status of said system (100) includes at least one of engine running condition, said coolant temperature, and said coolant flow-rate.

10. A method (200) for determining coolant flow in an engine (102), said method (200) comprising:
installing at least one flow sensor (104) between an outlet (106) of a water pump (124) and an inlet (110) of said engine (102) of a coolant circulation path, said flow sensor (104) configured to continuously measure and transmit at least one signal corresponding to a flow-rate of said coolant to a controller (or electronic control unit) (112),
wherein,
said controller (112) configured to maintain said engine (102) in ON condition, upon determining said flow-rate of said coolant is normal (or standard) in said coolant circulation path, and maintain said engine (102) in OFF condition, upon determining said flow-rate of said coolant is low in said coolant circulation path.