Condensate control system, vehicle, and condensate control method

Abstract

This application relates to a condensate control system, a vehicle, and a condensate control method. The condensate control system includes a water storage module and a delivery module. The water storage module is located in the intercooler and is used to collect and store condensate in the exhaust chamber. The delivery module is used to controllably deliver at least a portion of the condensate in the water storage module through the EGR module's intake pipe to the exhaust module, which has a purification device, to cool the gas in the intake pipe. This condensate control system achieves the collection and storage of condensate in the intercooler's exhaust chamber, reducing the occurrence of problems such as concentrated condensate flowing into the engine cylinders and causing engine misfires and vibrations, thus helping to improve the EGR rate. Furthermore, it can provide preliminary cooling of the gas in the EGR module's intake pipe, realizing the recovery and recycling of condensate. The condensate is ultimately discharged environmentally through the exhaust module, which not only reduces environmental pollution but also improves the efficiency of the engine system and significantly increases its thermal efficiency.

Description

Technical Field

[0001] This application relates to the field of automotive technology, and in particular to condensate control systems, vehicles, and condensate control methods. Background Technology

[0002] To improve the emissions performance and fuel economy of gasoline engines, engine systems have begun to adopt integrated water-cooled intercoolers and EGR (Exhaust Gas Recirculation) technology. Water-cooled intercooler technology can significantly shorten the intake manifold length and reduce the air temperature after the turbocharger, thereby achieving precise control of engine intake air temperature and increasing intake volume. EGR technology introduces exhaust gases into the engine, reducing peak combustion chamber temperature and effectively reducing nitrogen oxides (NOx). x This reduces emissions and improves engine thermal efficiency.

[0003] However, the exhaust gas introduced by the EGR system contains a large amount of water vapor. When this water vapor mixes with fresh air and enters the water-cooled intercooler, it condenses and accumulates in its air passages upon cooling. When the vehicle accelerates, the condensate accumulated in the air passages is carried by the airflow into the engine cylinders, causing misfires in one cylinder and leading to abnormal engine vibration. This problem is exacerbated, especially in high humidity or heavy rain.

[0004] In related technologies, to suppress condensation in the air passage of water-cooled intercoolers while ensuring EGR rate, condensate is typically treated by either directly discharging it or introducing it into the engine. However, directly discharging condensate carries harmful substances from the exhaust gases, causing environmental pollution, while introducing condensate into the engine cylinders can interfere with normal combustion and may even cause engine misfires, vibrations, and other malfunctions. Summary of the Invention

[0005] Therefore, it is necessary to provide a condensate control system, vehicle, and condensate control method to address the problem that the treatment of condensate in the air passage of water-cooled intercoolers may cause environmental pollution or affect engine combustion.

[0006] A condensate control system is applied to an engine system, the engine system including an intercooler, an EGR module, and an exhaust module, the exhaust module including a purification device; the condensate control system includes:

[0007] A water storage module is installed in the intercooler. The water storage module can be connected to or disconnected from the air outlet chamber of the intercooler. The water storage module is used to collect and store the condensate in the air outlet chamber.

[0008] A delivery module, connected to the water storage module, is used to controllably deliver at least a portion of the condensate in the water storage module to the exhaust module through the gas intake pipe of the EGR module to cool the gas in the gas intake pipe.

[0009] In one embodiment of this application, the delivery module includes at least one cooling pipe, at least a portion of which is disposed within the air intake pipe, and the cooling pipe is connected to the water storage module and the exhaust module.

[0010] In one embodiment of this application, a plurality of cooling pipes are provided, each cooling pipe is spaced apart, and at least a portion of the cooling pipes are arranged circumferentially along the air intake pipe.

[0011] In one embodiment of this application, the axial direction of the cooling pipe is arranged parallel to the axial direction of the air intake pipe.

[0012] In one embodiment of this application, the cooling pipe includes a cooling pipe inlet and a cooling pipe outlet, the cooling pipe inlet being connected to the water storage module; the conveying module further includes a first air guide pipe, the first air guide pipe being connected to the cooling pipe outlet, the first air guide pipe having a first air guide pipe outlet end, the first air guide pipe outlet end being disposed inside the exhaust pipe of the exhaust module, and the opening of the first air guide pipe outlet end facing the same direction as the airflow direction inside the exhaust pipe.

[0013] In one embodiment of this application, the delivery module further includes a second air guide pipe, which is connected to the cooling pipe inlet and passes through the side wall of the air intake pipe. The cooling pipe inlet can be connected to the water storage module through the second air guide pipe.

[0014] In one embodiment of this application, the exhaust module further includes an exhaust manifold, and the delivery module is further configured to controllably deliver a portion of the condensate in the water storage module to the exhaust manifold for mixing with the exhaust gas in the exhaust manifold.

[0015] In one embodiment of this application, the purification device is connected to the exhaust manifold, and the purification device is used to purify the mixture of condensate and exhaust gas.

[0016] In one embodiment of this application, the water storage module includes a water storage chamber with a water storage chamber inlet and a water storage chamber outlet. A guide section is provided at the water storage chamber inlet, and the water storage chamber inlet is connected to the air outlet chamber through the guide section. The water storage chamber outlet is connected to the conveying module.

