Vehicle Intercooler Bypass Valve Airflow Control
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Solution Overview
Problem
Existing intercooler systems in vehicles suffer from reduced cooling efficiency due to the need for separate paths for cooled and non-cooled air flows, leading to increased manufacturing costs and weight, as well as inefficient heat exchange with the radiator.
Innovation Solution
A method involving a bypass valve between the inlet and outlet of a U-shaped cooling part in the intercooler, which is controlled based on engine load, vehicle speed, and external air temperature to bypass compressed air directly, allowing it to bypass the cooling part when not needed, thereby optimizing air flow and heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate paths are formed for cooled and non-cooled air flows in the intercooler, then cooling function is provided, but manufacturing cost and weight increase
Solution Approach 1:
The patent merges the cooling path and bypass path into a single integrated intercooler structure. The bypass channel is formed within the same housing that contains the cooling channels, eliminating the need for separate bypass valves and reducing overall component weight while maintaining both cooling and bypass functions.
Solution Approach 2:
The intercooler housing is designed to serve multiple functions: it provides cooling channels for heat exchange and simultaneously incorporates bypass channels for direct air flow. This multi-functional design eliminates the need for additional separate components, reducing weight and manufacturing complexity.
2Reliability
If separate paths are formed for cooled and non-cooled air flows in the intercooler, then cooling function is provided, but manufacturing cost increases
Solution Approach 1:
The patent combines the cooling and bypass functions into a single intercooler housing with integrated channels. This unified structure reduces the number of separate parts that need to be manufactured and assembled, thereby lowering manufacturing costs while maintaining effective cooling performance.
Solution Approach 2:
The intercooler housing is designed as a multi-functional component that simultaneously provides cooling channels and bypass channels. This eliminates the need for additional separate bypass valves and associated manufacturing processes, reducing overall manufacturing cost.
3Reliability
If wind is supplied to radiator through intercooler, then cooling is provided, but cooling efficiency of radiator reduces when wind absorbs heat from intercooler
Solution Approach 1:
The patent implements a dynamic bypass system that adjusts air flow based on operating conditions. The bypass valve is controlled to open or close depending on whether the engine requires intercooler cooling or radiator cooling, allowing the system to dynamically allocate wind flow to the component that needs it most, thereby optimizing overall cooling efficiency.
Solution Approach 2:
The bypass channel is strategically positioned at the lower portion of the intercooler housing, allowing selective bypass of air flow. This localized bypass capability enables the system to redirect cooling air away from the intercooler when radiator cooling is prioritized, without compromising the overall cooling function.
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 enhances cooling efficiency by intensively cooling critical components, reduces system complexity and weight, and lowers manufacturing costs by eliminating the need for additional bypass valves, while maintaining effective cooling performance.
Implementation Method 1
a bypass valve that is disposed between an inlet and an outlet connected to the ends of a U-shaped cooling part and is opened/closed such that compressed air is directly bypassed from the inlet to the outlet, without passing through the cooling part
Implementation Method 2
the compressed air cooled through the cooling part and the compressed air at high temperature flowing in the inlet are mixed and flows out to the outlet
Data Source
AI summary
A method controls an intercooler of a vehicle including a bypass valve that is disposed between an inlet and an outlet connected to the ends of a U-shaped cooling part and is opened/closed such that compressed air is directly bypassed from the inlet to the outlet, without passing through the cooling part. The method includes determining whether to bypass compressed air injected in the intercooler by measuring one or more of engine load, vehicle speed, engine revolution speed, and gear stage, closing the bypass valve to block the flow between the inlet and the outlet when the compressed air needs to be bypassed, and opening the bypass valve such that the compressed air directly flows between the inlet and the outlet when it is smaller than the cooling reference value, when the compressed air does not need to be bypassed.