Intake air heating systems and methods
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Solution Overview
Problem
Existing intake air heating systems for internal combustion engines face challenges in efficiently controlling the air heater's temperature, leading to potential over-temperature conditions and increased wear when the engine starts from a warm condition, which can damage the air heater.
Innovation Solution
An intake air heating system that includes an air heater control module capable of determining the resistance of the air heater using voltage and current measurements, applying power based on resistance, and employing pulse width modulation to maintain the air heater within a predetermined resistance range, thereby controlling temperature accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the air heater is continuously powered to heat intake air during cold start conditions, then the intake air temperature increases improving ignition and combustion, but the air heater may reach over-temperature conditions causing increased wear or damage
Solution Approach 1:
The system continuously monitors the resistance of the air heater element and uses this feedback to determine when to apply or disconnect power. The control module compares the measured resistance against predetermined thresholds corresponding to temperature ranges, creating a closed-loop control system that prevents over-temperature conditions while maintaining effective heating during cold starts.
Solution Approach 2:
The system changes the electrical parameter being monitored from direct temperature measurement to resistance measurement. Since the resistance of the heating element changes predictably with temperature, this parameter substitution enables indirect temperature monitoring that is simpler and more reliable, allowing the control system to adjust power application based on resistance values that correlate to safe operating temperature ranges.
2Temperature
If the air heater is powered during warm engine conditions, then the intake air heating function is maintained, but the air heater experiences unnecessary over-temperature conditions increasing wear and damage risk
Solution Approach 1:
The resistance monitoring system provides continuous feedback about the thermal state of the air heater. When the engine transitions to warm operating conditions, the resistance increases accordingly, and the control module detects this change and automatically disconnects power, preventing unnecessary thermal stress and wear during conditions when heating is not required.
Solution Approach 2:
The system dynamically adjusts the power application to the air heater based on real-time resistance measurements. Rather than using a fixed timer or continuous operation, the control module continuously adapts the heating strategy to current engine and air heater conditions, enabling power to be applied only when and where needed, thereby reducing unnecessary thermal cycling and wear.
3Device complexity
If a simple timer-based control is used for the air heater, then the system complexity is reduced, but the temperature control precision decreases leading to over-temperature conditions
Solution Approach 1:
The system substitutes direct temperature sensing with resistance measurement, achieving precise temperature control through an indirect but more reliable parameter. This parameter change enables accurate monitoring of the heating element's thermal state without requiring complex temperature sensors, maintaining control precision while managing system complexity.
Solution Approach 2:
The system replaces mechanical or electronic timer-based control with an electrical measurement-based control system. Instead of relying on predetermined time intervals that may not account for varying environmental conditions, the system uses real-time resistance measurements to dynamically control heating, achieving superior temperature control precision through electrical sensing and feedback.
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 ensures precise temperature control of the air heater, preventing over-temperature conditions and reducing wear, while ensuring efficient and safe operation of the intake air heating system.
Implementation Method 1
an air heater configured to heat air an intake system of an engine
Implementation Method 2
measure a voltage on terminals of the air heater
Implementation Method 3
determine a resistance of the air heater based on the voltage on the terminals of the air heater and a current through the air heater
Data Source
AI summary
An intake air heating system for a vehicle includes: an air heater configured to heat air an intake system of an engine; an air heater control module configured to selectively apply power to the air heater via a power conductor; and a voltage sensor and communication module configured to: measure a voltage on terminals of the air heater; and transmit an indicator of the voltage to the air heater control module on the power conductor, where the air heater control module is further configured to: receive the indicator via the power conductor; determine a resistance of the air heater based on the voltage on the terminals of the air heater and a current through the air heater; and apply power to the air heater based on the resistance of the air heater.