[0017] In one embodiment of this application, the cross-sectional shape of the guide portion gradually decreases in the direction from the air outlet chamber to the water storage chamber inlet.

[0018] In one embodiment of this application, the water storage module further includes a liquid level detection element disposed in the water storage cavity, and the liquid level detection element is used to detect liquid level detection data in the water storage cavity.

[0019] A vehicle includes an engine system and the aforementioned condensate control system.

[0020] A condensate water control method, performed by the aforementioned vehicle, the condensate water control method comprising:

[0021] Collect and store the condensate in the outlet chamber of the intercooler;

[0022] Acquire the liquid level detection data of condensate in the water storage module;

[0023] Determine whether the liquid level detection data is greater than the preset liquid level data;

[0024] If so, at least a portion of the condensate in the water storage module is transported to the exhaust module through the gas intake pipe of the EGR module to cool the gas in the gas intake pipe.

[0025] If not, continue with the step of obtaining the liquid level detection data of the condensate in the water storage module.

[0026] In one embodiment of this application, the step of transporting at least a portion of the condensate in the water storage module to the exhaust module through the gas intake pipe of the EGR module to cool the gas in the gas intake pipe further includes: if so, transporting a portion of the condensate in the water storage module to the exhaust manifold.

[0027] The aforementioned condensate control system includes a water storage module and a delivery module. The water storage module collects and stores condensate from the intercooler outlet chamber, while the delivery module controllably delivers at least a portion of the condensate from the water storage module to the exhaust module, which has a purification device. During this process, the condensate passes through the EGR module's intake pipe, cooling the gas within the intake pipe. This configuration achieves the collection and storage of condensate from the intercooler outlet chamber, reducing the occurrence of condensate flowing into the engine cylinders and causing engine misfires and vibrations, thus helping to improve the EGR rate. Furthermore, the delivery module delivers the condensate collected by the water storage module to the exhaust module, where it provides preliminary cooling to the gas within the EGR module's intake pipe, achieving condensate recovery and recycling. The condensate is ultimately discharged environmentally through the exhaust module, reducing environmental pollution and improving engine system efficiency, significantly enhancing the engine system's thermal efficiency. Attached Figure Description

[0028] Figure 1This is a schematic diagram showing the location of the water storage module in the condensate control system of this application.

[0029] Figure 2 This is a cross-sectional view of the on / off valve assembly in the condensate control system of this application when it is closed.

[0030] Figure 3 This is a cross-sectional view of the on / off valve assembly in the condensate control system of this application when it is open.

[0031] Figure 4 This is a schematic diagram showing the interaction between the delivery module and the engine system in the condensate control system of this application.

[0032] Figure 5 This is a cross-sectional view showing the interaction between the delivery module and the engine system in the condensate control system of this application.

[0033] Figure 6 for Figure 5 A schematic diagram of the A-A' direction.

[0034] Figure 7 This is a schematic diagram of the connection relationship of one embodiment of the condensate control system of this application.

[0035] Figure 8 This is a schematic diagram showing the connection relationship of another embodiment of the condensate control system of this application.

[0036] Explanation of reference numerals in the attached figures:

[0037] 100. Intercooler; 110. Exhaust chamber;

[0038] 210. Air intake tube;

[0039] 300. Exhaust pipe;

[0040] 400. Exhaust manifold;

[0041] 1. Water storage module; 101. Water storage chamber; 1011. Water storage chamber inlet; 1012. Water storage chamber outlet; 1013. Flow guide;

[0042] 201, Cooling pipe; 2011, Cooling pipe inlet; 2012, Cooling pipe outlet; 202, First air guide pipe; 2021, First air guide pipe outlet end; 2022, First air guide pipe inlet end; 203, Second air guide pipe; 2031, Second air guide pipe inlet end; 2032, Second air guide pipe outlet end;

[0043] 3. Liquid level detection components;

[0044] 401. Switch valve body; 402. Adjusting spring; 403. Electromagnetic coil assembly;

[0045] 5. High-pressure pump;

[0046] 6. Connecting pipe;

[0047] 7. High-pressure nozzle. Detailed Implementation

[0048] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0049] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0050] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0051] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0052] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0053] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0054] See Figures 1-6 As shown in the figure, an embodiment of this application provides a condensate control system applied to an engine system. The engine system includes an intercooler 100, an EGR module, and an exhaust module. The exhaust module includes a purification device. The condensate control system includes a water storage module 1 and a delivery module. The water storage module 1 is disposed in the intercooler 100 and can be connected to or disconnected from the outlet chamber 110 of the intercooler 100. The water storage module 1 is used to collect and store condensate in the outlet chamber 110. The delivery module is connected to the water storage module 1 and is used to controllably deliver at least a portion of the condensate in the water storage module 1 to the exhaust module through the air intake pipe 210 of the EGR module to cool the gas in the air intake pipe 210.

[0055] This condensate control system collects and stores condensate from the outlet chamber 110 of the intercooler 100, reducing the occurrence of problems such as concentrated condensate flowing into the engine cylinder and causing engine misfire and vibration, thus helping to improve the EGR rate. Moreover, the condensate collected by the water storage module 1 can be transported to the exhaust module with a purification device through the delivery module, and the gas in the EGR module intake pipe 210 is initially cooled during this process, realizing the recovery and recycling of condensate. The condensate is finally discharged environmentally through the exhaust module, which not only reduces environmental pollution, but also helps to improve the efficiency of the engine system and significantly improves the thermal efficiency of the engine system.

