Condensation Control in Diesel Engine Air Intake via Exhaust Heat

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Solution Overview

Problem

Increased condensation in air intake systems of diesel engines due to exhaust gas recirculation can damage engine components and affect combustion, necessitating a system to control condensation levels.

Innovation Solution

A condensation collection system comprising a condensation collection line, accumulator, and expulsion line, where condensation is collected from the air intake, stored in an accumulator, and then expelled to the atmosphere via an exhaust pipe, utilizing heat from the exhaust pipe to vaporize and vent the condensation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If EGR levels are increased to meet environmental requirements, then emissions are reduced, but condensation formation in the air intake system increases

Engineering Contradiction:

ImproveemissionsVSAvoidcondensation formation

Core Design Contradiction:

Object-generated harmful factorsVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the condensation from the air intake system by introducing a condensation collection line that diverts condensation away from the intake manifold. The condensation is collected in an accumulator and then expelled through a separate line, removing this harmful substance from the system while allowing EGR to continue operating at high levels for emissions control.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an intermediary condensation collection system between the air intake system and the atmosphere. This intermediary system includes a condensation collection line, accumulator, and expulsion line that act as a mediator to handle condensation separately, preventing it from damaging engine components or affecting combustion while allowing the EGR system to function optimally.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If condensation is not removed from the air intake system, then the system remains simple, but engine components may be damaged and combustion is adversely affected

Engineering Contradiction:

Improveair intake system complexityVSAvoidengine component reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent segments the condensation removal function from the main air intake system by creating separate dedicated components: a condensation collection line, an accumulator, and an expulsion line. This segmentation allows the condensation handling to be dealt with independently, protecting the main intake system while managing condensation through specialized pathways.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The condensation expulsion line is designed to utilize the engine's existing exhaust heat to vaporize and expel condensation automatically. The system serves itself by using the engine's own thermal energy to eliminate the problem of condensation accumulation, eliminating the need for external heating systems or complex active removal mechanisms.

Inventive Principle:

Principle #25Self-service

3Reliability

If a condensation removal system is added to the air intake system, then condensation damage is prevented, but system complexity increases

Engineering Contradiction:

Improveengine component protectionVSAvoidcondensation collection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent merges the condensation removal function with the existing exhaust system by routing the expulsion line through or near the exhaust manifold. This integration allows the system to use the exhaust system's thermal mass and flow characteristics to aid condensation vaporization and expulsion, reducing the need for separate dedicated heating components.

Inventive Principle:

Principle #5Merging (Combining)

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

Effectively reduces condensation in the air intake system, preventing damage to engine components and improving combustion efficiency by removing excess condensation and reducing emissions.

Implementation Method 1

A portion of the condensation expulsion line is disposed in contact with an engine exhaust pipe

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

utilizing heat from the exhaust pipe to vaporize and vent the condensation

Methodology Applied

Scientific EffectVaporization: Evaporation

Data Source

PatentUS8205602B2System and method of controlling an amount of condensation in an engine air intake system

Publication Date: 2012.06.26 INT ENGINE INTPROP CO LLC

AI summary

A condensation collection system for an internal combustion engine having an exhaust gas recirculation system comprises a condensation collection line, a condensation accumulator, and a condensation expulsion line. The condensation collection line is disposed in fluid communication with an air intake system of an internal combustion engine. The condensation accumulator is in fluid communication with the condensation collection line. The condensation collection line being disposed between the air intake system and the condensation accumulator. The condensation expulsion line is in fluid communication with the condensation accumulator. A portion of the condensation expulsion line is disposed in contact with an engine exhaust pipe. The condensation expulsion line has an opening to vent condensation to the atmosphere.