Charge Air Cooler Condensation Trap for Misfire-Free Drainage
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Solution Overview
Problem
High humidity in turbocharged engines leads to condensation forming on charge air coolers, which can result in engine misfires and power loss due to water droplets entering the combustion chambers, and existing solutions like liquid traps can cause boost pressure loss and environmental emissions issues.
Innovation Solution
A condensation trap is coupled to the outlet duct of the charge air cooler, temporarily storing condensate in a reservoir and releasing it back into the airflow at a controlled rate, reducing the amount reaching the combustion chambers and avoiding environmental contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If condensation is collected in a liquid trap with drain valve, then condensation entering combustion chambers is reduced, but boost pressure is lost due to valve sticking and drainage requirements
Solution Approach 1:
The harmful condensation is extracted from the airflow stream and collected in a reservoir, separating it from the main gas flow. This prevents condensation from entering combustion chambers while avoiding the need for drain valves that cause boost pressure loss.
Solution Approach 2:
A reservoir acts as an intermediary between the condensation collection point and the outlet duct. Instead of directly draining condensation to the exterior (which causes energy loss), the reservoir temporarily stores it and allows controlled return to the airflow stream.
2Quantity of substance
If condensation is drained to vehicle surroundings, then collection tank can be emptied, but regulated emissions are released into environment
Solution Approach 1:
Instead of discarding condensation to the exterior environment, the system recovers it by returning it to the outlet duct. The condensation is discarded from the harmful path (combustion chambers) but recovered in a controlled manner back into the airflow stream.
3Productivity
If condensate is released quickly to outlet duct, then reservoir drainage is efficient, but engine misfire occurs due to high condensate rate
Solution Approach 1:
The condensate release is performed periodically or in controlled intervals rather than continuously or all at once. This allows the reservoir to drain efficiently while limiting the instantaneous rate of condensate entry into the airflow stream to levels that prevent engine misfire.
Solution Approach 2:
The system dynamically adjusts the condensate release rate based on operating conditions. The release mechanism can modulate the flow rate to match engine demands, ensuring efficient drainage while maintaining combustion stability under varying load conditions.
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
This approach minimizes engine instability and power loss by regulating condensate release, preventing engine misfires, and ensuring environmentally safe disposal of condensate, while maintaining engine performance and avoiding boost pressure issues.
Implementation Method 1
condensation (e.g., water droplets) may form on any internal surface of the charge air cooler that is cooler than the dew point of the compressed air
Data Source
AI summary
Various systems and methods are described for a charge air cooler coupled to an engine. One example method comprises collecting condensate discharged from the cooler in a condensation trap coupled to an outside surface of a bend in an outlet duct of the cooler; during a first condition, temporarily storing the condensate in a reservoir of the condensation trap; and, during first and second conditions, releasing the condensate to the outlet duct in a direction of airflow via a tube.