[0056] The condensate control system described in this application is applied to the engine system. The core of the engine system is the engine itself, which is equipped with an intake module, an EGR (Exhaust Gas Recirculation) module, and an exhaust module. The intake module primarily filters and cools outside air and distributes it to the engine cylinders. The EGR module primarily reduces nitrogen oxide emissions, improves fuel economy, and suppresses engine knock. The exhaust module is primarily used for exhaust gas purification to meet vehicle emission standards.

[0057] The intake module includes an intercooler 100, which is typically a water-cooled intercooler. Its main functions are to reduce intake air temperature, increase air density, increase intake volume, and improve engine power and fuel economy. The intercooler 100 includes an exhaust chamber 110, which collects the cooled intake air flowing from various heat exchange channels, acting as a rectifier, pressure stabilizer, and airflow balancer. When the EGR module introduces exhaust gas, the exhaust gas contains a significant amount of water vapor. This water vapor mixes with fresh air and enters the water-cooled intercooler. Upon cooling (when the coolant temperature is low), it condenses and accumulates in the air passages of the water-cooled intercooler, forming condensate. This condensate then collects at the exhaust chamber 110.

[0058] The EGR module includes an intake pipe 210, which is connected to the exhaust manifold 400 of the engine system. The intake pipe 210 is used to draw out the high-temperature exhaust gas in the exhaust manifold 400 and then transport the exhaust gas to the downstream structure of the EGR module.

[0059] The exhaust module includes a purification device, which may be a three-way catalytic converter.

[0060] See Figures 1-3 As shown, the condensate control system includes a water storage module 1, which is installed in the intercooler 100. The water storage module 1 can be connected to or disconnected from the exhaust chamber 110. The water storage module 1 is used to collect and store the condensate in the exhaust chamber 110. The water storage module 1 can be connected to or disconnected from the exhaust chamber 110 to achieve condensate collection and storage control. When the water storage module 1 is connected to the exhaust chamber 110, the condensate in the exhaust chamber 110 can enter the water storage module 1 for collection and storage; when the water storage module 1 is disconnected from the exhaust chamber 110, the condensate in the exhaust chamber 110 cannot enter the water storage module 1, thereby achieving condensate collection and storage control.

[0061] In one embodiment, the water storage module 1 is located below the air outlet chamber 110. When the water storage module 1 is connected to the air outlet chamber 110, the condensate in the air outlet chamber 110 can flow downward to the water storage module 1 under the action of gravity, which is conducive to the rapid collection of condensate.

[0062] The condensate control system also includes a conveying module, which is connected to the water storage module 1, allowing condensate from the water storage module 1 to enter the conveying module. The conveying module controllably conveys at least a portion of the condensate from the water storage module 1 through the EGR module's intake pipe 210 to the exhaust module to cool the gas within the intake pipe 210. In other words, at least a portion of the condensate from the water storage module 1 can be conveyed to the exhaust module by the conveying module, and during this process, the condensate passes through the EGR module's intake pipe 210, thus providing preliminary cooling to the high-temperature exhaust gas within the intake pipe 210, achieving condensate recycling. Finally, the condensate is purified and discharged through the exhaust module.

[0063] In one embodiment of this application, the delivery module includes at least one cooling pipe 201, at least a portion of the structure of the cooling pipe 201 is disposed within the air intake pipe 210, and the cooling pipe 201 can be connected to the water storage module 1 and the exhaust module.

[0064] See Figures 5-6 As shown, the conveying module includes at least one cooling pipe 201. The number of cooling pipes 201 can be selected as needed, for example, one, two, five, eight, or nine cooling pipes 201 can be installed. Cooling pipes 201 are suitable for purging condensate. The cooling pipes 201 can be partially or entirely installed within the gas intake pipe 210 to provide preliminary cooling for the high-temperature exhaust gas within the gas intake pipe 210.

[0065] Cooling pipe 201 can be connected to water storage module 1 and exhaust module. When cooling pipe 201 is connected to water storage module 1 and exhaust module, water storage module 1 is connected to exhaust module through cooling pipe 201, and condensate in water storage module 1 can enter exhaust module through cooling pipe 201. When cooling pipe 201 is not connected to water storage module 1 and exhaust module, water storage module 1 and exhaust module are not connected, and condensate in water storage module 1 cannot enter exhaust module through cooling pipe 201.

[0066] In one embodiment, see [reference] Figure 7 As shown, the water storage module 1 and the cooling pipe 201 are controllably connected or disconnected via a connecting pipe 6, etc. Specifically, a high-pressure pump 5 is installed on the connecting pipe 6. The high-pressure pump 5 is mainly used to pressurize and transport the condensate, thereby improving the condensate transport efficiency. When the high-pressure pump 5 is turned on, the water storage module 1 is connected to the cooling pipe 201, and the condensate in the water storage module 1 is transported to the cooling pipe 201 under the action of the high-pressure pump 5, and then to the exhaust module. When the high-pressure pump 5 is turned off, the water storage module 1 is not connected to the cooling pipe 201, and the condensate in the water storage module 1 cannot be transported to the cooling pipe 201 and the exhaust module, thus realizing the control of condensate transport.

