Charge-Air Cooler De-icing via Electric Supercharger Recirculation
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Solution Overview
Problem
Internal combustion engines with charge-air coolers face issues with ice formation during low temperatures, leading to reduced efficiency and potential component degradation, especially during shutdown periods when ice is not melted and new ice forms upon restart.
Innovation Solution
Incorporating an electrically driveable compressor in the intake system with a bypass line that recirculates heated air through the charge-air cooler to melt ice, even during engine shutdown, using a sensor to control the temperature and prevent water evaporation, and a collecting vessel to manage condensate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the charge-air cooler cools the compressed charge air to increase density and improve charging, then the temperature of the charge air is reduced and density is increased, but ice may form in the charge-air cooler during low temperature operation
Solution Approach 1:
The system performs preliminary heating of the charge air before it enters the charge-air cooler by utilizing hot exhaust gases. This preliminary action ensures that the charge air temperature remains above the dew point and freezing point, preventing ice formation while still allowing effective cooling and density increase in the CAC.
Solution Approach 2:
Hot exhaust gases serve as an intermediary heating medium that transfers thermal energy to the charge air before it enters the charge-air cooler. This intermediary heating process prevents ice formation without directly heating the CAC, maintaining the cooling function while preventing harmful ice accumulation.
2Productivity
If the CAC is cooled to maintain efficient charge air delivery, then charge air density is increased, but during shutdown periods ice accumulates and degrades CAC performance
Solution Approach 1:
The system maintains continuous protection against ice formation by utilizing the thermal energy from exhaust gases during operation and the insulation properties during shutdown. The charge air is continuously heated to above freezing temperatures whenever the engine is running, and the insulated CAC maintains this temperature during shutdown periods, ensuring uninterrupted protection against ice accumulation.
Solution Approach 2:
The system uses its own operational characteristics - specifically the heat generated during normal engine operation and the insulation built into the CAC - to automatically prevent ice formation during shutdown periods without requiring external energy input or additional active heating systems.
3Power
If recirculated exhaust gas is increased to improve combustion efficiency, then power output is enhanced, but the amount of condensed water and ice formation in the CAC increases
Solution Approach 1:
The system changes the temperature parameter of the charge air by pre-heating it with exhaust gases before it enters the CAC. This parameter change ensures that even with high recirculated exhaust gas content that increases water vapor, the charge air temperature remains above the dew point and freezing point, allowing high power output without excessive ice formation.
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
Prevents ice accumulation and maintains charge-air cooler efficiency by continuously warming the air and melting ice, ensuring consistent engine performance and reducing the risk of component damage from ice formation.
Implementation Method 1
the electric supercharger introduces heat into the air situated in the intake system by compression
Implementation Method 2
a charge-air cooler (CAC) arranged in the intake system downstream of the compressor, that cools the compressed charge air
Implementation Method 3
liquids previously contained in the combustion air still in gaseous form, in particular water, may condense out if the dew point temperature of a component of the gaseous air flow is undershot
Implementation Method 4
a bypass line is provided, which branches off from the intake system, so as to form a first junction point, downstream of the electrically driveable compressor and downstream of the charge-air cooler
Data Source
AI summary
Methods and systems are provided for de-icing a charge-air cooler of a boosted engine system when the engine is turned off. In one example, a method may include recirculating air through a bypass passage including an activated electric supercharger and the CAC. The air is warmed by compression and thaws ice accumulated in the CAC.