Engine Intake Air Temperature Management via Segmented Flow Control
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Solution Overview
Problem
Existing systems for managing engine intake air temperature struggle to maintain optimal conditions for exhaust gas aftertreatment components, particularly under cooler ambient conditions, which can hinder the regeneration of components like particulate filters and oxidation catalysts.
Innovation Solution
A system that includes air flow control devices and sensors to selectively control air flow from external and internal sources to the engine intake manifold, using processors to adjust air flow based on temperature signals to maintain temperatures within specific ranges, ensuring adequate conditions for exhaust gas aftertreatment component regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air flow control devices are used to manage intake air temperature, then exhaust gas temperature for aftertreatment regeneration is improved, but device complexity increases
Solution Approach 1:
The air flow control system is segmented into multiple independent control devices (first air flow control device and second air flow control device) that can be selectively activated. Each device manages a specific air flow path, allowing the system to divide the temperature control function into manageable segments rather than using a single complex control mechanism.
Solution Approach 2:
The system dynamically switches between different air flow control devices based on operating conditions. The control strategy adapts the air flow management approach in real-time, selecting appropriate devices and control modes according to engine load, ambient temperature, and aftertreatment requirements, thereby optimizing temperature control while managing system complexity.
2Reliability
If active regeneration events are increased to maintain aftertreatment components, then component regeneration is improved, but fuel consumption increases
Solution Approach 1:
The system performs preliminary temperature management of the intake air to ensure that exhaust gas temperatures are already within the optimal range for passive regeneration before active regeneration events are necessary. By proactively controlling air flow and temperature, the system reduces the frequency and intensity of active regeneration events, thereby lowering fuel consumption while maintaining aftertreatment component reliability.
Solution Approach 2:
The system changes operational parameters (air flow rates, temperature setpoints, control device activation) to optimize the balance between passive and active regeneration. By adjusting these parameters dynamically, the system can extend the intervals between active regeneration events while ensuring that aftertreatment components remain within acceptable temperature ranges, thus reducing fuel consumption.
3Reliability
If intake air temperature is increased to enable aftertreatment regeneration, then regeneration capability is improved, but engine efficiency may deteriorate
Solution Approach 1:
The system applies different temperature management strategies to different air flow paths and operating conditions. Rather than uniformly increasing intake air temperature, the system locally adjusts temperature control based on specific engine loads, ambient conditions, and aftertreatment requirements, thereby enabling regeneration capability while preserving overall engine efficiency.
Solution Approach 2:
The intake air temperature management is dynamic and adapts to changing engine operating conditions. The system continuously adjusts control parameters based on real-time sensor data, switching between different control modes to maintain the optimal balance between enabling aftertreatment regeneration and preserving engine efficiency across varying operational scenarios.
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 extends the range of engine loads suitable for passive and active regeneration, reducing the frequency of active regeneration events and potentially leading to fuel savings by maintaining optimal intake air temperatures, even under cold ambient conditions.
Implementation Method 1
The air flow control device has a first inlet, a second inlet and an outlet. The engine has an air intake manifold fluidly coupled to the outlet of the air flow control device. The first air flow conduit has one end fluidly coupled to the first air inlet of the air flow control device and an opposite end arranged to receive therein air from outside of the engine compartment. The second air flow conduit has one end fluidly coupled to the second air inlet of the air flow control device and an opposite end arranged inside of the engine compartment to receive therein air surrounding the engine.
Data Source
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AI summary
A system for managing engine intake air temperature may comprise a first air flow control device having an inlet coupled to an outlet of a turbocharger compressor and a first outlet coupled to an inlet of a charge air cooler. A second outlet is coupled via a bypass conduit to the air intake manifold. The first air flow control device may selectively control air flow from the compressor outlet to the charge air cooler and/or bypass conduit. The system may alternatively or additionally include a second air flow control device having a first inlet receiving air external to the engine compartment, a second inlet receiving air from within the engine compartment and surrounding the engine and an outlet providing air flow to the engine. The second air flow control device may selectively control airflow from the first and/or second inlets thereof to the engine.