[0067] In one embodiment, the high-pressure pump 5 can adjust its operating speed to control the delivery speed of condensate, ensuring that the condensate in the water storage module 1 is discharged in a timely manner, without the need to set up an excessively large water storage module 1, reducing the space occupied and facilitating structural setup and control.

[0068] In one embodiment of this application, a plurality of cooling pipes 201 are provided, each cooling pipe 201 is spaced apart, and at least a portion of the cooling pipes 201 are arranged circumferentially along the air intake pipe 210.

[0069] See Figures 5-6 As shown, the sidewall of the cooling pipe 201 serves as the heat exchange surface between condensate and high-temperature exhaust gas. In one embodiment, multiple cooling pipes 201 are provided, each being a small-diameter tube. This increases the heat exchange area between condensate and high-temperature exhaust gas within a limited space, improving the heat exchange and cooling effect. The cooling pipes 201 are spaced apart, allowing the high-temperature exhaust gas in the intake pipe 210 to pass between them, enabling more thorough heat exchange between the condensate and the exhaust gas, further improving heat exchange efficiency. Furthermore, at least some of the cooling pipes 201 are arranged circumferentially along the intake pipe 210 to fully utilize the internal space of the intake pipe 210 and ensure heat exchange efficiency.

[0070] In one embodiment, nine cooling pipes 201 are provided, eight of which are arranged around the circumference of the air intake pipe 210 and are located close to the inner wall of the air intake pipe 210. The other cooling pipe 201 is located at the center of the air intake pipe 210 and is arranged at intervals from the other cooling pipes 201 to achieve reasonable utilization of the internal space of the air intake pipe 210.

[0071] In one embodiment, all cooling pipes 201 can be arranged around the circumference of the air intake pipe 210 to avoid the travel path of high-temperature gas in the air intake pipe 210, reduce airflow resistance, and reduce the impact of the cooling pipes 201 arrangement on the airflow in the air intake pipe 210.

[0072] In one embodiment of this application, the axial direction of the cooling pipe 201 is arranged parallel to the axial direction of the air intake pipe 210.

[0073] See Figures 5-6 As shown, the airflow direction of the high-temperature exhaust gas inside the intake pipe 210 is as follows: Figure 5 As indicated by the middle arrow b, the axial direction of the cooling pipe 201 is parallel to the axial direction of the gas intake pipe 210 to minimize the flow resistance of the cooling pipe 201 to the high-temperature exhaust gas, making the flow of the high-temperature exhaust gas in the gas intake pipe 210 smoother, thereby ensuring EGR efficiency.

[0074] In one embodiment of this application, the cooling pipe 201 includes a cooling pipe inlet 2011 and a cooling pipe outlet 2012. The cooling pipe inlet 2011 can be connected to the water storage module 1. The conveying module also includes a first air guide pipe 202, which is connected to the cooling pipe outlet 2012. The first air guide pipe 202 has a first air guide pipe outlet end 2021, which is disposed in the exhaust pipe 300 of the exhaust module. The opening of the first air guide pipe outlet end 2021 faces the same direction as the airflow in the exhaust pipe 300.

[0075] See Figure 5 As shown, the cooling pipe 201 includes a cooling pipe inlet 2011 and a cooling pipe outlet 2012. The cooling pipe inlet 2011 can be connected to the water storage module 1. When the cooling pipe inlet 2011 is connected to the water storage module 1, the condensate in the water storage module 1 can enter the cooling pipe 201. When the cooling pipe 201 is entirely placed in the air intake pipe 210, both the cooling pipe inlet 2011 and the cooling pipe outlet 2012 are located inside the air intake pipe 210. In one embodiment, a portion of the structure of the cooling pipe 201 is placed inside the air intake pipe 210. Specifically, the cooling pipe inlet 2011 is located inside the air intake pipe 210, while the cooling pipe outlet 2012 is located outside the air intake pipe 210 and placed inside the exhaust pipe 300 of the exhaust module, to facilitate structural arrangement.

[0076] In one embodiment, the delivery module further includes a first air guide pipe 202, which is connected to the cooling pipe outlet 2012. The first air guide pipe 202 is placed inside the exhaust pipe 300 to guide the condensate in the cooling pipe 201 into the exhaust pipe 300. The gas flow direction within the exhaust pipe 300 is as follows: Figure 5 As indicated by the middle arrow a, the first air guide pipe 202 has a first air guide pipe outlet end 2021, which is located inside the exhaust pipe 300 of the exhaust module. The opening of the first air guide pipe outlet end 2021 faces the same direction as the airflow inside the exhaust pipe 300. After the condensate in the cooling pipe 201 exchanges heat with the high-temperature exhaust gas in the air intake pipe 210, almost all of the condensate is vaporized. The vaporized condensate enters the exhaust pipe 300 through the first air guide pipe outlet end 2021. Since the opening of the first air guide pipe outlet end 2021 faces the same direction as the airflow inside the exhaust pipe 300, the flow direction of the vaporized condensate is also the same as the airflow direction inside the exhaust pipe 300. This arrangement will not disturb the airflow inside the exhaust pipe 300 and will allow the vaporized condensate to be stably discharged with the airflow inside the exhaust pipe 300.

