Control method for an air intake intercooler that heats or cools intake air of an engine and a control system thereof
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air intake intercoolers for engines are limited to cooling functions, failing to maintain optimal intake air temperature across varying conditions, especially at low speeds and high ambient temperatures, leading to inefficiencies and increased costs due to oversized designs.
Innovation Solution
A control system with a primary thermal management unit using Peltier effect thermocouples to dynamically adjust intake air temperature by heating or cooling, controlled by an engine ECU based on real-time intake temperature sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the intercooler is designed according to the maximum working condition and maximum ambient temperature boundary, then the cooling performance at high ambient temperature is improved, but the intercooler volume and cost increase due to large design margin
Solution Approach 1:
The patent applies dynamics by making the intercooler system adjustable through a control unit that regulates the flow path selection valve. The system dynamically switches between different flow paths (first flow path for high ambient temperature, second flow path for low ambient temperature) based on real-time temperature sensing, allowing the intercooler to adapt its cooling capacity to actual operating conditions rather than being fixed for maximum conditions
Solution Approach 2:
The patent changes the parameter of flow path configuration based on ambient temperature parameters. The control unit adjusts the flow path selection valve to direct coolant flow through different circuits (first coolant circuit or second coolant circuit) depending on the detected ambient temperature, thereby changing the effective heat exchange parameters to match actual cooling needs
2Temperature
If the intercooler is designed for maximum cooling capacity, then the cooling performance is improved, but the device complexity and cost increase
Solution Approach 1:
The patent segments the intercooler system into multiple independent flow paths and control elements. The intercooler is divided into a first flow path and a second flow path, with a flow path selection valve that can direct flow through either path. This segmentation allows the system to achieve variable cooling capacity without requiring a completely different design for each operating condition
Solution Approach 2:
The patent makes the intercooler system multi-functional by enabling it to perform both high-capacity cooling (through the first flow path) and low-capacity cooling or bypass (through the second flow path) using the same physical intercooler structure. The control unit and flow path selection valve enable the single intercooler device to serve multiple cooling needs across different operating conditions
3Device complexity
If conventional cooling-only systems are used, then the structure is simple, but the adaptability to different operating conditions deteriorates
Solution Approach 1:
The patent transforms the static cooling system into a dynamic one by incorporating a control unit and flow path selection valve that can actively adjust the cooling mode based on ambient temperature sensor feedback. The system transitions from a fixed configuration to an adjustable one, enabling adaptation across a wide temperature range while maintaining reasonable structural complexity
Solution Approach 2:
The patent implements feedback control by using an ambient temperature sensor to continuously monitor environmental conditions and feed this information to the control unit. The control unit processes this feedback signal and automatically adjusts the flow path selection valve to the appropriate position, creating a closed-loop control system that adapts to changing operating conditions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Maintains optimal intake air temperature, improving engine performance and reducing costs by minimizing the need for oversized intercoolers and preventing excessive exhaust temperatures.
Implementation Method 1
A control system with a primary thermal management unit using Peltier effect thermocouples to dynamically adjust intake air temperature by heating or cooling
Data Source
AI summary
Provided are a control method for an air intake intercooler of an engine and a control system thereof, which relates to the technical field of intercoolers. The air intake intercooler includes a primary thermal management unit that can heat and cool intake air. The control method for the air intake intercooler includes acquiring real-time air intake temperature of an air inlet of the intake intercooler; controlling the primary thermal management unit to turn on a heating mode in response to the real-time air intake temperature being lower than a set minimum temperature limit value; and controlling the primary thermal management unit to turn on a cooling mode in response to the real-time air intake temperature being higher than the set maximum temperature limit.