Auxiliary Cooling System for Turbo Engine EGR Temperature Control
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Solution Overview
Problem
Conventional EGR cooling systems in vehicles suffer from low cooling efficiency due to high-temperature engine cooling water, limiting the reduction of temperatures in EGR gas and bearing housing, which in turn restricts fuel efficiency improvements.
Innovation Solution
An auxiliary cooling system with separate cooling structures and timing for circulating cooling water, including a first line connecting a radiator and intercooler, a second line connecting the intercooler to the intake manifold, and a third line connecting the intake manifold to the radiator, EGR cooler, compressor housing, and bearing housing, with a bypass valve to manage cooling water flow and temperature optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional EGR cooling system uses engine cooling water, then the engine cooling function is provided, but the cooling efficiency is low due to high temperature of engine cooling water
Solution Approach 1:
The cooling system is divided into two separate loops: a high-temperature loop for engine cooling and a low-temperature loop for EGR gas cooling. This segmentation allows each loop to operate at its optimal temperature range, with the low-temperature loop using cooler water from the radiator outlet to efficiently cool EGR gas, while the high-temperature loop handles engine cooling independently.
Solution Approach 2:
A bypass valve acts as an intermediary to control the flow of cooling water between the high-temperature and low-temperature loops. It selectively directs cooling water to either the radiator or the EGR cooler based on operating conditions, enabling efficient temperature management and resolving the contradiction between engine cooling requirements and EGR cooling efficiency.
2Temperature
If cooling water is circulated immediately after ignition, then cooling effect is provided, but catalyst activation is prevented due to insufficient temperature
Solution Approach 1:
The bypass valve dynamically adjusts cooling water flow based on engine operating conditions and temperature requirements. During warm-up phase, it directs cooling water through the engine block to maintain catalyst activation temperature. During normal operation, it redirects flow to the radiator for effective cooling, thus resolving the contradiction between maintaining temperature for catalyst activation and providing cooling effect.
Solution Approach 2:
The cooling water circulation is controlled in periodic phases: initial circulation through the engine block for warm-up and catalyst activation, followed by redirection to the radiator for cooling when temperature thresholds are met. This periodic control strategy ensures both catalyst activation and cooling efficiency are achieved at appropriate times.
3Loss of energy
If high-temperature cooling water is used for EGR cooling, then engine cooling is effective, but fuel efficiency cannot be improved due to insufficient temperature reduction in EGR gas
Solution Approach 1:
By segmenting the cooling system into separate high-temperature and low-temperature loops, the patent enables the EGR cooler to receive cool water from the radiator outlet (low-temperature loop) rather than hot water from the engine block (high-temperature loop). This results in more effective EGR gas cooling, improved fuel efficiency, and eliminated the trade-off between engine cooling effectiveness and EGR temperature reduction.
4Reliability
If cooling water flow is increased, then cooling performance is improved, but energy consumption increases due to water pump operation
Solution Approach 1:
The electric water pump operates periodically rather than continuously, activating only when EGR cooling is required and deactivating when the engine reaches normal operating temperature. The bypass valve controls flow distribution to match cooling demands, reducing unnecessary pump operation and energy consumption while maintaining adequate cooling performance when needed.
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
Enhances fuel efficiency by improving cooling performance, reducing engine block friction, extending turbine housing lifetime, and ensuring proper catalyst activation, while preventing turbine wheel damage through controlled cooling water circulation.
Implementation Method 1
a radiator (10) and an intercooler (20)
Implementation Method 2
a radiator (10) and an intercooler (20)
Implementation Method 3
an intercooler (20) connected to an intake manifold (30)
Implementation Method 4
supply cooling water discharged from the intake manifold to an EGR (exhaust gas recirculation) cooler
Implementation Method 5
supply cooling water discharged from the intake manifold to an EGR (exhaust gas recirculation) cooler
Implementation Method 6
an electric water pump (110) installed on the first line (100) so that cooling water flows from the radiator (10) toward the intercooler (20) through the first line (100)
Implementation Method 7
a bypass valve (310) selectively directs transferring cooling water (410), heated while passing through a turbine housing (70), to the radiator (10) or transferring the cooling water to the radiator (10) via an engine block (1) or a heater (2)
Implementation Method 8
heated while passing through a turbine housing (70)
Implementation Method 9
heated while passing through a turbine housing (70)
Data Source
AI summary
An auxiliary cooling system which is provided separately from an engine cooling passage in a vehicle provided with a turbo engine. The auxiliary cooling system includes a first line which connects a radiator and an intercooler to each other and on which an electric water pump is installed. A second line connects the intercooler and an intake manifold. A third line connects the intake manifold and the radiator, and a bypass valve selectively directly transfers cooling water, heated while passing through a turbine housing provided on a path of the third line, to the radiator or transfers the cooling water to the radiator via an engine block or a heater. Cooling water discharged from the intake manifold passes through an ETC (electronic throttle control) unit and thus reduces a temperature of intake air passing through the ETC unit.