Coolant Circuit Bypass for Intercooler Condensation Control
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Solution Overview
Problem
Existing coolant circuit devices for supercharged internal combustion engines face challenges in preventing condensation and icing in intercoolers at low ambient temperatures, requiring complex control systems and hardware to manage coolant mixing ratios effectively.
Innovation Solution
A coolant circuit device with a parallel valve bypass set to a minimum coolant mixing ratio greater than zero, integrated with a 3/2-way valve, allowing for discrete switching states and reduced thermal stress by controlling coolant flow through the radiator or bypass, thereby simplifying the system and reducing thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a steplessly or continuously controllable 3/2-way valve is used to regulate coolant temperature and prevent condensation, then the air temperature in the intercooler can be raised to counteract condensation of atmospheric moisture, but the device complexity increases due to required control hardware, position feedback, and temperature sensors
Solution Approach 1:
The patent segments the coolant flow control into two independent parts: a conventional 3/2-way valve for main flow control and a separate bypass circuit with a simple on/off valve for minimum flow control. This segmentation allows each valve to have a simplified function, eliminating the need for complex continuous control while still achieving the temperature regulation goal to prevent condensation.
Solution Approach 2:
The bypass circuit acts as an intermediary element that provides a minimum coolant flow path independent of the main 3/2-way valve. This intermediary bypass ensures that even when the main valve is in certain positions, a minimum amount of coolant flows through the system, simplifying the control logic and reducing the need for complex feedback systems.
2Productivity
If the coolant temperature is lowered to increase cooling capacity, then the cooling performance improves, but the risk of condensation and icing in the intercooler increases at low ambient temperatures
Solution Approach 1:
The patent implements dynamic control of coolant flow by using the 3/2-way valve to adjust the mixing ratio between cooled and bypass coolant based on operating conditions. This dynamic adjustment allows the system to optimize cooling capacity while maintaining the outlet temperature above the condensation point, preventing icing and condensation in the intercooler.
Solution Approach 2:
The system changes the coolant flow parameters (temperature and flow rate) by adjusting the 3/2-way valve position and bypass valve state. By varying these parameters dynamically, the system achieves high cooling capacity when needed while maintaining minimum temperature thresholds to prevent condensation and icing at low ambient temperatures.
3Speed
If a pilot stream is maintained through the thermostat to guarantee quick temperature information reaches the actuator, then the response time improves, but the minimum throughput requirement increases the complexity of flow control
Solution Approach 1:
The patent extracts the minimum flow control function from the main thermostat system by implementing a separate bypass circuit. This bypass circuit handles the minimum flow requirement independently, allowing the main thermostat to focus on temperature regulation without the added complexity of maintaining minimum throughput, while still ensuring quick response through the bypass path.
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 configuration effectively counters atmospheric moisture condensation, reduces thermal stresses, and eliminates the need for complex control hardware, ensuring the coolant temperature remains above freezing and below dew point, preventing icing and condensation in the intercooler.
Implementation Method 1
The intercooler is a heat exchanger that reduces the temperature of the air supplied to the engine in the intake tract of the supercharged internal combustion engine. The intercooler dissipates some of the heat generated by the compression of the air in the compressor.
Implementation Method 2
a coolant circulating pump circulates a coolant, e.g. cooling water, in a cooling circuit with return lines between the intercooler and the on-board radiator
Implementation Method 3
a valve bypass, which is connected in parallel to the valve, provides a minimum coolant mixing ratio of essentially greater than zero
Data Source
Figure 1~2
AI summary
The invention relates to a coolant circuit device (10) comprising an intercooler (12), a radiator (14), a coolant circulation pump (16), and a valve (18), wherein the coolant circulation pump (16) circulates coolant from the radiator (14) to the intercooler (12) and back, and the valve (18) allows the coolant mixture ratio to be varied to control the air temperature in the intercooler (12). According to the invention, a bypass (20) is provided, which is connected in parallel to the valve (18) and provides a minimum coolant mixture ratio of substantially greater than zero.