CAC Condensate Dispersion via Orifice Plate
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Solution Overview
Problem
Current charge air coolers (CACs) in forced induction engines accumulate condensate, which can lead to undesirable engine performance due to unmetered condensate droplets entering the combustion chamber, especially in humid environments and during steady-state partial load conditions.
Innovation Solution
A CAC condensation dispersion system that includes a condensate pickup tube and conveyance tube to redirect accumulated condensate back to the compressor inlet, with a control valve and orifice plate to disperse the condensate as a mist, controlled by a system that considers ambient humidity, throttle inlet air pressure, and engine torque demand to prevent adverse engine impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If CAC cools compressed air below dew point to enhance combustion efficiency, then combustion efficiency is improved, but condensate accumulates and causes harmful droplets to enter combustion chamber
Solution Approach 1:
The patent extracts condensate from the harmful location (outlet tank where it would form droplets) and relocates it to a safe location (inlet duct where it can evaporate). The condensate pickup tube removes liquid condensate from the outlet tank, and the conveyance tube transports it to the inlet duct, preventing harmful droplet formation while maintaining the cooling benefit.
Solution Approach 2:
The patent introduces an intermediary system (condensate pickup tube, conveyance tube, and orifice plate) between the condensate source and the combustion chamber. The orifice plate acts as a mediator that disperses condensate into fine droplets and reintroduces it at the inlet, transforming it from a harmful substance to a beneficial pre-cooled moisture source.
2Object-generated harmful factors
If condensate is removed completely from CAC, then harmful droplets are prevented, but combustion chamber loses beneficial pre-cooled moisture
Solution Approach 1:
The patent converts the harmful condensate (which would normally be discarded as waste) into a beneficial substance by reintroducing it at the compressor inlet. The condensate serves dual purposes: it prevents harmful droplet accumulation in the outlet tank and provides pre-cooled moisture to the combustion chamber, improving combustion efficiency while eliminating the original harm.
Solution Approach 2:
Instead of discarding condensate through drainage, the patent recovers it and redistributes it to where it is most beneficial - the compressor inlet. The condensate pickup tube collects the condensate, and the conveyance tube delivers it back to the inlet duct, transforming a waste removal system into a recovery and reuse system.
3Object-generated harmful factors
If condensate is dispersed as fine droplets at compressor inlet, then harmful effects are eliminated, but system complexity increases
Solution Approach 1:
The patent applies local quality by placing the orifice plate at a specific location (inlet duct) where condensate dispersion is most beneficial. Rather than attempting to disperse condensate throughout the entire system, the solution focuses on the critical local area where moisture needs to be reintroduced, simplifying the overall system while achieving the desired effect.
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 system effectively disperses condensate in a metered fashion, preventing droplet formation and enhancing engine performance by ensuring condensate is reintroduced only when conditions are favorable, thus maintaining optimal combustion efficiency and reducing engine errors.
Implementation Method 1
a condensate conveyance tube having a first end connected to the pickup tube outlet and an opposite second end in fluid communication with the compressor inlet
Implementation Method 2
the in-line orifice plate defines an orifice nozzle configured to disperse a plug of liquid condensate into a mist condensate into the inlet duct
Implementation Method 3
CAC are typically air-to-air or air-to-water heat exchangers where heat from the higher temperature compressed combustion air flowing through the CAC is transferred to an exterior air or coolant flow
Implementation Method 4
The effectiveness of the CAC can cause the compressed combustion airflow through the CAC to experience a transition in temperature to fall below the dew point temperature, thereby causing moisture in the combustion air to condense forming liquid condensate
Data Source
AI summary
A charge air cooler (CAC) condensation dispersion system including a compressor for generating a hot compressed air flow; a CAC having an inlet tank for receiving the hot compressed air flow and an outlet tank for discharging a cooled compressed air flow; a condensate pickup tube having an inlet disposed in a lower volume of space within the outlet tank and an opposite outlet; and a condensate conveyance tube having a first end connected to the outlet of the pickup tube and an opposite second in in fluid connection with the inlet of the compressor. A solenoid actuated control valve is disposed in-line with the condensate conveyance tube. A controller configured to send a signal to the solenoid valve to selectively cycle the control valve between an open state and a closed state. An in-line orifice plate is disposed adjacent the second end of the condensate conveyance tube.