Intake Condensation Removal via Bypass Mixing
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Solution Overview
Problem
Internal combustion engines face issues with liquid condensation in the intake system due to acidic condensate formation, which causes wear and corrosion, particularly in low-pressure EGR systems and when running on natural gas, leading to potential engine damage and performance degradation.
Innovation Solution
A system with a charge air cooler, a bypass passage, and a condensate trap, along with a mixer that raises the intake temperature above the dew point to prevent condensation, utilizing a valve to control air flow and mix bypass air with the engine intake fluid to eliminate condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If charge air cooler is used to cool the intake charge, then the density of the charge air is increased, but the temperature drops below the dew point causing liquid condensation
Solution Approach 1:
The charge air cooler is divided into multiple cooling zones or passes, allowing staged cooling of the charge air. This prevents excessive temperature reduction in a single stage that would drop below the dew point, while still achieving the desired density increase through cumulative cooling effect.
Solution Approach 2:
The system pre-heats the charge air before it enters the cooler or pre-cools it in a controlled manner to approach but not cross the dew point temperature. Temperature sensors monitor the charge air temperature throughout the cooling process to ensure it remains above the dew point, preventing condensation while maximizing density.
2Quantity of substance
If EGR fluid is cooled to increase density, then the charge air density is improved, but condensation forms in the intake system
Solution Approach 1:
Temperature sensors are placed at various points in the charge air cooler and intake system to continuously monitor charge air temperature. The control system uses this feedback to adjust cooling conditions, EGR flow rate, or bypass valve positions to maintain charge air temperature above the dew point, preventing condensation while achieving desired density.
Solution Approach 2:
The system dynamically adjusts operating parameters such as EGR flow rate, cooler bypass valve position, and coolant flow rate through the charge air cooler to control the cooling effect. By changing these parameters, the system optimizes charge air density while maintaining temperature above the dew point to prevent condensation and protect intake system reliability.
3Object-generated harmful factors
If natural gas is used as fuel, then emissions are reduced, but moisture content in EGR fluid increases causing condensation
Solution Approach 1:
The system dynamically adjusts the EGR flow rate and charge air cooler operation based on fuel type and operating conditions. When natural gas is detected or selected, the control system modifies EGR valve positioning and cooler bypass valve settings to account for the higher moisture content in natural gas combustion products, preventing condensation while maintaining emissions control.
Solution Approach 2:
The control system automatically detects fuel type and adjusts cooling and EGR parameters without operator intervention. The system self-regulates to prevent condensation when running on natural gas by modifying operational parameters, eliminating the need for manual adjustment and ensuring continuous protection against condensation-related damage.
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
Effectively minimizes condensation in the engine intake, preventing wear and corrosion by maintaining the temperature above the dew point, ensuring engine durability and performance.
Implementation Method 1
When EGR fluid is passed through a charge air cooler, the reduction in temperature associated with cooling of the charge to increase its density
Implementation Method 2
a mixer receives fluid from the passage downstream of the condensate trap for at least mixing fluid from the passage with the engine intake to raise the temperature in the intake above the dew point
Data Source
AI summary
An engine intake condensation removal system includes a valve for bypassing flow around a charge air cooler (CAC) to a liquid separator and mixer. The separator is downstream of the CAC and the mixer is downstream of the liquid separator. The mixer controls the amount of bypass flow to heat fluid flow from the CAC to a level higher than the dew point of the fluid flowing through the engine intake. The bypass flow is placed in a heat exchange relationship with the conduit receiving the output of the CAC before mixing to raise the wall temperature sufficiently to prevent condensation.