Intake Manifold Air Bypass Control for Low-Load Temperature Stability
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Solution Overview
Problem
Internal combustion engines designed for alternative fuels face challenges with low intake manifold temperatures at sub-maximum loads, leading to reduced emissions performance and limited alternative fuel substitution, which existing systems like the '858 patent fail to adequately address.
Innovation Solution
An intake manifold temperature system with a compressor bypass valve and controller that adjusts air flow through an air cooler based on ambient and manifold conditions to maintain optimal intake manifold temperature, using sensors and an electronic control module to actuate the bypass valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air flow through the air cooler is increased to cool the intake air, then the intake air temperature decreases, but the intake manifold temperature becomes too low at sub-maximum loads, reducing emissions performance and alternative fuel combustion efficiency
Solution Approach 1:
The air flow path is segmented into two separate paths: one through the air cooler for heat dissipation, and another through the bypass passage for temperature maintenance. The bypass valve controls the distribution of air between these two paths, allowing independent optimization of cooling efficiency and temperature maintenance.
Solution Approach 2:
The bypass valve dynamically adjusts the proportion of air flow through the bypass passage versus the air cooler based on real-time operating conditions. This dynamic control enables the system to adapt to varying load conditions, maintaining optimal intake manifold temperature across different operating regimes.
2Adaptability or versatility
If a bypass passage is added to allow air to bypass the air cooler, then the system gains temperature control flexibility, but the device complexity increases
Solution Approach 1:
The bypass valve serves multiple functions: it controls the proportion of air bypassing the cooler, regulates intake manifold temperature, and adapts to different operating conditions. This multi-functionality is achieved through a single integrated component rather than multiple separate systems.
Solution Approach 2:
The bypass valve acts as an intermediary component that mediates between the compressor outlet and the intake manifold, controlling the mixing of cooled and bypassed air. This intermediary element enables precise temperature control without requiring complex multi-component systems.
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 maintains optimal intake manifold temperature, enhancing engine performance, efficiency, and emissions control by adapting air flow to compensate for low ambient or engine loads, preventing overheating and ensuring stable combustion.
Implementation Method 1
an air cooler connected downstream of the compressor
Implementation Method 2
an electronically-controlled bypass valve connected downstream of the compressor, the bypass valve configured to control a proportion of air flow through the bypass passage and through the air cooler
Implementation Method 3
a compressor, an air cooler connected downstream of the compressor
Data Source
AI summary
An intake manifold temperature system including an internal combustion engine, an intake manifold connected to the internal combustion engine, an air supply system configured to supply compressed air to the internal combustion engine, an ambient condition sensor, an air system sensor, a manifold condition sensor, and a controller. The air supply system may include a compressor, an air cooler connected downstream of the compressor, a bypass passage connected downstream of the compressor to provide compressed air to the intake manifold, the air having bypassed the air cooler, and an electronically-controlled bypass valve connected downstream of the compressor, the bypass valve configured to control a proportion of air flow through the bypass passage and through the air cooler. The controller may be configured to actuate the bypass valve based on signals and a desired intake manifold temperature.