Intercooler-Based Ambient Temperature Diagnosis for Blocked Air Intake

Solution Overview

Problem

Engine control systems face challenges in accurately determining ambient air temperature, leading to false diagnostic failures when the air intake mechanism is blocked, as they cannot differentiate between outside and inside air temperatures, causing erroneous notifications.

Innovation Solution

A system and method that determine an estimated ambient air temperature using the cooling capacity, ambient air flow rate, and cooling flow rate of the intercooler, comparing it with the ambient air temperature sensor value to trigger error notifications only when the difference exceeds a threshold, thereby reducing false failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the engine control system uses a single ambient air temperature sensor to determine air temperature, then the system structure remains simple, but the system cannot differentiate between outside air temperature and inside air temperature when the air intake mechanism is blocked, leading to false diagnostic failures

Engineering Contradiction:

Improveambient air temperature measurement accuracyVSAvoiddiagnostic reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The intercooler system is utilized for a dual purpose: its original cooling function and as an additional temperature sensing mechanism. By measuring temperature differential across the intercooler and calculating cooling capacity, the system generates an estimated ambient air temperature that serves as a backup verification method for the primary temperature sensor, thereby improving diagnostic reliability without adding dedicated hardware.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses the intercooler's own operational characteristics (temperature differential, cooling capacity, airflow rate) to generate temperature information that serves the diagnostic function. The intercooler essentially 'self-reports' ambient temperature information through its cooling performance, eliminating the need for additional temperature sensors while improving measurement reliability.

Inventive Principle:

Principle #25Self-service

2Productivity

If the system triggers error notifications based on temperature sensor readings alone, then the diagnostic response is quick and simple, but false error notifications are generated when the air diverter valve state changes due to air intake blockage

Engineering Contradiction:

Improvediagnostic processing speedVSAvoiderror notification accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system implements a feedback mechanism where the estimated ambient air temperature (derived from intercooler performance) continuously verifies the plausibility of the primary temperature sensor readings. When the air diverter valve state changes, the intercooler's cooling capacity and temperature differential provide feedback information that helps the control system distinguish between actual sensor failures and normal operational variations, reducing false error notifications while maintaining quick diagnostic response.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If additional temperature sensors are installed to differentiate between outside and inside air temperatures, then measurement accuracy improves, but the system complexity and cost increase

Engineering Contradiction:

Improveair temperature differentiation accuracyVSAvoidsensor system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The intercooler system is utilized for a dual purpose: its original cooling function and as an additional temperature sensing mechanism. By measuring temperature differential across the intercooler and calculating cooling capacity, the system generates an estimated ambient air temperature that serves as a backup verification method for the primary temperature sensor, thereby improving diagnostic reliability without adding dedicated hardware.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses the intercooler's own operational characteristics (temperature differential, cooling capacity, airflow rate) to generate temperature information that serves the diagnostic function. The intercooler essentially 'self-reports' ambient temperature information through its cooling performance, eliminating the need for additional temperature sensors while improving measurement reliability.

Inventive Principle:

Principle #25Self-service

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 reduces false diagnostic failures by accurately determining the state of the air diverter valve, allowing for adjustments in temperature models and diagnostic capabilities, enhancing the robustness of air intake temperature management without requiring additional hardware or sensors.

Implementation Method 1

A cooling capacity of an intercooler associated with the vehicle is determined

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS11801842B2Estimating ambient air temperature and diagnosing sensor failure using intercooler efficiency

Publication Date: 2023.10.31 PACCAR INC

AI summary

Examples of the present disclosure describe systems and methods for determining an estimated ambient air temperature in an environment in which a vehicle is operating. The estimated ambient air temperature may be compared to an ambient temperature sensor value. The comparison may be used to determine whether an ambient air temperature sensor of the vehicle is functioning properly or if an error notification or fault code should be triggered.