Intercooler Cooling Air Control via Boost Pressure
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Solution Overview
Problem
Existing devices for controlling charge air temperature in air-cooled charge air coolers for supercharged internal combustion engines are complex in structure due to the need for closed-loop control systems.
Innovation Solution
A device using boost pressure as a control variable to regulate the amount of cooling air, implemented through a hydraulic motor driven by a proportional valve, simplifies the control mechanism by employing open-loop control, ensuring constant cooling based on engine power output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If closed-loop control is used to control charge air temperature, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the temperature sensor and feedback control mechanism from the system, replacing complex closed-loop control with a simplified open-loop control based on boost pressure. The control device directly adjusts cooling air quantity according to boost pressure signals without requiring temperature feedback, thereby reducing structural complexity while maintaining adequate control precision.
Solution Approach 2:
The patent changes the control parameter from charge air temperature (requiring temperature sensors and feedback) to boost pressure (readily available from engine management). This parameter substitution simplifies the control system by eliminating the need for temperature measurement and feedback loops, while still achieving effective temperature control through the established relationship between boost pressure and required cooling.
2Temperature
If cooling air quantity is increased to maintain constant temperature, then charge air cooling effectiveness is improved, but energy consumption increases
Solution Approach 1:
The patent implements dynamic adjustment of cooling air quantity based on real-time boost pressure conditions. The control device varies the fan speed and cooling air flow rate according to the current engine operating point, matching cooling supply to actual thermal demand. This prevents excessive cooling (and associated energy waste) while ensuring adequate temperature stability when required.
Solution Approach 2:
The system dynamically changes the cooling air quantity parameter in response to boost pressure variations. By linking cooling air flow rate to boost pressure levels, the system optimizes energy consumption by providing maximum cooling only when high boost pressure (and thus high thermal load) is present, rather than maintaining constant high cooling flow that would waste energy during low-load operation.
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 solution reduces the thermal load on the intercooler and maintains adequate cooling of charge air by adjusting the cooling air quantity according to engine speed, resulting in a simpler and more effective cooling system.
Implementation Method 1
an air-cooled charge air cooler (12) for a supercharged internal combustion engine (20)
Implementation Method 2
a fan device (22) for generating a flow of cooling air (24) that impinges on the charge air cooler (12)
Data Source
Figure 1~5
Figure 2~3
Figure 4
AI summary
The device (10) has a fan device (22) for producing cooling air flow (24) subjected to an air-cooled intercooler (12). A control device (44) is provided for influencing cooling air quantity in accordance with a supplied control variable to show a load pressure available at the intercooler. The fan device includes an exhaust rotor (28) that is rotatably shiftable by a power supply unit (26).