Charge Air Cooler Temperature Control for Condensate and Misfire Prevention
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Solution Overview
Problem
Existing systems for controlling condensate formation in charge air coolers (CACs) of turbocharged engines are inadequate, leading to corrosion and engine misfires, as they rely solely on ambient and intake air temperature control, which can result in increased vehicle drag and engine over-temperature issues.
Innovation Solution
A method involving the adjustment of an electric fan and grille shutter operation based on CAC outlet temperature, vehicle speed, and engine coolant temperature to manage condensate formation, optimizing fuel economy and reducing energy losses while maintaining engine coolant temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If restriction devices are closed for a prolonged period to control condensate formation, then condensate formation is reduced, but engine temperatures increase over optimal levels
Solution Approach 1:
The patent applies dynamics by making the restriction devices adjustable and controllable rather than fixed. The controller dynamically adjusts the position of intake air flow restriction and ambient air flow restriction based on real-time temperature readings from sensors, allowing the system to adapt to changing operating conditions and prevent both condensate formation and engine overheating
Solution Approach 2:
The system implements feedback control by using sensors to continuously monitor intake air temperature and ambient air temperature, then using this information to automatically adjust the restriction devices. This closed-loop control ensures the system responds to actual conditions rather than operating in a fixed state
2Temperature
If restriction devices are open for a prolonged period to control condensate formation, then engine temperature is maintained, but aerodynamic drag on the vehicle increases
Solution Approach 1:
The restriction devices are designed to be dynamically adjustable rather than fixed in position. The controller modifies the opening degree of both intake air flow restriction and ambient air flow restriction based on real-time temperature conditions, allowing the system to minimize drag when conditions permit while maintaining temperature control when needed
Solution Approach 2:
The system changes the physical parameter of air flow restriction degree based on temperature conditions. By varying this parameter dynamically, the system optimizes the balance between engine temperature maintenance and aerodynamic drag reduction, rather than maintaining a constant restriction level
3Temperature
If intake air temperature is controlled using ambient air flow restriction and intake air flow restriction, then charge air cooler effectiveness is maintained, but vehicle drag and energy loss increase
Solution Approach 1:
The system uses dynamically controllable restriction devices that can adjust their opening degree based on real-time conditions. This allows the system to maintain charge air cooler effectiveness only when necessary, rather than maintaining constant restriction, thereby reducing aerodynamic drag and energy loss during periods when temperature control is not critical
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 effectively reduces condensate formation and corrosion, prevents engine misfires, and improves fuel economy by dynamically controlling the CAC outlet temperature and air flow, thereby optimizing vehicle performance and efficiency.
Implementation Method 1
adjusting fan rotation speed or rotation direction in response to a temperature at a charge air cooler outlet
Implementation Method 2
Turbo charged engines utilize a Charge Air Cooler (CAC) to cool compressed air from the turbocharger, before it enters the engine. Ambient air from outside the vehicle travels across the CAC to cool intake air passing through the inside of the CAC
Implementation Method 3
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
Data Source
AI summary
Methods and systems are provided for reducing corrosion of a charge air cooler and reducing engine misfire due to condensate formation. In response to charge air cooler outlet temperature, electric fan operation and grille shutter opening is adjusted. Electric fan operation and grille shutter opening may also be controlled in response to vehicle operating conditions.