Compressor Outlet Temperature Regulation via Torque Prediction
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Solution Overview
Problem
Current engine systems struggle to balance engine performance and component integrity due to limitations in regulating compressor outlet temperature, often leading to premature degradation and reduced performance, as existing methods rely on static intake air temperature measurements that do not accurately reflect component temperatures.
Innovation Solution
An engine control system that adjusts torque output based on a predicted future compressor outlet temperature profile, using current and predicted engine operating conditions, including driver behavior and external vehicle data, to maintain temperatures below thresholds, thereby preventing overheating and degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If engine torque is limited based on measured intake air temperature to protect components, then component integrity is improved, but engine performance deteriorates due to unnecessary torque limitations during transient high load conditions
Solution Approach 1:
The system performs preliminary cooling of the intake conduit by reducing engine torque before the compressor outlet temperature reaches dangerous levels. The controller predicts future temperature based on current conditions and proactively limits torque to prevent overheating, rather than reacting after damage occurs. This is evident in the patent where torque is limited based on predicted temperature profiles to maintain component integrity while minimizing performance impact.
Solution Approach 2:
The system dynamically adjusts torque limitations based on the thermal state of the intake conduit and compressor. Rather than using fixed torque limits, the controller continuously monitors temperature sensors and adjusts the torque profile in real-time to match the actual thermal conditions. This allows the system to maintain high performance when temperatures are acceptable while providing protection when temperatures approach critical thresholds.
2Temperature
If torque is limited during high load conditions to reduce compressor outlet temperature, then temperature control is improved, but engine performance deteriorates unnecessarily during transient conditions
Solution Approach 1:
The system applies preliminary torque limitation to cool the intake conduit before compressor outlet temperature becomes critical. By predicting future temperature based on current operating conditions and conduit thermal state, the system proactively reduces torque to prevent temperature excursions, achieving temperature control while minimizing performance impact through targeted rather than continuous limitation.
Solution Approach 2:
The system applies torque limitation selectively based on the local thermal state of the intake conduit. Rather than uniformly limiting torque based solely on compressor outlet temperature, the controller considers the specific thermal conditions of the conduit section and applies differentiated torque profiles. This allows precise temperature control in critical areas while maintaining performance in less critical operating conditions.
3Device complexity
If measured intake air temperature is used for torque limitation, then temperature monitoring is simplified, but measurement precision deteriorates because sensor readings do not reflect actual component temperatures
Solution Approach 1:
The system introduces an intermediary thermal model that translates simple intake air temperature sensor readings into accurate predictions of actual component temperatures. The controller uses the temperature sensor data combined with conduit thermal state information to calculate the true thermal state of the compressor and intake conduit, bridging the gap between simple measurement and accurate component temperature knowledge.
Solution Approach 2:
The system replaces direct mechanical temperature measurement at critical components with a thermal modeling approach. Instead of installing temperature sensors directly on the compressor and intake conduit (which would increase complexity), the system uses a thermal model that calculates component temperatures based on intake air temperature measurements and thermal physics principles, achieving accurate measurement without additional hardware.
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 more precise regulation of compressor outlet and intake conduit temperatures, enhancing engine performance by avoiding unnecessary torque limitations and reducing component degradation.
Implementation Method 1
Turbochargers and superchargers compress intake air entering the engine using an intake compressor. Because this compression may cause an increase in air temperature
Implementation Method 2
a charge air cooler is utilized downstream of the compressor outlet to reduce air temperature before combustion
Implementation Method 3
the controller determined a thermal model of the compressor and an intake conduit coupled between the compressor outlet and the charge air cooler inlet
Data Source
AI summary
Methods and systems are provided for controlling a boosted engine system, having a turbocharger and a charge air cooler, to limit overheating of a compressor outlet. In one example, a method includes predicting an engine torque profile based on current and future engine operating conditions. The method then models a compressor outlet temperature profile and reduces engine torque output to limit overheating of the compressor outlet.