EGR Coolant Temperature Control for Condensation Prevention
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Solution Overview
Problem
Low-pressure loop exhaust gas recirculation systems in internal combustion engines are susceptible to condensation, which is detrimental to turbocharger or supercharger compressor performance and life, while also reducing fuel efficiency and increasing emissions.
Innovation Solution
A system and method for controlling condensation in low-pressure loop exhaust gas recirculation systems, including EGR and charge air condensation temperature modules that determine condensation temperatures and provide coolants to coolers at or above these temperatures to prevent condensation, thereby maintaining system performance and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If low-pressure loop EGR system is used, then brake thermal efficiency is improved, but condensation susceptibility increases
Solution Approach 1:
The system calculates the condensation temperature of the EGR gas before it enters the cooler, and based on this predetermined knowledge, controls the coolant temperature to be at or above the condensation temperature. This preliminary determination of the condensation point allows the system to prevent condensation before it occurs, while still achieving efficient cooling for improved brake thermal efficiency.
Solution Approach 2:
The system dynamically adjusts the coolant temperature parameter based on the calculated condensation temperature of the EGR gas. By changing the coolant temperature parameter to maintain it at or above the condensation temperature, the system prevents condensation formation while still providing sufficient cooling to maintain low-pressure loop operation and improve brake thermal efficiency.
2Temperature
If exhaust gas is cooled below condensation temperature, then cooling efficiency is improved, but condensation occurs causing harmful effects
Solution Approach 1:
The system uses sensors to monitor parameters such as EGR gas temperature, pressure, and humidity, and feeds this information back to the controller. The controller continuously calculates the condensation temperature based on this feedback and adjusts the coolant temperature accordingly, ensuring the EGR gas is cooled efficiently but never below its condensation temperature, thus preventing harmful condensation.
Solution Approach 2:
Instead of using a simple mechanical thermostat or fixed-temperature cooling system, the invention replaces the mechanical control with a computational approach. The controller calculates the condensation temperature based on measured parameters and uses this information to control the coolant temperature, substituting mechanical temperature control with an intelligent, calculation-based system that prevents condensation while maintaining cooling efficiency.
3Reliability
If condensation is prevented by raising coolant temperature, then turbocharger life is improved, but cooling performance may be reduced
Solution Approach 1:
The system dynamically adjusts the coolant temperature based on real-time conditions rather than using a fixed temperature setting. As the EGR gas temperature, pressure, and composition change during operation, the controller continuously recalculates the condensation temperature and adjusts the coolant temperature accordingly. This dynamic approach ensures the minimum cooling performance needed to prevent condensation and protect turbocharger life, while avoiding excessive temperature raises that would reduce cooling effectiveness.
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
Prevents condensation in the low-pressure loop EGR system, enhancing the life and performance of turbochargers or superchargers, while maintaining fuel efficiency and reducing emissions by effectively managing condensation temperatures.
Implementation Method 1
EGR cooler positioned upstream of the compressor... charge air cooler positioned downstream of the compressor and upstream of the intake manifold
Implementation Method 2
susceptible to condensation generation, which condensation or liquid water in the system is highly detrimental to performance and life of the turbocharger or supercharger compressor
Data Source
AI summary
A system and method for condensation management in a low-pressure loop EGR system are provided. The system includes an EGR condensation temperature module configured to determine an EGR condensation temperature of recirculated exhaust gas upstream of an EGR cooler and an EGR coolant temperature controller communicably coupled to the EGR condensation temperature module. The EGR coolant temperature controller provides EGR coolant to the EGR cooler at or above the EGR condensation temperature. The system also includes a charge air condensation temperature module configured to determine a charge air condensation temperature of charge air upstream of a charge air cooler and a charge air coolant temperature controller communicably coupled to the charge air condensation temperature module. The charge air coolant temperature controller provides charge air coolant to the charge air cooler at or above the charge air condensation temperature.