Turbocharged Piston Engine Charge Air Cooling
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Solution Overview
Problem
In turbocharged piston engines, the condensation of water vapor in charge air can lead to significant corrosion and erosion of engine components due to high pressure and humidity levels, particularly on the high-pressure side of the charge air system.
Innovation Solution
A dual cooling circuit system is implemented, comprising a low-temperature cooling circuit and a high-temperature cooling circuit, where the charge air is cooled by a charge air cooler with low-temperature liquid, and the temperature of the cooling liquid is controlled by adding high-temperature liquid to ensure the charge air temperature remains above its dew point, thereby preventing condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If charge air is cooled by a charge air cooler to increase pressure and improve combustion efficiency, then the combustion efficiency is improved, but water vapor condenses into water causing corrosion and erosion of engine components
Solution Approach 1:
The invention changes the temperature parameter of the cooling liquid dynamically. By controlling the temperature of the cooling liquid in the charge air cooler to be above the dew point temperature, the system maintains effective cooling for combustion efficiency while preventing water vapor condensation that causes corrosion and erosion.
Solution Approach 2:
The invention implements a feedback control system that monitors the dew point temperature of the charge air and adjusts the cooling liquid temperature accordingly. The control unit receives temperature information from sensors and automatically regulates the cooling liquid temperature to prevent condensation while maintaining optimal cooling performance.
2Temperature
If the temperature of cooling liquid is reduced to improve cooling efficiency, then the cooling efficiency is improved, but the temperature drops below the dew point causing water condensation
Solution Approach 1:
The invention dynamically adjusts the temperature parameter of the cooling liquid based on the dew point temperature of the charge air. By maintaining the cooling liquid temperature above the dew point while still providing effective cooling, the system achieves optimal cooling efficiency without causing water condensation.
Solution Approach 2:
The invention makes the cooling liquid temperature dynamic rather than static. The temperature of the cooling liquid is continuously adjusted based on operating conditions and dew point temperature, allowing the system to adapt to changing conditions and prevent condensation while maintaining cooling efficiency.
3Device complexity
If a single cooling circuit is used to simplify the system, then the device complexity is reduced, but the ability to control condensation is insufficient
Solution Approach 1:
The invention divides the cooling system into two separate circuits: a first cooling circuit for components requiring lower temperatures and a second cooling circuit for components requiring higher temperatures. This segmentation allows independent temperature control of the charge air cooler, enabling precise condensation prevention while maintaining overall system reliability.
Solution Approach 2:
The invention creates a multi-functional cooling system where the first cooling circuit handles general cooling needs and the second cooling circuit specifically addresses charge air cooling with condensation prevention. This multi-functionality allows the system to handle different temperature requirements simultaneously while maintaining simplicity through a coordinated dual-circuit architecture.
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 the amount of condensate in the charge air system, minimizing corrosion and erosion damage to engine components.
Implementation Method 1
pressurised charge air is cooled by a charge air cooler into which low-temperature cooling liquid is fed
Implementation Method 2
The temperature of the low-temperature cooling liquid is controlled by adding high-temperature cooling liquid thereto
Data Source
AI summary
The invention relates to a method of operating a turbocharged piston engine (1), which comprises a low-temperature cooling circuit (13) for low-temperature cooling liquid, a high-temperature cooling circuit (19) for high-temperature cooling liquid, and a charge air cooler (12) connected to the low-temperature cooling circuit (13). In the method charge air is pressurised at least in one stage, the pressurised charge air is cooled by the charge air cooler (12) into which low- temperature cooling liquid is fed, a dew point of the pressurised charge air downstream of the charge air cooler (12) is defined, and temperature of the charge air leaving the charge air cooler (12) is adjusted to be higher than the dew point by controlling temperature of the low-temperature cooling liquid fed into the charge air cooler (12). The temperature of the low-temperature cooling liquid is controlled by adding high-temperature cooling liquid thereto.