Charge Air Cooler Flow Control for Condensation Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Internal combustion engines with turbocharging or supercharging devices face issues with condensation buildup in charge air cooler systems, leading to potential engine misfires, premature component wear, and airflow restrictions due to ice accumulation, especially in humid and cold conditions.
Innovation Solution
An internal combustion engine assembly with a charge air cooler system equipped with an electronic control unit and a flow adjustment mechanism, such as a valve or flap, that can be selectively positioned to manage condensation buildup by adjusting air velocity through the CAC system, preventing condensation from entering the intake manifold and reducing ice formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the charge air cooler system operates in humid conditions with high external airflow, then cooling efficiency is improved, but condensation buildup occurs in the CAC system
Solution Approach 1:
The patent extracts the condensation accumulation problem from the CAC system by providing a separate condensate reservoir and evacuation mechanism. The flow adjustment mechanism directs condensation away from the intake manifold through dedicated pathways, separating the harmful condensation removal function from the primary cooling function.
Solution Approach 2:
The flow adjustment mechanism performs preliminary action by proactively managing condensation before it can cause harmful effects. By controlling air velocity through the CAC system in advance, the system prevents condensation from accumulating in harmful quantities, rather than reacting after problems occur.
2Productivity
If the CAC system cools intake air to increase density, then volumetric efficiency improves, but ice accumulation occurs in cold conditions
Solution Approach 1:
The patent applies parameter changes by adjusting air velocity through the CAC system based on operating conditions. The flow adjustment mechanism modifies flow parameters (velocity, pressure) to prevent ice accumulation while maintaining cooling efficiency. In cold conditions, the system adjusts parameters to reduce condensation and ice formation.
Solution Approach 2:
The electronic control unit provides feedback control for the flow adjustment mechanism, monitoring system conditions and adjusting air velocity accordingly. This feedback loop ensures the system maintains optimal cooling while preventing ice accumulation in cold environments.
3Object-generated harmful factors
If air velocity through the CAC system is increased, then condensation evacuation improves, but cooling efficiency decreases
Solution Approach 1:
The patent applies dynamics by making the air velocity adjustable rather than fixed. The flow adjustment mechanism dynamically adapts velocity based on operating conditions, allowing optimization between condensation evacuation and cooling efficiency for different scenarios.
Solution Approach 2:
The system applies partial action by using the flow adjustment mechanism to selectively control air velocity only when needed for condensation management, rather than continuously operating at maximum velocity. This allows maintaining cooling efficiency while providing sufficient condensation evacuation capability.
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 effectively prevents engine misfires and maintains airflow by managing condensation and ice buildup within the CAC system, ensuring consistent engine performance across varying conditions.
Implementation Method 1
A CAC is a heat exchange device used to cool the air charge and, thus, further improve volumetric efficiency of the engine by increasing intake air charge density through cooling
Implementation Method 2
The heat exchange process can cause moisture to condense and, thus, form inside the CAC system, especially when conducted in conditions where the ambient air flowing through the turbocharging or supercharging device and CAC is substantially humid
Data Source
AI summary
An engine assembly with an air intake system and a turbocharger device in fluid communication with the air intake system includes an electronic control unit in communication with the air intake system and turbocharger device. A CAC system is in downstream fluid communication with the turbocharger device and in upstream fluid communication with the air intake system and includes at least one flow adjustment mechanism in communication with the electronic control unit and selectively positionable between a first position and one or more second positions to adjust velocity of air from the turbocharger device flowing through the CAC system and to manage condensation buildup in the CAC system and/or to open a bypass duct in order for some or all of the turbo airflow to bypass the CAC system to reduce or eliminate condensation buildup in the CAC system at warm ambient conditions and ice buildup at cold ambient conditions.