Charge Air Cooler Condensate Drain Valve Control
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Solution Overview
Problem
Turbocharged and supercharged engines face issues with condensate formation in charge air coolers, leading to engine misfires and combustion instability, and existing methods to address this decrease engine performance by reducing boost pressure.
Innovation Solution
A method involving a drain valve in the charge air cooler that opens during a compressor bypass valve event, draining condensate to an alternate location, thereby reducing the likelihood of engine misfires and maintaining boost pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If condensate is drained from the CAC to the intake manifold, then condensate removal is achieved, but boost pressure decreases and engine performance is reduced
Solution Approach 1:
The patent introduces an intermediary component - the alternate drainage path through the exhaust manifold - to resolve the contradiction. Instead of directly draining condensate to the intake manifold (which harms engine power), the system routes condensate through the exhaust manifold as an intermediate stage, allowing condensate removal while preserving boost pressure and engine performance.
2Reliability
If the drain valve is opened during compressor bypass valve event, then condensate is effectively removed, but system complexity increases
Solution Approach 1:
The patent merges the control of two valves (compressor bypass valve and drain valve) into a single coordinated action triggered by the same condition (compressor surge detection). This combining of control logic reduces overall system complexity while maintaining effective condensate removal during critical events.
Solution Approach 2:
The system performs preliminary action by opening the drain valve in anticipation of condensate accumulation problems during compressor bypass events. The drain valve is opened before significant condensate buildup can occur, preventing engine misfires and combustion instability proactively rather than reactively.
3Productivity
If mass air flow increases during acceleration, then engine power is improved, but condensate is stripped from CAC and drawn into engine causing misfire
Solution Approach 1:
The patent converts the harmful effect of increased mass air flow (which strips condensate and causes misfire) into a beneficial condition. By opening the drain valve during high flow conditions, the system uses the very air flow that causes the problem to facilitate condensate removal, transforming the harmful stripping action into a useful drainage mechanism.
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
Effectively reduces the risk of engine misfires and combustion instability while maintaining engine performance by draining condensate during compressor bypass valve events, thereby avoiding the decrease in boost pressure.
Implementation Method 1
an intercooler or charge air cooler (CAC) may be utilized to cool the heated air thereby increasing its density
Implementation Method 2
Condensate may form in the CAC when the ambient air temperature decreases, or during humid or rainy weather conditions, where the intake air is cooled below the water dew point
Implementation Method 3
a drain valve positioned in the CAC may be opened before and/or during the compressor bypass valve event. In one example, the drain valve may be opened in response to opening the compressor bypass valve
Implementation Method 4
the duration may be based on a required decrease in pressure at an outlet of the CAC during the compressor bypass valve event
Data Source
AI summary
Methods and systems are provided for draining condensate from a charge air cooler during a compressor bypass valve event. In one example, an engine controller may open a drain valve in the charge air cooler in response to potential compressor surge conditions. Opening the drain valve may be further based on an amount of condensate in the charge air cooler and a required decrease in pressure at an outlet of the compressor during the compressor bypass valve event.