Intake System Crankcase Ventilation Bulge Condensate Management
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Solution Overview
Problem
Existing intake systems for internal combustion engines face issues with condensate formation, which can damage turbochargers and contaminate components, leading to reduced functionality and increased noise due to the introduction of crankcase ventilation gases, especially when introduced upstream of compressors.
Innovation Solution
The intake system incorporates a crankcase ventilation duct with a lateral bulge and a trough-shaped recess, where condensate is directed to flow into the exhaust gas recirculation duct, minimizing direct contact with the air flow and using a PTC heating element to evaporate condensate, thus reducing condensate formation and ensuring it does not reach downstream components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If crankcase ventilation gases are introduced directly into the intake manifold upstream of the compressor, then the ventilation function is achieved, but condensate forms and causes damage to the compressor and contamination of components
Solution Approach 1:
The patent introduces an intermediary structure (the bulge with trough-shaped recess) between the crankcase ventilation channel and the intake manifold. This intermediary structure serves as a mediator that captures condensate through gravity-driven flow into the recess and directs it to the exhaust gas recirculation channel, preventing direct contact with the compressor while maintaining ventilation function.
Solution Approach 2:
The patent converts the harmful condensate into a beneficial flow by utilizing gravity to direct condensate from the crankcase ventilation channel into the exhaust gas recirculation channel. The condensate that would otherwise damage the compressor is instead channeled to be evaporated by hot exhaust gases, transforming a harmful effect into a beneficial one.
2Adaptability or versatility
If crankcase ventilation gases are introduced upstream of the compressor, then ventilation is achieved, but noise increases due to turbulence and condensate
Solution Approach 1:
The bulge structure acts as an intermediary that intercepts and redirects the flow of crankcase ventilation gases. By directing gases into the trough-shaped recess and then to the exhaust gas recirculation channel, it eliminates direct turbulent mixing with the main intake air stream, thereby reducing noise generation.
3Device complexity
If a common actuator controls both throttle valve and exhaust gas recirculation valve, then device size is reduced, but control precision for separate functions is compromised
Solution Approach 1:
The patent applies multi-functionality by using a single common actuator to control both the throttle valve and exhaust gas recirculation valve. The actuator can position itself in different states (fully open, fully closed, or intermediate) to independently control each function, achieving both device size reduction and maintained control precision through intelligent positioning.
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 design significantly reduces condensate formation, prevents contamination of components, and extends the service life of moving parts by ensuring condensate is either evaporated or directed away from critical areas, reducing noise and maintaining component functionality.
Implementation Method 1
using a PTC heating element to evaporate condensate
Implementation Method 2
PTC heating element
Implementation Method 3
condensate is directed to flow into the exhaust gas recirculation duct
Data Source
Figure 1
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Figure 3
AI summary
Known intake systems for internal combustion engines comprise a suction duct (12), a port (14) of an exhaust gas recirculation duct (16) into the suction duct (12), and a crankcase breather duct (52) that extends into the suction duct (12). In order to prevent downstream parts such as compressors from being damaged by condensates, according to the invention, the crankcase breather duct (52) projects into a lateral bulge (54) in the suction duct (12).