Charge Air Cooler Failure Detection via Multi-Point Temperature Ratio
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Solution Overview
Problem
Existing methods for detecting failures in charge air coolers of supercharged engines are fragile and unreliable, as they rely on only two temperature measurements, making them susceptible to errors due to sensor malfunctions or incorrect placements.
Innovation Solution
A method that determines air temperatures at multiple points in the air supply circuit, calculates a parameter representative of the cooler's efficiency, and compares it to a predetermined threshold value, providing a more comprehensive and reliable diagnosis through continuous, iterative monitoring using embedded electronic processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only two temperature measurements are used to detect cooler failure, then the measurement system is simple, but the diagnosis reliability is low due to sensor malfunction or incorrect placement
Solution Approach 1:
The air supply circuit is segmented into multiple measurement zones (between filter and compressor, between compressor and cooler, between cooler and engine) with temperature sensors placed at each segment. This segmentation allows independent verification of temperature changes at each stage, making the system resilient to individual sensor failures and enabling more reliable cooler efficiency assessment through comparative analysis of temperature differentials across segments.
2Measurement precision
If multiple temperature measurements are taken at different points in the air supply circuit, then the diagnosis accuracy improves, but the device complexity increases
Solution Approach 1:
The patent introduces an electronic control unit that acts as an intermediary to receive, process, and analyze temperature data from multiple sensors. This intermediary component centralizes the complexity of handling multiple measurements, performing automated calculations of temperature differentials, and generating diagnostic outputs, thereby managing measurement precision requirements without proportionally increasing overall system complexity.
3Reliability
If continuous monitoring is performed by successive iterations, then the failure detection timeliness improves, but the processing energy consumption increases
Solution Approach 1:
The monitoring system performs periodic temperature measurements and comparisons at defined intervals rather than continuous real-time processing. The electronic control unit evaluates temperature differentials at regular intervals, calculating cooler efficiency parameters periodically. This periodic action maintains timely failure detection capability while significantly reducing processing energy consumption compared to continuous monitoring, as the system can enter low-power states between measurement cycles.
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 allows for instantaneous and accurate detection of cooler failures, ensuring the engine's reliability by providing a clear and timely alert to the driver, thus preventing potential engine damage.
Implementation Method 1
charge air cooler (5)... the temperature of the air Tape between the compressor and the cooler and the temperature of the air Tsras between said cooler and the engine
Data Source
AI summary
A method for detecting a failure of a charge air cooler placed in an air supply circuit of an engine, the circuit including an air filter and a compressor. The method is performed continuously and repeatedly. The method includes: determining temperature Tair of the air between the filter and the compressor, the temperature of the air Tapc between the compressor and the cooler, and the temperature of the air Tsras between the cooler and the engine; calculating the Tapc-Tsras/Tapc-Tair ratio, which is a parameter indicative of effectiveness of the cooler; comparing the parameter against a predetermined threshold effectiveness value; and making a diagnosis as to whether the cooler is operating correctly or incorrectly, on the basis of the comparison.