Intake Conduit Condensate Retention for Engine Misfire Prevention
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Solution Overview
Problem
Forced induction systems in internal combustion engines experience misfires and increased exhaust temperatures due to sudden ingestion of large condensate quantities, which form in humid conditions and are not effectively managed by existing technologies.
Innovation Solution
Incorporation of condensate retaining structures, such as sections with enlarged diameters or weirs within the intake conduit, to restrict the flow of condensate, preventing sudden delivery to the engine and allowing gradual release during high load conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If forced induction devices compress air to increase power and reduce emissions, then oxygen delivery per unit volume is improved, but air temperature increases which counteracts the benefit
Solution Approach 1:
An intercooler is introduced as an intermediary component between the forced induction device and the engine. This heat exchange device transfers heat from the compressed air to a cooling medium (air or liquid), reducing the temperature of the compressed air before it enters the engine while preserving the increased oxygen concentration achieved by compression
2Temperature
If intercoolers cool compressed air to reduce temperature, then air temperature is improved, but moisture condenses forming condensate pools in the intake system
Solution Approach 1:
Condensate retention structures (such as enlarged diameter sections or weirs) are introduced to extract and separate the harmful condensate from the main airflow path. These structures cause condensate to pool in designated areas rather than being carried into the engine, effectively removing the harmful substance while preserving the cooling benefit
3Productivity
If airflow through the intake system increases rapidly during high load conditions, then power delivery is improved, but collected condensate is suddenly delivered all at once to the engine causing misfires
Solution Approach 1:
Condensate retention structures are positioned upstream in the intake system to preemptively capture and hold condensate before it can be suddenly delivered to the engine during high load conditions. The structures create a buffer that prevents the harmful effect from occurring in the first place
Solution Approach 2:
The enlarged diameter sections or weir structures create a cushioning effect by providing a reservoir that absorbs the sudden surge of condensate that would otherwise be delivered to the engine during rapid acceleration or high load conditions, protecting the engine from the harmful impact
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
Prevents misfires and reduces exhaust temperatures by ensuring a gradual delivery of condensate, maintaining engine stability and performance even under high load conditions.
Implementation Method 1
Intercoolers are heat exchange devices placed between a forced induction device and the engine. By passing compressed air through an intercooler, the air delivered to the engine can be compressed while maintaining a relatively lower temperature.
Implementation Method 2
cooling the air with the intercooler can cause moisture within the compressed air to condense, producing a condensate in the form of water droplets in the intake system
Data Source
AI summary
An intake system for an internal combustion engine may include an air inlet; a forced induction device downstream from the air inlet; an intercooler downstream from the forced induction device; and an intake conduit configured to guide air from the intercooler to an internal combustion engine. In addition, the system may include a condensate retaining structure associated with the intake conduit and configured to restrict the flow of condensate through the intake conduit.