Engine Intake Flow Control Module for Cold Start Heating
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Solution Overview
Problem
Existing internal combustion engine intake systems face challenges in efficiently managing oxidizer temperatures, particularly during cold starts, leading to increased emissions and energy losses, as conventional heat exchangers are ineffective in rapidly increasing intake manifold temperatures.
Innovation Solution
An engine system with a flow control module and heat exchanger that selectively controls fluid communication between the oxidizer flow path and the compressor outlet, utilizing exhaust heat to increase intake manifold temperature during cold starts, and recirculating compressor discharge flow to enhance oxidizer heating, while adjusting configurations based on temperature thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional heat exchanger is used to heat intake air, then some thermal energy transfer occurs, but the heating effectiveness is insufficient to rapidly increase intake manifold temperatures during cold starts
Solution Approach 1:
The system dynamically switches between different operational modes using a flow control module that can bypass the heat exchanger or direct flow through it, allowing the system to adapt to varying temperature conditions and maximize heating effectiveness during cold starts while maintaining efficiency at steady state
Solution Approach 2:
The patent introduces an intermediary recirculation path that allows compressor discharge to be redirected back to the heat exchanger inlet, creating a closed-loop system that concentrates thermal energy transfer and dramatically improves heating effectiveness during cold start conditions
2Temperature
If the flow control module directs oxidizer through the heat exchanger during cold starts, then intake manifold temperature increases, but system complexity increases due to additional control requirements
Solution Approach 1:
The flow control module serves multiple functions: it acts as a bypass valve, a recirculation control, and a flow distribution device, all within a single component that integrates seamlessly with the existing compressor and heat exchanger infrastructure, minimizing additional complexity
Solution Approach 2:
The system uses its own compressor discharge as the heating medium, eliminating the need for external heat sources or additional energy input systems. The recirculation path allows the system to self-regulate and maintain temperature without external control inputs beyond the flow control module
3Temperature
If compressor discharge is recirculated through the heat exchanger, then oxidizer heating is enhanced, but pressure losses may increase due to additional flow paths
Solution Approach 1:
The system applies partial recirculation rather than full recirculation, where only a portion of the compressor discharge is redirected through the heat exchanger. This partial action provides sufficient heating enhancement while minimizing the additional pressure losses and viscous energy losses associated with the recirculation path
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 approach effectively mitigates white smoke emissions, improves fuel efficiency, and promotes more complete combustion during startup, while maintaining lower intake manifold temperatures at steady-state conditions to reduce NOx formation.
Implementation Method 1
heat exchangers may be used to cool an oxidizer stream to increase engine power, increase engine efficiency, or both
Implementation Method 2
Such intake heat exchangers may effect thermal communication between the oxidizer stream and a flow of ambient air or a flow of engine coolant
Implementation Method 3
especially when the engine includes a compressor to boost the pressure of the oxidizer upstream of the variable volume
Implementation Method 4
Alternatively, a fluid, such as liquid water, may be injected into the oxidizer stream to cool the oxidizer stream by evaporation therein
Data Source
AI summary
An engine system includes an internal combustion engine having an intake duct and an exhaust duct; a flow control module fluidly coupled to the intake duct; a compressor in fluid communication with the intake duct via the flow control module; a heat exchanger having an exhaust flow path in fluid communication with the exhaust duct, and having an oxidizer flow path, an outlet of the compressor being in selective fluid communication with the intake duct via the flow control module and the oxidizer flow path of the heat exchanger; a first temperature sensor in fluid communication with the intake duct; and a controller operatively coupled to the flow control module and the first temperature sensor, the controller being configured to actuate the flow control module between a first configuration and a second configuration based at least in part on a signal from the first temperature sensor.