Electrified Air System Cold Start Recirculation
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Solution Overview
Problem
Conventional engines face challenges in operating efficiently near design limits without de-rating, particularly during cold-start conditions, which can lead to engine damage and reduced performance.
Innovation Solution
An electrified air system with a controller that monitors operating conditions and adjusts the compressor assembly and valve configurations to enact non-derating countermeasures, including recirculating intake airflow to warm the engine and maintain optimal operating parameters, thereby preventing engine damage and maintaining power output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the engine operates near its design limits to maintain power output, then productivity is improved, but reliability deteriorates due to increased risk of engine damage
Solution Approach 1:
The controller preemptively activates the compressor assembly and adjusts valve configurations before the engine reaches critical operating conditions during cold-start. By anticipating potential hazards and applying protective measures in advance, the system allows the engine to operate near design limits without actually reaching damaging conditions, thus maintaining power output while preventing engine damage.
2Productivity
If the engine operates during cold-start conditions, then productivity is maintained, but object-affected harmful factors increase due to cold-start damage risk
Solution Approach 1:
The system converts the cold intake air, which would normally be harmful during cold-start, into a beneficial resource. The compressor assembly compresses the cold intake airflow, and through controlled recirculation and mixing with warmer exhaust gases, the cold air is transformed into a useful component that helps maintain power output while the overall system temperature gradually increases, turning the cold-start condition from a hazard into an opportunity for efficient operation.
3Reliability
If the compressor assembly is activated to warm the engine during cold-start, then reliability is improved, but use of energy increases
Solution Approach 1:
The system uses the engine's own exhaust gases to assist in warming the intake charge. By recirculating a portion of the warm exhaust gases back through the compressor assembly and mixing them with the cold intake air, the system leverages the engine's self-generated thermal energy to reduce the burden on the compressor motor, thereby improving reliability during cold-start while minimizing additional energy consumption.
4Reliability
If the valve is adjusted to recirculate airflow to prevent stalling, then reliability is improved, but device complexity increases
Solution Approach 1:
The valve assembly is designed to perform multiple functions: it controls airflow recirculation to prevent compressor stalling, regulates the mixing ratio of cold intake air and warm exhaust gases, and assists in temperature management during different operating conditions. By consolidating these functions into a single multi-functional valve system controlled by the existing engine control unit, the patent improves reliability through stalling prevention while minimizing the increase in device complexity.
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 allows the engine to operate closer to its limits while minimizing damage and maintaining power output by using the electrified air system to compensate for cold-start issues and prevent stalling, ensuring efficient operation and extended engine life.
Implementation Method 1
a compressor assembly having a compressor housing and a compressor wheel movable with respect to the compressor housing, where the compressor housing includes a compressor inlet and a compressor outlet, and where the compressor assembly is operable in an activated configuration in which the compressor wheel is driven relative to the compressor housing
Implementation Method 2
recirculating intake airflow to warm the engine and maintain optimal operating parameters
Data Source
AI summary
An intake system for use with an internal combustion engine having one or more cylinders. The intake system including a compressor assembly having an inlet and an outlet, and where the outlet is configured to be open to and in fluid communication with at least one of the one or more cylinders. The intake system also includes a passageway extending between and in fluid communication with the inlet and the outlet and configured to direct a first flow of gasses and a controller in operable communication with the compressor assembly. Where the intake system is operable in a first mode in which the majority of gasses of the first flow of gasses flow through the passageway toward the outlet, and a second mode in which the majority of gasses of the first flow of gasses flow through the passageway toward the inlet.