Charge Air Cooler Control for Boosted Engines
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Solution Overview
Problem
Existing charge air cooler systems in turbocharged engines face challenges in maintaining precise control over manifold charge air temperature, leading to increased condensate formation and combustion instability due to reliance on ambient temperature adjustments alone, which can be slow to respond and inefficient.
Innovation Solution
A method that adjusts the charge air cooler fan, coolant pump, engine cooling fan, and grille shutters based on a combination of target manifold charge air temperature and additional air and coolant temperatures, including ambient air temperature, CAC coolant temperature, and CAC inlet air temperature, to optimize cooling and reduce condensate formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If CAC cooling is adjusted based on measured manifold charge air temperature alone, then the system can respond to temperature deviations, but the response precision decreases and condensate formation or combustion instability increases
Solution Approach 1:
The system performs preliminary cooling actions by adjusting grille shutters and engine cooling fan based on predicted temperature deviations from ambient air temperature changes, before the manifold charge air temperature actually deviates from target. This prevents temperature fluctuations before they occur, maintaining precision and preventing condensate formation.
Solution Approach 2:
The system uses feedback from multiple temperature sensors (ambient air temperature, CAC coolant temperature, CAC inlet air temperature) combined with measured manifold charge air temperature to continuously adjust cooling device operations. This multi-parameter feedback loop enables precise control while maintaining combustion stability.
2Speed
If CAC cooling devices are adjusted in response to manifold charge air temperature increases, then temperature control is achieved, but the system responds slowly and may increase rather than decrease downstream charge air temperatures
Solution Approach 1:
The system anticipates temperature changes by monitoring ambient air temperature and predicting their effect on manifold charge air temperature. Cooling devices are adjusted in advance before the actual temperature deviation occurs, achieving both fast response and high precision control.
Solution Approach 2:
The system dynamically adjusts cooling device operations based on real-time temperature conditions and predicted trends. By continuously adapting the cooling strategy to current and anticipated conditions, the system achieves rapid response while maintaining precise temperature control accuracy.
3Reliability
If cooling devices are run continuously to maintain target temperature, then temperature control is maintained, but engine operating efficiency decreases and wear on cooling system components increases
Solution Approach 1:
The system operates cooling devices periodically rather than continuously, activating them only when temperature deviations are predicted or detected. This periodic operation based on actual need maintains reliable temperature control while significantly reducing energy consumption and component wear.
Solution Approach 2:
The system changes operational parameters of cooling devices (grille shutter position, fan speed, pump output) dynamically based on temperature conditions. By adjusting parameters to match actual cooling needs rather than maintaining fixed high-level operation, the system achieves reliable control with improved efficiency and reduced wear.
4Adaptability or versatility
If ambient air temperature adjustments are used to control CAC cooling, then the system can adapt to environmental conditions, but the response is slow and precision is reduced
Solution Approach 1:
The system uses ambient air temperature as a leading indicator to predict future manifold charge air temperature changes. By taking preliminary cooling actions based on ambient temperature trends before they affect the manifold, the system maintains both environmental adaptability and precise temperature control.
Solution Approach 2:
The system uses CAC coolant temperature and CAC inlet air temperature as intermediary parameters that link ambient conditions to manifold charge air temperature. These intermediary measurements provide early warning of temperature changes, enabling precise control while adapting to environmental 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 enhances the precision and accuracy of maintaining the target manifold charge air temperature, reducing condensate formation and combustion instability while increasing engine efficiency and reducing wear on cooling system components.
Implementation Method 1
CACs may either use cooled coolant passing through the CAC or ambient air passing across the CAC to cool charge air passing through the inside of the CAC
Implementation Method 2
CACs may either use cooled coolant passing through the CAC or ambient air passing across the CAC to cool charge air passing through the inside of the CAC
Data Source
AI summary
Methods and systems are provided for adjusting a charge air cooler fan or charge air cooler coolant pump and an engine cooling fan and/or vehicle grille shutters based on a target manifold charge air temperature. In one example, the grille shutter position and/or engine cooling fan speed may be adjusted based on a difference between a target manifold charge air temperature and a temperature of the charge air cooler cooling medium. Further, the charge air cooler fan speed or charge air cooler coolant pump speed may be adjusted based on a difference between a charge air cooler inlet charge air temperature and the target manifold charge air temperature.