Charge Flow Temperature Estimation Using Sensor Synthesis
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Solution Overview
Problem
Internal combustion engine control systems face increased complexity, cost, and weight due to the need for multiple sensors to accurately control engine operations, which complicates emissions reduction and fuel efficiency.
Innovation Solution
A method for estimating charge flow temperature at the intake manifold using a combination of temperature signals from a charge air cooler outlet sensor and an exhaust gas recirculation outlet sensor, eliminating the need for a physical sensor at the intake manifold by employing a control module that calculates the estimated charge flow temperature based on fresh air and exhaust gas recirculation fractions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional sensors are included in the engine system to improve control accuracy, then measurement precision is improved, but device complexity and system cost increase
Solution Approach 1:
The patent creates a virtual copy of the charge flow temperature sensor by using a control module that calculates estimated temperature based on readings from existing sensors (intake air temperature sensor and exhaust gas temperature sensor). This computational copy eliminates the need for additional physical sensors while maintaining measurement accuracy.
Solution Approach 2:
The control module acts as an intermediary that synthesizes temperature information from multiple existing sensors to produce an accurate estimate of charge flow temperature. Instead of directly measuring with another sensor, the system uses the control module to mediate and calculate the temperature based on available data from other parts of the system.
2Measurement precision
If additional sensors are installed to improve control accuracy, then measurement precision is improved, but system weight increases
Solution Approach 1:
The patent replaces physical sensor weight with computational processing weight. By creating a virtual temperature sensor through calculation algorithms in the control module, the system eliminates the need for additional physical sensing components, thereby reducing overall system weight while maintaining measurement precision.
3Measurement precision
If multiple sensors are used to improve control accuracy, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the need to manufacture and install additional physical temperature sensors by creating a computational copy through the control module. This approach reduces manufacturing costs associated with sensor acquisition, installation, and calibration while achieving the same measurement precision through software-based temperature estimation.
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 system cost and weight by synthesizing sensor inputs, improving engine control accuracy and fuel efficiency while meeting emissions standards without the need for additional physical sensors.
Implementation Method 1
a charge air cooler outlet temperature sensor configured to provide a first temperature signal
Implementation Method 2
an exhaust gas recirculation outlet temperature sensor configured to provide a second temperature signal
Implementation Method 3
determine an the estimated charge flow temperature at an intake manifold temperature sensing position based on a combination of the first temperature signal multiplied by an estimated fresh air fraction and the second temperature signal multiplied by an exhaust gas recirculation fraction
Data Source
AI summary
An engine air system for charge flow temperature estimation includes a charge air cooler outlet temperature sensor configured to provide a first temperature signal, an exhaust gas recirculation outlet temperature sensor configured to provide a second temperature signal, and a control module configured to receive the first temperature signal and the second temperature signal. The control module includes a charge flow temperature estimation module configured to determine an the estimated charge flow temperature at an intake manifold temperature sensing position based on a combination of the first temperature signal multiplied by an estimated fresh air fraction and the second temperature signal multiplied by an exhaust gas recirculation fraction.