[0077] In one embodiment, the first air guide pipe 202 is a bent pipe structure for convenient pipe connection. Furthermore, the first air guide pipe 202 also includes a first air guide pipe inlet end 2022, which is connected to the cooling pipe outlet 2012 of each cooling pipe 201 to achieve the convergence of condensate (or vaporized condensate) in each cooling pipe 201.

[0078] In one embodiment of this application, the delivery module further includes a second air guide pipe 203, which is connected to the cooling pipe inlet 2011. The second air guide pipe 203 passes through the side wall of the air intake pipe 210, and the cooling pipe inlet 2011 can be connected to the water storage module 1 through the second air guide pipe 203.

[0079] See Figure 5 As shown, to facilitate pipeline connection, the delivery module also includes a second air guide pipe 203, which is connected to the cooling pipe inlet 2011. The second air guide pipe 203 passes through the side wall of the air intake pipe 210 to guide condensate into the cooling pipe 201. The cooling pipe inlet 2011 can be connected to the water storage module 1 through the second air guide pipe 203. In one embodiment, when the high-pressure pump 5 is turned on, the cooling pipe inlet 2011 is connected to the water storage module 1 through the second air guide pipe 203; when the high-pressure pump 5 is turned off, the cooling pipe inlet 2011 cannot be connected to the water storage module 1 through the second air guide pipe 203.

[0080] In one embodiment, the second air guide pipe 203 includes a second air guide pipe inlet end 2031 and a second air guide pipe outlet end 2032. The second air guide pipe inlet end 2031 can be connected to the water storage module 1 through a connecting pipe 6, etc., and the second air guide pipe outlet end 2032 is connected to the cooling pipe inlet 2011 of each cooling pipe 201 respectively, so as to deliver condensate to each cooling pipe 201 respectively.

[0081] In one embodiment of this application, the exhaust module further includes an exhaust manifold 400, and the delivery module is also used to controllably deliver a portion of the condensate in the water storage module 1 to the exhaust manifold 400 to mix with the exhaust gas in the exhaust manifold.

[0082] See Figure 8 As shown, the exhaust module also includes an exhaust manifold 400, which can be connected to a delivery module. In this case, the delivery module is also used to controllably deliver a portion of the condensate from the water storage module 1 to the exhaust manifold 400 to mix with the exhaust gas within the exhaust manifold 400. Through this configuration, the condensate can be directly introduced into the exhaust manifold 400 and then discharged, preventing it from passing through the engine and thus eliminating the impact of condensate on engine combustion.

[0083] In one embodiment, the condensate control system further includes a high-pressure nozzle 7, which is located near the exhaust manifold 400 and at the outlet end of the connecting pipe 6. The condensate in the water storage module 1 can be sprayed into the exhaust manifold 400 through the high-pressure nozzle 7, so that the condensate enters the exhaust manifold 400 more evenly.

[0084] In one embodiment of this application, the purification device is connected to the exhaust manifold 400, and the purification device is used to purify the mixture of condensate and exhaust gas.

[0085] The purification device is connected to the exhaust manifold 400. After the condensate and exhaust gas are mixed, a mixture is formed. This mixture enters the purification device, which is used to purify the mixture of condensate and exhaust gas to achieve environmentally friendly emissions of condensate and exhaust gas, thereby meeting the environmental emission requirements of the vehicle.

[0086] In one embodiment, the purification device is also connected to the exhaust pipe 300 to purify the mixture of condensate and exhaust gas entering the exhaust pipe 300, thereby achieving environmentally friendly discharge of condensate and exhaust gas.

[0087] In one embodiment of this application, the water storage module 1 includes a water storage chamber 101, which has a water storage chamber inlet 1011 and a water storage chamber outlet 1012. A guide section 1013 is provided at the water storage chamber inlet 1011, and the water storage chamber inlet 1011 is connected to the air outlet chamber 110 through the guide section 1013. The water storage chamber outlet 1012 is connected to the conveying module.

[0088] See Figures 1-3 As shown, the water storage module 1 includes a water storage chamber 101, which has a storage space to store the condensate from the air outlet chamber 110. The specific volume of the water storage chamber 101 can be set as needed. The water storage chamber 101 has a water storage chamber inlet 1011 and a water storage chamber outlet 1012. The water storage chamber inlet 1011 is connected to the air outlet chamber 110 in a communicable or disconnected manner, and the water storage chamber outlet 1012 is connected to the conveying module.

[0089] In one embodiment, a guide section 1013 is provided at the inlet 1011 of the water storage chamber. The inlet 1011 of the water storage chamber is connected to the outlet chamber 110 through the guide section 1013. The guide section 1013 is used to guide the condensate flowing out of the outlet chamber 110, so that the condensate quickly enters the water storage chamber 101. Moreover, the guide section 1013 can also temporarily store the condensate to achieve a buffer for the collection and storage of condensate.

