Air Intake Module With Segmented Ducts And Electric Compressor
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Solution Overview
Problem
Existing air intake systems for combustion engines are inefficient at low engine speeds and bulky, leading to increased size and complexity, with turbochargers being inefficient at low rpm and causing air heating, which reduces air density and power output.
Innovation Solution
A compact air intake module with a mechatronic system featuring an electric motor to control throttle valves and a single connector for the electric air compressor, integrated with a cooling duct and a junction pipe, allowing for independent air flow control and pressure increase, reducing size and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a turbocharger is used to increase airflow into the engine, then engine power is improved at high speeds, but the system becomes inefficient at low engine speeds and heats the air reducing density
Solution Approach 1:
The air intake system is segmented into two separate circuits: a first circuit with a first throttle valve for natural aspiration at low speeds, and a second circuit with a second throttle valve and electric compressor for forced induction at high speeds. This segmentation allows each circuit to operate optimally in its designated speed range, resolving the contradiction between low-speed efficiency and high-speed power.
Solution Approach 2:
The system dynamically switches between the first and second air intake circuits based on engine speed conditions. The mechatronic system controls the throttle valves to open or close the respective circuits, enabling the system to adapt its behavior to current operating conditions and maintain optimal efficiency across the entire operating range.
2Power
If additional air ducts and throttle valves are added to create different air intake circuits, then engine performance across different speeds is improved, but the system becomes bulky and complex
Solution Approach 1:
Multiple functional components are merged into a single integrated housing structure. The first air duct, second air duct, first throttle valve, second throttle valve, and electric compressor are all housed within one common housing, reducing the number of separate components and simplifying installation while maintaining the dual-circuit functionality.
Solution Approach 2:
The mechatronic system with the single electric motor performs multiple functions: it controls both the first throttle valve and the second throttle valve, enabling a single control system to manage the entire dual-circuit air intake system, thereby reducing control complexity.
3Adaptability or versatility
If air ducts with convoluted routes are used to route air, then different air intake circuits can be formed, but excess mass and volume are generated in the engine compartment
Solution Approach 1:
The first air duct and second air duct are integrated within a single housing structure, eliminating the need for separate external air ducts. This merging of air pathways into a compact unified structure reduces the volume occupied in the engine compartment while maintaining the ability to provide different air intake circuits.
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
The solution enables increased engine power independently of engine speed, reduces size and integration complexity, and maintains air pressure and cooling efficiency, improving engine performance and compactness.
Implementation Method 1
The electric air compressor can be attached, notably by screwing, to the housing. The housing may include a cooling duct for cooling the air circulating in the air intake module.
Implementation Method 2
The housing may include a cooling duct for cooling the air circulating in the air intake module.
Implementation Method 3
a single cooler equipped with an air-to-water type heat exchanger
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Air intake module (1) for combustion engine (2), characterized in that it comprises: - an electric air compressor (10), - a first air duct (11), - a second air duct (12), - a first throttle valve (21) capable of modifying the air flow in the first air duct (11), - a second throttle valve (22) capable of modifying the air flow in the second air duct (12), - and a one-piece housing (30) comprising the first air duct (11) and the second air duct (12), the housing being provided with a first cylindrical portion (31) cooperating with the first throttle valve (21) and provided with a second cylindrical portion (32) cooperating with the second throttle valve (22).