Charge Air Cooler Fluid Spraying Control
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Solution Overview
Problem
Existing methods for spraying fluids onto charge air coolers in motor vehicles are not resource-efficient and do not adapt well to the operating mode of the cooler, leading to unnecessary fluid consumption and potential torque and power losses.
Innovation Solution
A method that measures and compares multiple temperatures using sensors and a control unit to determine the optimal times for spraying fluid onto the charge air cooler, allowing for selective and staged fluid application based on temperature intervals, thereby reducing resource usage and matching the spraying cycle to the cooler's operating mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unregulated or continuous spraying of fluid onto the charge air cooler is performed, then the cooling effect is maintained, but fluid consumption increases and resource efficiency deteriorates
Solution Approach 1:
The spraying system dynamically adjusts its operation based on real-time temperature measurements from multiple sensors. The control unit activates spraying only when temperature thresholds are exceeded, transitioning from static continuous spraying to dynamic conditional spraying, thereby reducing fluid consumption while maintaining cooling reliability
Solution Approach 2:
The system implements feedback control by continuously monitoring temperatures at the charge air cooler inlet and outlet using first and second sensors. The control unit receives this temperature feedback and adjusts spraying activation accordingly, ensuring cooling effectiveness is maintained only when thermally necessary, thus optimizing fluid usage
2Loss of substance
If multiple temperature measurements and comparisons are performed before spraying, then fluid consumption is reduced, but the control system complexity increases
Solution Approach 1:
The control logic is segmented into distinct evaluation stages: first temperature measurement at inlet, second temperature measurement at outlet, sequential comparison operations, and conditional spraying activation. This segmentation of the control process into discrete temperature-check steps simplifies implementation while achieving reduced fluid consumption through multi-parameter evaluation
Solution Approach 2:
The system changes operational parameters (spraying activation) based on measured temperature parameters. By monitoring temperature values and comparing them against reference thresholds, the system adjusts fluid spraying parameters dynamically, reducing overall fluid consumption while maintaining manageable control complexity through parameter-based decision logic
3Loss of substance
If fluid is sprayed selectively based on temperature intervals, then resource efficiency improves, but the measurement and control precision requirements increase
Solution Approach 1:
The system applies partial spraying action by activating fluid spraying only when temperature exceeds reference values, rather than continuous spraying. This partial action approach reduces resource consumption while the use of multiple temperature sensors and sequential comparison ensures sufficient measurement precision is achieved for accurate activation decisions
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 reduces fluid consumption, minimizes resource usage, and optimizes the spraying process to avoid unnecessary torque and power losses, making it suitable for production vehicles by allowing a smaller fluid reservoir and reducing installation space and weight requirements.
Implementation Method 1
spraying at least some of the fluid onto the charge air cooler during a spray-on cycle
Implementation Method 2
spraying a fluid onto a charge air cooler... reduces fluid consumption... optimizes the spraying process
Data Source
AI summary
A method for spraying a fluid onto a charge air cooler of a motor vehicle includes measuring a first temperature with the aid of a first sensor of the motor vehicle; measuring a second temperature with the aid of a second sensor of the motor vehicle; comparing the first temperature with a first reference temperature by a controller of the motor vehicle; comparing the second temperature with a second reference temperature by the controller of the motor vehicle if the first temperature is higher than the first reference temperature or equal to the first reference temperature; and spraying at least some of the fluid onto the charge air cooler during a spray-on cycle if the second temperature is higher than the second reference temperature or equal to the second reference temperature.