Hybrid Intercooler Integrating Air Conditioning for Engine Cooling
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Solution Overview
Problem
Conventional intercooler systems face inefficiencies in cooling compressed intake air, leading to reduced charging efficiency and potential knocking in engines, as they rely on either air-cooled or water-cooled methods without integrated optimization.
Innovation Solution
A hybrid intercooler system that integrates air-cooled and water-cooled units with an air conditioning system, using a bypass line and valves to control the flow of refrigerant and air conditioning system operation to optimize cooling efficiency without a separate cooling line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional air-cooled intercooler is used, then the structure is simple, but the cooling efficiency is insufficient leading to reduced charging efficiency and potential knocking
Solution Approach 1:
The patent combines air-cooled and water-cooled intercooler systems into a hybrid configuration. The air-cooled section handles initial cooling while the water-cooled section provides additional cooling capacity, thereby improving overall cooling efficiency and charging efficiency without completely abandoning the simple air-cooled design
Solution Approach 2:
The air conditioning system is designed to serve dual functions: cooling the cabin and cooling the intercooler water. By integrating the intercooler cooling function into the existing air conditioning system, the patent eliminates the need for a separate cooling line while improving charging efficiency
2Productivity
If a separate cooling line is added to cool the water-cooled intercooler, then the cooling efficiency improves, but the device complexity and cost increase
Solution Approach 1:
The air conditioning system is designed to serve dual functions: cooling the cabin and cooling the intercooler water. By integrating the intercooler cooling function into the existing air conditioning system, the patent eliminates the need for a separate cooling line while improving charging efficiency
Solution Approach 2:
The air conditioning system cools itself by using its own refrigerant cycle to cool the intercooler water. The water circulating through the intercooler absorbs heat from the compressed air, and the heated water is then cooled by the air conditioning system's evaporator, creating a self-sustaining cooling loop
3Reliability
If the air conditioning system operates continuously to cool the intercooler, then the intake air temperature is stabilized, but the energy consumption increases
Solution Approach 1:
The patent implements dynamic control of the air conditioning system based on real-time monitoring of compressed air temperature and engine operating conditions. The system adjusts the cooling capacity and operation timing of the air conditioning compressor to match the actual cooling demand, thereby stabilizing intake air temperature while minimizing energy consumption
Solution Approach 2:
The system incorporates temperature sensors and control units that continuously monitor the compressed air temperature and provide feedback to the air conditioning control system. This feedback mechanism enables the system to adjust its operation to maintain optimal intake air temperature while avoiding unnecessary energy consumption
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 hybrid system effectively cools compressed intake air from high to low temperatures, improving engine power and fuel efficiency while reducing weight and cost, and preventing knocking by stabilizing intake air temperature.
Implementation Method 1
an air cooling unit (100) to exchange heat between outside air passing through outer walls of a plurality of compressed intake air passages (110) and compressed intake air flowing in the compressed intake air passages (110) so as to cool the compressed intake air
Implementation Method 2
a water cooling unit (200) to exchange heat between a water-cooling-unit refrigerant surrounding the outer walls of the compressed intake air passages (110) and the compressed intake air cooled by the air cooling unit (100)
Implementation Method 3
cooling the water-cooled intercooler using an air conditioning system without a separate cooling line
Data Source
AI summary
A method of controlling a hybrid intercooler system integrated with an air conditioning system includes: starting operation of the air conditioning system by opening first and second air conditioning valves and operating a compressor, when an operation signal of the air conditioning system is determined to be applied; measuring a first temperature by measuring a temperature of compressed air at an outlet of the hybrid intercooler system, after the starting operation of the air conditioning system; and starting operation of a first water cooling unit by opening first and second bypass valves, when the measured first temperature exceeds a predetermined first reference temperature. This method stabilizes the temperature of intake air passing through the inlet of an intercooler using a water cooling unit and increases the cooling efficiency of the intercooler using an air cooling unit.