[0090] In one embodiment, a switching valve assembly is further provided between the water storage chamber inlet 1011 and the air outlet chamber 110. Specifically, the switching valve assembly is disposed within the water storage chamber inlet 1011. When the switching valve assembly is open, the condensate in the air outlet chamber 110 enters the water storage chamber 101 through the guide section 1013 and the water storage chamber inlet 1011 in sequence; when the switching valve assembly is closed, the condensate in the air outlet chamber 110 temporarily collects in the guide section 1013.

[0091] In one embodiment, the switching valve assembly is a solenoid valve, comprising a switching valve body 401, an adjusting spring 402, and a solenoid coil assembly 403. The solenoid coil assembly 403 provides electromagnetic force to open the switching valve body 401. When the electromagnetic force of the solenoid coil assembly 403 disappears, the switching valve body 401 closes under the restoring force of the adjusting spring 402. (See also...) Figures 2-3 As shown, when the switch valve body 401 moves from the closed position to the open position, the switch valve body 401 moves away from the air outlet chamber 110 in the water storage chamber inlet 1011, so that the condensate water passes through the gap between the switch valve body 401 and the inner wall of the water storage chamber inlet 1011 and then enters the water storage chamber 101.

[0092] Moreover, especially during heavy rain, there is a lot of condensate in the intercooler 100. During the opening of the switching valve assembly, the structural design of the aforementioned guide section 1013 can continuously increase the flow area of ​​the condensate, thereby accelerating the outflow of condensate from the water storage chamber 101, preventing condensate from accumulating in the intake manifold of the intercooler 100 and flowing into the engine, thus improving structural reliability.

[0093] In one embodiment of this application, the cross-sectional shape of the guide portion 1013 gradually decreases in the direction from the air outlet chamber 110 to the water storage chamber inlet 1011.

[0094] In one embodiment, the cross-sectional shape of the guide section 1013 gradually decreases in the direction from the air outlet chamber 110 to the water storage chamber inlet 1011, that is, the guide section 1013 has a funnel-shaped structure. This shape of the guide section 1013 is conducive to the collection and guidance of condensate, thereby improving the collection efficiency of condensate.

[0095] In one embodiment of this application, the water storage module 1 further includes a liquid level detection element 3, which is disposed in the water storage cavity 101 and is used to detect the liquid level detection data in the water storage cavity 101.

[0096] See Figures 1-3As shown, the water storage module 1 also includes a liquid level detection element 3, which can be a liquid level sensor. The liquid level detection element 3 is disposed in the water storage chamber 101 and is used to detect the liquid level value (i.e., liquid level detection data) in the water storage chamber 101 to obtain the amount of condensate stored in the water storage chamber 101. When the condensate in the water storage chamber 101 exceeds the preset liquid level data, the condensate is controlled to be transported to the exhaust pipe 300, or the condensate is controlled to be transported to both the exhaust pipe 300 and the exhaust manifold 400.

[0097] In one embodiment, the condensate control system is controlled as a whole by an ECU (Electronic Control Unit). The signal input terminal of the ECU is electrically connected to the signal output terminal of the liquid level detection element 3, and the signal output terminal of the ECU is electrically connected to the signal input terminals of the switching valve assembly, the high-pressure pump 5, and the high-pressure nozzle 7.

[0098] In one embodiment, the signal output terminal of the ECU is electrically connected to the solenoid coil assembly 403 of the switching valve assembly. The ECU can collect the intake pressure of the intercooler 100 and control the switching valve body 401 to open by balancing the intake pressure and the electromagnetic force of the solenoid coil assembly 403, so that condensate enters the water storage chamber 101.

[0099] This embodiment also provides a vehicle, including an engine system and the aforementioned condensate control system.

[0100] This vehicle employs the condensate control system of this embodiment, which collects and stores condensate in the outlet chamber 110 of the intercooler 100. This reduces the occurrence of problems such as concentrated condensate flowing into the engine cylinder, causing engine misfire and vibration, thereby helping to improve the EGR rate. Furthermore, the condensate collected by the water storage module 1 can be transported to the exhaust module through the delivery module. During this process, the gas in the intake pipe 210 of the EGR module is initially cooled, realizing the recovery and recycling of condensate. The condensate is finally discharged environmentally through the exhaust module, which not only reduces environmental pollution but also helps to improve the efficiency of the engine system and significantly improves the thermal efficiency of the engine system.

[0101] This type of vehicle significantly improves the EGR rate, fully leveraging the contribution of EGR technology to engine economy. It also achieves the collection, recycling, and environmentally friendly discharge of intercooler condensate, preventing condensate from concentrating in the engine cylinders and causing misfires. Simultaneously, it solves the pollution problems caused by untreated condensate being discharged into the environment and the issue of condensate re-entering the engine and affecting combustion. Furthermore, it utilizes the low-temperature condensate to condense the high-temperature gas in the EGR intake pipe, lowering the exhaust gas temperature within the EGR system. This completely resolves the problem of condensate limiting EGR rate improvement and reduces the exhaust gas temperature within the EGR system, thereby improving engine thermal efficiency.

