Charge Air Heating via Working Fluid for Exhaust Thermal Management
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Solution Overview
Problem
Current thermal management techniques for internal combustion engine exhaust gases face limitations such as high smoke and hydrocarbon emissions, inability to achieve target temperatures, and inefficiency, necessitating improved methods for effective thermal management.
Innovation Solution
A system and method involving a heat transfer system that heats charge air in the intake of an internal combustion engine using a heat exchange with a working fluid circulated through the intake, incorporating a heat pump loop and charge air plumbing to manage exhaust gas temperature, thereby optimizing aftertreatment device operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional thermal management techniques (exhaust throttles, intake throttles, charge air cooler bypass) are used to increase exhaust gas temperature, then aftertreatment device operation is improved, but engine efficiency decreases and charge flow is reduced
Solution Approach 1:
A heat exchanger is introduced as an intermediary device to transfer heat from the working fluid to the charge air. This allows thermal energy to be transferred without directly altering the exhaust gas flow path or intake air flow path, thereby avoiding the efficiency losses associated with direct throttling or bypass methods while still achieving the desired temperature increase in the charge air and subsequently in the exhaust gas.
Solution Approach 2:
The system changes the temperature parameter of the charge air by heating it with the heat exchanger before it enters the combustion chambers. This parameter change allows the exhaust gas temperature to be increased without requiring changes to the exhaust gas flow rate or the intake air flow rate, thus maintaining engine efficiency while achieving the thermal management objective.
2Temperature
If exhaust gas temperature is increased to improve aftertreatment device operation, then pollutant treatment is enhanced, but smoke and hydrocarbon emissions increase
Solution Approach 1:
The charge air is heated in advance before entering the combustion chambers, which prepares the combustion process to occur at optimized temperatures. This preliminary heating action ensures that combustion is more complete and efficient, reducing the formation of smoke and hydrocarbon emissions while still achieving the necessary exhaust gas temperature for effective aftertreatment device operation.
Solution Approach 2:
The system incorporates sensors to monitor exhaust gas temperature, charge air temperature, and emission levels. Based on this feedback, the control system adjusts the operation of the heat exchanger and working fluid circulation to maintain optimal temperature conditions that simultaneously achieve effective aftertreatment and minimize harmful emissions, creating a closed-loop control system that balances temperature management with emission control.
3Temperature
If charge air temperature is increased to achieve target exhaust gas temperature, then thermal management effectiveness is improved, but energy consumption increases
Solution Approach 1:
The system recovers thermal energy from the working fluid that would otherwise be wasted and uses it to heat the charge air through the heat exchanger. By recovering and reusing this thermal energy, the system achieves the desired charge air temperature increase without proportionally increasing energy consumption, as the heat source is the working fluid's excess thermal energy rather than additional fuel combustion or dedicated heating elements.
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 thermal management by achieving target exhaust gas temperatures, improving aftertreatment device efficiency, and reducing emissions, while maintaining operational efficiency and effectiveness.
Implementation Method 1
heating the charge air in the intake by a heat exchange to the charge air from a working fluid that is circulated through the intake
Data Source
AI summary
Heating of the charge air in an intake is provided by a working fluid that is circulated through the intake to exchange heat with the charge air. The heated charge air can be used in response to a thermal management condition for an exhaust gas produced by operation of the internal combustion engine.