Electrically Driven Compressor for Turbocharger Condensate Prevention
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Solution Overview
Problem
Condensate formation in supercharged internal combustion engines due to exhaust gas recirculation can lead to increased noise emissions and turbocharger compressor degradation, limiting the effectiveness of nitrogen oxide emission reduction and fuel efficiency improvements.
Innovation Solution
An integrated system with an electrically drivable compressor and a low-pressure exhaust gas recirculation system, where the electrically drivable compressor heats fresh air to prevent condensate formation by increasing the charge-air temperature, and the exhaust gas recirculation system is configured to bypass the cooler during cold starts or low ambient temperatures to maintain efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If exhaust gas recirculation is implemented to reduce nitrogen oxide emissions, then emission reduction is improved, but condensate formation increases causing noise emissions and turbocharger compressor degradation
Solution Approach 1:
The system performs preliminary heating of the intake air using the electrically drivable compressor before the exhaust gas recirculation takes place. This pre-heating action prevents the subsequent cooling effect that would otherwise cause condensate formation when cold intake air mixes with recirculated exhaust gas.
Solution Approach 2:
The system changes the temperature parameter of the intake air by using the electrically drivable compressor to heat the air. This parameter change raises the intake air temperature to a level where condensate formation is prevented when exhaust gas is recirculated, allowing higher EGR rates without the harmful condensate effect.
2Object-generated harmful factors
If exhaust gas recirculation rate is increased to minimize nitrogen oxide emissions, then emission reduction is improved, but condensate formation and turbocharger compressor degradation worsen
Solution Approach 1:
The system performs preliminary heating of the intake air using the electrically drivable compressor before the exhaust gas recirculation takes place. This pre-heating action prevents the subsequent cooling effect that would otherwise cause condensate formation when cold intake air mixes with recirculated exhaust gas.
Solution Approach 2:
The system changes the temperature parameter of the intake air by using the electrically drivable compressor to heat the air. This parameter change raises the intake air temperature to a level where condensate formation is prevented when exhaust gas is recirculated, allowing higher EGR rates without the harmful condensate effect.
3Productivity
If supercharging is implemented to increase power output and improve fuel efficiency, then productivity is improved, but the complexity of the system increases
Solution Approach 1:
The electrically drivable compressor is designed to perform multiple functions: it provides supercharging to increase power output, and simultaneously heats the intake air to prevent condensate formation during exhaust gas recirculation. This multi-functionality reduces the need for separate dedicated components.
Solution Approach 2:
The electrically drivable compressor serves itself by using its primary supercharging function to also accomplish the secondary function of heating intake air. The compressor's operation during normal supercharging inadvertently provides the heating effect needed for condensate prevention, reducing the need for additional dedicated heating components.
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 condensate formation across a wider temperature range, enhancing fuel economy, reducing emissions, and preventing turbocharger compressor degradation, while allowing for higher exhaust gas recirculation rates to minimize nitrogen oxide emissions.
Implementation Method 1
the electrically drivable compressor heats fresh air to prevent condensate formation by increasing the charge-air temperature
Implementation Method 2
Hot exhaust gas flow is fed to the turbine and expands in the turbine with a release of energy, which rotates the shaft
Implementation Method 3
The charge-air cooler lowers the temperature and thereby increases the density of the charge air
Data Source
AI summary
Methods and systems are provided for a supercharged internal combustion engine having staged boosting devices. In one example, a system may include an engine coupled to an intake system for receiving charge air and an exhaust system for discharging exhaust gases, an electrically driven compressor arranged in the intake system upstream of a turbocharger compressor, a bypass line, including a bypass valve, coupled across the electrically driven compressor, a throttle arranged at an inlet of the electrically driven compressor, and an exhaust gas recirculation system that couples the exhaust system downstream of the exhaust turbine to the intake system upstream of the electrically driven compressor via a first recirculation branch and between the electrically driven compressor and the turbocharger compressor via a second recirculation branch. In this way, the electrically driven compressor may be operated to reduce condensate formation at an inlet of the turbocharger compressor.