[0102] This embodiment also provides a condensate control method, executed by the aforementioned vehicle, the condensate control method comprising:

[0103] Collect and store the condensate in the outlet chamber 110 of the intercooler 100;

[0104] Acquire the liquid level detection data of the condensate in the water storage module 1;

[0105] Determine if the liquid level detection data is greater than the preset liquid level data;

[0106] If so, at least a portion of the condensate in the water storage module 1 is transported to the exhaust module through the gas intake pipe 210 of the EGR module to cool the gas in the gas intake pipe 210.

[0107] If not, continue with the step of obtaining the liquid level detection data of the condensate in the water storage module 1.

[0108] This condensate control method enables the collection and storage of condensate in the outlet chamber 110 of the intercooler 100, reducing the occurrence of problems such as concentrated condensate flowing into the engine cylinder and causing engine misfire and vibration, thus helping to improve the EGR rate. Moreover, the condensate collected by the water storage module 1 can be transported to the exhaust module through the delivery module, and the gas in the EGR module intake pipe 210 is initially cooled during this process, realizing the recovery and recycling of condensate. The condensate is finally discharged environmentally through the exhaust module, which not only reduces environmental pollution, but also helps to improve the efficiency of the engine system and significantly improves the thermal efficiency of the engine system.

[0109] In one embodiment of this application, if so, the step of transporting at least a portion of the condensate in the water storage module 1 to the exhaust module through the gas intake pipe 210 of the EGR module to cool the gas in the gas intake pipe 210 further includes: if so, transporting a portion of the condensate in the water storage module 1 to the exhaust manifold 400.

[0110] When the condensate level detection data in the water storage module 1 is greater than the preset level data, some of the condensate in the water storage module 1 can be transported to the exhaust manifold 400, so that the condensate can directly enter the exhaust module without passing through the air intake pipe 210 of the EGR module. When there is too much condensate in the water storage module 1, the condensate can be quickly discharged, thereby meeting the control needs of different condensate conditions.

[0111] The condensate control method of this embodiment will be described in detail below:

[0112] Step S01: Collect and store the condensate in the outlet chamber 110 of the intercooler 100.

[0113] During normal vehicle operation, when condensation causes engine misfire, the ECU adjusts the electromagnetic force of the solenoid coil assembly 403. By balancing the intake pressure of the exhaust chamber 110 and the electromagnetic force of the solenoid coil assembly 403, the ECU controls the switch valve body 401 to move away from the exhaust chamber 110. The condensate collection channel opens, and the condensate flows along the inner wall of the guide section 1013 into the water storage chamber 101, thereby collecting and storing the condensate in the exhaust chamber 110.

[0114] When there is no condensation causing engine misfire, the ECU adjusts the electromagnetic force of the solenoid coil assembly 403. By balancing the intake pressure of the exhaust chamber 110 and the electromagnetic force of the solenoid coil assembly 403, the ECU controls the switch valve body 401 to move and reset towards the exhaust chamber 110 under the action of the adjusting spring 402. The condensate collection channel is closed, which can prevent engine oil from flowing into the water storage chamber 101 from the inner wall of the intercooler 100 intake passage.

[0115] Step S02: Obtain the liquid level detection data of the condensate in the water storage module 1.

[0116] The level detection device 3 detects the level of condensate in the water storage module 1 and obtains the level detection data. Then, the level detection device 3 sends the level detection data to the ECU.

[0117] Step S03: Determine whether the liquid level detection data is greater than the preset liquid level data.

[0118] The ECU compares the obtained liquid level detection data with the preset liquid level data and determines whether the liquid level detection data is greater than the preset liquid level data.

[0119] Step S04: If so, at least a portion of the condensate in the water storage module 1 is transported to the exhaust module through the gas intake pipe 210 of the EGR module to cool the gas in the gas intake pipe 210.

[0120] If the liquid level detection data is greater than the preset liquid level data, then there is a lot of condensate in the water storage chamber 101. The ECU controls the high-pressure pump 5 to start working, and some or all of the condensate in the water storage chamber 101 is transported to the cooling pipe 201 and then to the exhaust module. After the condensate enters the cooling pipe 201, it can initially cool the high-temperature exhaust gas in the intake pipe 210, thereby lowering the gas temperature in the intake pipe 210. The condensate, after exchanging heat with the high-temperature exhaust gas, is completely or partially vaporized and enters the exhaust pipe 300, where it mixes with the exhaust gas. After being purified by the purification device, it is discharged.

[0121] In addition, if there is too much condensate in the water storage chamber 101, some of the condensate can be transported to the exhaust manifold 400, so that the condensate can be directly mixed with the exhaust gas in the exhaust manifold 400 and then discharged after being purified by the purification device, thereby accelerating the discharge treatment of condensate.

[0122] Step S05: If not, continue with the step of obtaining the liquid level detection data of the condensate in the water storage module 1.

[0123] If the liquid level detection data is less than or equal to the preset liquid level data, then there is relatively little condensate in the water storage chamber 101, and the condensate in the water storage chamber 101 can continue to be monitored.

[0124] The condensate control system of this application also has the following beneficial effects:

[0125] 1. This condensate control system can completely remove condensate from the engine body, thus completely eliminating the impact of water vapor on engine combustion.

[0126] 2. Condensate is usually mixed with organic oil, and direct discharge will pollute the environment. The condensate control system of this application can control the condensate to pass through the engine three-way catalytic converter purification system before being discharged, so as to achieve the purpose of environmentally friendly discharge.

