Charge-Air Cooler Bypass Control for Engine Shutdown Stability
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Solution Overview
Problem
Existing internal combustion engine systems with charge-air cooling face issues such as continuous cooling under all operating conditions, leading to inefficiencies and shuddering during engine shutdown due to incomplete bypass functionality.
Innovation Solution
A method utilizing a two-stage switchable shut-off element and a continuously adjustable shut-off element to control charge-air flows, allowing for full, partial, or no cooling, and preventing charge air from reaching the engine during shutdown, thereby addressing inefficiencies and shuddering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a bypass line is provided to allow charge air to bypass the charge-air cooler, then charge air can be supplied non-cooled during warm-up and regeneration phases, but the bypass line cannot be fully shut off leading to continuous cooling and engine shuddering during shutdown
Solution Approach 1:
The shut-off element is divided into two independent stages: a first shut-off element with two positions (open/closed) and a second shut-off element with continuously adjustable positions. This segmentation allows the system to achieve both full bypass (first element closed, second element fully closed) and complete shutdown (both elements closed) capabilities, resolving the contradiction between adaptability and reliability
2Productivity
If charge air is continuously cooled under all operating conditions, then charge air density is maximized for power output, but engine efficiency decreases during warm-up and regeneration phases requiring non-cooled charge air
Solution Approach 1:
The system dynamically adjusts the cooling state of charge air by controlling the position of the shut-off elements based on operating conditions. During power output phases, the first shut-off element is open and the second is adjusted to maximize cooling. During warm-up and regeneration phases, the first shut-off element is closed to bypass the cooler entirely, eliminating energy loss while maintaining productivity
3Ease of operation
If only a continuously adjustable shut-off element is used in the bypass line, then charge-air flow can be partially bypassed, but the charge-air cooler cannot be fully deactivated resulting in continuous cooling
Solution Approach 1:
The control system is segmented into two independent shut-off elements with different functionality. The first shut-off element provides binary control (full bypass or full cooling) while the second provides continuous modulation. This segmentation enables both complete deactivation of the charge-air cooler and precise flow control, resolving the contradiction between ease of operation and adaptability
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
Enables demand-dependent charge-air cooling, improving engine efficiency and preventing shuddering by allowing for non-cooled charge air supply during warm-up and regeneration phases, and ensuring complete engine shutdown.
Implementation Method 1
a charge-air cooler to be provided in the intake line, by means of which charge-air cooler the charge air is cooled before it enters the at least one cylinder. The cooler lowers the temperature and thereby increases the density of the charge air
Implementation Method 2
supercharging, wherein supercharging is primarily a method for increasing power, in which the charge air required for the combustion process in the engine is compressed, as a result of which a greater mass of charge air can be supplied to each cylinder per working cycle
Data Source
AI summary
A method for operating an engine having a cylinder, an intake line for supplying charge air to the cylinder, and a device for controlling charge-air flows conducted via a charge-air cooler and via a bypass line around the charge-air cooler, comprises controlling the charge-air flows using the device, the device including a two-stage switchable shut-off element and a continuously adjustable shut-off element, wherein the two-stage switchable shut-off element, which is arranged parallel to the bypass line in the, is switched between only an open position and a closed position, and the bypass line is opened up or shut off to a greater or lesser extent by the shut-off element which is continuously adjustable between an open position and a closed position. In this way, shuddering of the engine during shut down is prevented.