Intake Air Conditioning Device for Engine Testing
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Solution Overview
Problem
Current devices for conditioning intake air for internal combustion engine testing lack independent control over temperature and humidity at high pressure conditions, are energy inefficient, and require costly civil works and infrastructure, limiting their effectiveness in simulating real driving emissions (RDE) conditions.
Innovation Solution
The device combines an engine boosting emulator (EBOR) with a bubble reactor humidifier (BUBRER) to provide controlled temperature and humidity levels independently of pressure, using an electrical heater and mechanical compressor, along with a water-to-air cooler and chiller, to efficiently condition intake air for testing engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If steam is injected in air at room pressure to increase humidity, then humidity control is achieved, but the solution is not possible at high pressure conditions (e.g., 3 bar) because steam must be generated at high pressure and temperature higher than 100°C, creating a large risk
Solution Approach 1:
The patent introduces a water reservoir and heating element as intermediaries to generate humidity. Instead of injecting steam directly into high-pressure air (which creates safety risks), the system heats water in a reservoir to generate steam, then introduces this steam into the compressed air stream. This intermediary approach allows humidity control at high pressure without directly generating high-temperature steam in the compressed air path, thereby reducing safety risks.
Solution Approach 2:
The system performs preliminary action by pre-heating water in a reservoir before introducing it into the compressed air stream. The water is heated to generate steam in advance, and this pre-generated steam is then mixed with the high-pressure air. This preliminary preparation allows the system to achieve high humidity levels at high pressure without requiring steam generation to occur at the high-pressure point, thus avoiding the safety hazards of high-temperature steam generation in the compressed air path.
2Adaptability or versatility
If the test cell room is fully conditioned to emulate atmospheric conditions, then environmental simulation is achieved, but the installation is extremely expensive due to required civil works and huge energy consumption
Solution Approach 1:
The patent extracts the humidity control function from the general environmental conditioning of the test cell. Instead of conditioning the entire test cell room (which requires expensive civil works and huge energy consumption), the system isolates the humidity control to a separate, compact steam injection unit that processes only the air stream needing humidity adjustment. This extraction allows environmental simulation to be achieved without the excessive energy consumption and infrastructure requirements of full room conditioning.
Solution Approach 2:
The system applies local quality by providing humidity control only where needed in the air stream, rather than conditioning the entire test cell environment. The steam injection unit is positioned to directly affect the intake air, applying humidity locally to the specific flow path rather than uniformly across the whole test cell. This localized approach significantly reduces energy consumption and infrastructure requirements compared to full environmental conditioning.
3Stress or pressure
If high pressure, low flow rotary-volumetric compressors are used to simulate high altitude, then pressure ratio is achieved, but energy consumption is high (high Ampere)
Solution Approach 1:
The patent employs a centrifugal compressor that serves multiple functions: it provides the necessary pressure ratio for high altitude simulation, maintains high air flow rates for large engine displacements, and operates with lower energy consumption compared to rotary-volumetric compressors. The centrifugal design inherently offers better efficiency for high flow applications, allowing the system to achieve both high pressure ratio and high flow rate while reducing energy consumption (lower Ampere).
4Quantity of substance
If low pressure, high flow turbofans are used to provide air flow, then air flow rate is achieved, but pressure ratio is insufficient for high altitude simulation
Solution Approach 1:
The centrifugal compressor is designed to perform multiple functions simultaneously: it delivers high air flow rates suitable for large engine displacements while also achieving the necessary pressure ratios for high altitude simulation. This multi-functional capability allows the system to satisfy both requirements (high flow rate and high pressure ratio) that cannot be met by dedicated low-pressure turbofans, thereby enabling accurate high altitude simulation without sacrificing air flow rate.
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
This solution offers precise control over intake air conditions, reducing energy consumption and infrastructure needs, enabling effective simulation of high altitude and high flow rate conditions while being mobile and cost-effective, with synergies that enhance existing systems like MEDAS for full control of pressure, temperature, and humidity.
Implementation Method 1
a mechanical compressor (12) for compressing intake air to a desired pressure and temperature values
Implementation Method 2
a heater (22) for increasing the temperature of the intake air
Implementation Method 3
a water-to-air cooler (14) for lowering the temperature of the intake air
Implementation Method 4
a chiller (16) for lowering the temperature and the humidity of the intake air
Implementation Method 5
a humidifier (26) located between the heater (22) and the outlet point (k)
Implementation Method 6
a first cyclonic separator (18) for removing condensed humidity from the intake air
Data Source
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AI summary
The present invention relates to a device, method and use for conditioning intake air for testing internal combustion engines. The device comprises a line for transporting intake air from an inlet point (a) to an outlet point (k), and the following components between said inlet point (a) and said outlet point (k): a mechanical compressor for compressing intake air to desired pressure and temperature values; a chiller for lowering the temperature and humidity of the intake air; a first cyclonic separator for removing condensed humidity from the intake air; a first bypass valve for bypassing both the chiller and the first cyclonic separator; a heater for increasing the temperature of the intake air; and a second bypass valve for bypassing the heater.The conditioned intake air is suitable for feeding directly to an internal combustion engine to be tested or to an additional device for further conditioning the pressure thereof.