EGR Cooler Dual Coolant Loop for Condensed Water Control
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Solution Overview
Problem
Existing cooling systems for internal combustion engines face challenges in reducing condensed water generation in intercoolers due to delayed responsiveness of EGR gas temperature changes, particularly during sudden engine operating condition changes.
Innovation Solution
A cooling system with a dual circulation flow path system, where a first coolant circulates through an EGR cooler and intercooler to dehumidify EGR gas, and a second coolant with a higher temperature is used to pre-cool the EGR gas before it enters the EGR cooler, ensuring the outlet gas temperature is at or below the dew point, thereby reducing condensed water generation without complex control measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the circulation flow rate of coolant A supplied to the EGR cooler is increased to actively generate condensed water, then condensed water generation in the intercooler is reduced, but the response delay of EGR gas temperature change worsens
Solution Approach 1:
The cooling system is divided into two independent circulation flow paths: a first circulation flow path (coolant A) that supplies coolant to the EGR cooler and intercooler, and a second circulation flow path (coolant B) that supplies coolant only to the EGR cooler. This segmentation allows independent control of cooling parameters for each component, enabling the system to actively generate condensed water in the EGR cooler by controlling coolant B flow rate without being constrained by the cooling requirements of the intercooler.
Solution Approach 2:
The second circulation flow path pre-cools the EGR gas before it enters the first circulation flow path's EGR cooler section. By performing preliminary cooling action on the EGR gas, the system ensures that the gas temperature is sufficiently reduced to generate condensed water quickly, improving the responsiveness of condensed water generation when engine operating conditions change suddenly.
2Object-affected harmful factors
If separate circulation flow paths are used for EGR cooler and intercooler, then condensed water generation is reduced, but device complexity increases
Solution Approach 1:
The EGR cooler is designed with multi-functionality to serve both circulation flow paths. It includes a first EGR-cooler inner flow path for coolant A and a second EGR-cooler inner flow path for coolant B, allowing a single component to perform cooling functions for both independent flow paths. This reduces the need for separate cooling components and minimizes system complexity while maintaining the benefits of separate flow path control.
Solution Approach 2:
The first EGR-cooler inner flow path and second EGR-cooler inner flow path are merged within the same EGR cooler housing structure. By combining the cooling functions of both circulation flow paths into a single integrated EGR cooler component, the system reduces the number of separate parts and simplifies the overall device structure while maintaining independent coolant circulation control.
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
The system effectively reduces condensed water generation in the intercooler by dehumidifying EGR gas and maintaining a higher coolant temperature for efficient cooling, enhancing responsiveness to engine condition changes and maintaining engine performance.
Implementation Method 1
The radiator is configured to cool a first coolant to or below a dew point of the EGR gas flowing into the EGR cooler
Implementation Method 2
The EGR cooler is disposed in the EGR passage and is configured to cool EGR gas
Implementation Method 3
the generation of condensed water in the intercooler is reduced
Implementation Method 4
The pump is disposed in the first circulation flow path and is configured to circulate the first coolant
Implementation Method 5
The intercooler is disposed in the intake passage and is configured to cool intake air
Data Source
AI summary
A cooling system is mounted on an internal combustion engine equipped with an EGR device including an EGR passage. The cooling system includes: an intercooler disposed in the intake passage; an EGR cooler disposed in the EGR passage; a condensed water discharger configured to discharge condensed water generated in the EGR cooler from the EGR passage; a radiator configured to cool a first coolant to or below a dew point of the EGR gas flowing into the EGR cooler; a first circulation flow path configured to circulate the first coolant in the order of the radiator, the EGR cooler, and the intercooler; and a pump disposed in the first circulation flow path and configured to circulate the first coolant such that an outlet gas temperature of the EGR cooler is equal to or lower than the dew point of the EGR gas flowing into the EGR cooler.