Comprex Charger Electrical Drive and Liquid Cooling Integration
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Solution Overview
Problem
Internal combustion engines with exhaust gas turbocharging face challenges in achieving consistent power across all engine speed ranges due to torque drops at lower speeds, and exhaust gas recirculation systems encounter issues with condensate formation and reduced exhaust gas availability, which affect efficiency and emissions.
Innovation Solution
The implementation of a comprex charger with a liquid cooling system integrated into the charger's housing, which functions as both a charge air cooler and EGR cooler, and an electrical drive independent of crankshaft rotational speed, allowing precise control of exhaust gas recirculation and improved packaging by eliminating the need for separate cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an exhaust gas turbocharger is used to provide charging, then power output is improved, but torque drops at lower engine speeds occur due to reduced exhaust gas mass flow
Solution Approach 1:
The patent applies dynamics by making the charger's rotational speed adjustable and independent of crankshaft rotational speed. The controller dynamically adapts the charger's operation based on operating conditions, allowing optimal performance across the entire engine speed range including low-speed torque requirements.
Solution Approach 2:
The patent changes the parameter of rotational speed independence by using an electrically driven charger instead of a mechanically coupled turbocharger. This allows the charge pressure ratio to be maintained across varying engine speeds by independently controlling the charger's rotational speed through electrical power.
2Ease of operation
If a mechanically driven charger is used, then a mechanical or kinematic connection is required, but packaging space in the engine bay is increased
Solution Approach 1:
The patent replaces the mechanical connection system with an electrical drive system. The charger is driven by an electric motor that can be positioned remotely from the charger, eliminating the need for direct mechanical coupling and reducing packaging constraints in the engine bay.
Solution Approach 2:
The patent introduces an electrical power transmission system as an intermediary between the power source and the charger. This allows the charger to be driven without a direct mechanical connection, enabling flexible positioning and reduced packaging space requirements.
3Object-generated harmful factors
If exhaust gas recirculation is implemented, then emissions are reduced, but condensate formation occurs and exhaust gas availability is reduced
Solution Approach 1:
The patent applies preliminary action by cooling the charge air before it enters the combustion chambers. The liquid cooling system pre-cools the compressed charge air, preventing condensate formation when exhaust gas is recirculated and mixed with the charge air.
Solution Approach 2:
The patent changes the temperature parameter of the charge air through liquid cooling. By maintaining the charge air temperature above the dew point, the system prevents condensate formation while still allowing effective exhaust gas recirculation for emissions reduction.
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 solution enhances power delivery across all engine speed ranges, improves exhaust gas recirculation efficiency, reduces emissions, and simplifies packaging by integrating the cooling system within the comprex charger, thereby addressing torque drops and emissions challenges.
Implementation Method 1
The cooler lowers the temperature and thereby increases the density of the charge air, such that the cooler also contributes to improved filling of the cylinders, that is to say to a greater air mass. Compression by cooling takes place.
Implementation Method 2
an electrical drive independent of crankshaft rotational speed
Data Source
AI summary
Methods and systems are provided for a comprex charger. In one example, a comprex charger is integrally arranged with an electric machine and shares a cooling arrangement therewith.