[0127] 3. The water storage module 1 of the condensate control system is integrated with the air outlet chamber 110 of the intercooler 100, which can reduce the space occupied by the engine compartment layout and simplify the number of parts.

[0128] 4. The condensate control system of this application can deliver low-temperature condensate through the cooling pipe 201 into the exhaust pipe 300 to cool the high-temperature gas in the EGR module intake pipe 210, further reducing the temperature of the air-fuel mixture in the engine cylinder and the maximum combustion temperature, reducing in-cylinder heat transfer loss, lowering the combustion temperature, significantly improving the anti-knock capability of the air-fuel mixture, and further optimizing the combustion center of gravity to the ideal position, thereby improving the engine thermal efficiency.

[0129] 5. The condensate control system of this application can achieve unlimited and continuous collection of condensate, and the condensate will not affect the combustion of the engine even in severe weather such as heavy rain.

[0130] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0131] The above embodiments merely illustrate several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A condensate control system, characterized in that, The system is applied to an engine system, which includes an intercooler (100), an EGR module, and an exhaust module, the exhaust module including a purification device; the condensate control system includes: A water storage module (1) is installed in the intercooler (100). The water storage module (1) can be connected to or disconnected from the air outlet chamber (110) of the intercooler (100). The water storage module (1) is used to collect and store the condensate in the air outlet chamber (110). The delivery module is connected to the water storage module (1). The delivery module is used to controllably deliver at least a portion of the condensate in the water storage module (1) to the exhaust module through the gas intake pipe (210) of the EGR module to cool the gas in the gas intake pipe (210).

2. The condensate control system according to claim 1, characterized in that, The delivery module includes at least one cooling pipe (201), at least a portion of which is disposed within the air intake pipe (210). The cooling pipe (201) is connected to the water storage module (1) and the exhaust module.

3. The condensate control system according to claim 2, characterized in that, Multiple cooling pipes (201) are provided, with each cooling pipe (201) spaced apart, and at least a portion of the cooling pipes (201) are arranged circumferentially along the air intake pipe (210).

4. The condensate control system according to claim 2, characterized in that, The cooling pipe (201) is arranged parallel to the axial direction of the air intake pipe (210).

5. The condensate control system according to claim 2, characterized in that, The cooling pipe (201) includes a cooling pipe inlet (2011) and a cooling pipe outlet (2012). The cooling pipe inlet (2011) can be connected to the water storage module (1). The conveying module also includes a first air guide pipe (202). The first air guide pipe (202) is connected to the cooling pipe outlet (2012). The first air guide pipe (202) has a first air guide pipe outlet end (2021). The first air guide pipe outlet end (2021) is disposed in the exhaust pipe (300) of the exhaust module, and the opening of the first air guide pipe outlet end (2021) is oriented in the same direction as the airflow direction in the exhaust pipe (300).

6. The condensate control system according to claim 5, characterized in that, The delivery module also includes a second air guide pipe (203), which is connected to the cooling pipe inlet (2011). The second air guide pipe (203) passes through the side wall of the air intake pipe (210), and the cooling pipe inlet (2011) can be connected to the water storage module (1) through the second air guide pipe (203).

7. The condensate control system according to claim 1, characterized in that, The exhaust module also includes an exhaust manifold (400), and the delivery module is also used to controllably deliver a portion of the condensate in the water storage module (1) to the exhaust manifold (400) to mix with the exhaust gas in the exhaust manifold (400).

8. The condensate control system according to claim 7, characterized in that, The purification device is connected to the exhaust manifold (400) and is used to purify the mixture of condensate and exhaust gas.

9. The condensate control system according to any one of claims 1-8, characterized in that, The water storage module (1) includes a water storage chamber (101), which has a water storage chamber inlet (1011) and a water storage chamber outlet (1012). A flow guide (1013) is provided at the water storage chamber inlet (1011). The water storage chamber inlet (1011) is connected to the air outlet chamber (110) through the flow guide (1013). The water storage chamber outlet (1012) is connected to the conveying module.

10. The condensate control system according to claim 9, characterized in that, In the direction from the air outlet chamber (110) to the water storage chamber inlet (1011), the cross-sectional shape of the guide section (1013) gradually decreases.

11. The condensate control system according to claim 9, characterized in that, The water storage module (1) also includes a liquid level detection element (3), which is disposed in the water storage cavity (101) and is used to detect the liquid level detection data in the water storage cavity (101).

12. A vehicle, characterized in that, Includes the engine system and the condensate control system as described in any one of claims 1-11.

13. A method for controlling condensate, characterized in that, Performed by the vehicle of claim 12, the condensate control method includes: Collect and store the condensate in the outlet chamber (110) of the intercooler (100); Obtain the liquid level detection data of the condensate in the water storage module (1); Determine whether the liquid level detection data is greater than the preset liquid level data; If so, at least a portion of the condensate in the water storage module (1) is transported to the exhaust module through the gas intake pipe (210) of the EGR module to cool the gas in the gas intake pipe (210); If not, continue with the step of obtaining the liquid level detection data of the condensate in the water storage module (1).

14. The condensate control method according to claim 13, characterized in that, The step of cooling the gas in ...

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