Intercooler Cooling System with Dynamic Coolant Flow Control
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Solution Overview
Problem
Conventional intercoolers only cool air when its temperature is higher than a preset level, leading to potential malfunctions in swirl control valves and durability issues when low-temperature air is mixed with EGR gas, necessitating an additional heating device.
Innovation Solution
A cooling system that includes an intercooler for heating air when its temperature is low, comprising a thermostat, control valves, and a controller to manage coolant flow between the intercooler, radiator, and low temperature radiator, ensuring efficient heating and cooling based on engine and intake air temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an intercooler is used only for cooling air when temperature is high, then cooling function is achieved, but heating function is lost and additional heating devices are needed
Solution Approach 1:
The intercooler is designed to perform both cooling and heating functions by controlling coolant flow direction. When the engine is cold, the intercooler heats intake air using coolant from the engine. When the engine is warm, it cools intake air using coolant from the radiator, eliminating the need for separate heating and cooling devices.
Solution Approach 2:
The system dynamically switches the intercooler's function between heating and cooling based on engine temperature conditions. Control valves adjust coolant flow paths in real-time, allowing the intercooler to adapt its thermal function according to the engine's thermal state and intake air temperature requirements.
2Productivity
If low-temperature air is mixed with EGR gas, then fuel efficiency may improve, but swirl control valve malfunctions and durability issues occur
Solution Approach 1:
The system preemptively heats low-temperature intake air using the intercooler before it is mixed with EGR gas and supplied to the swirl control valve. This prevents the harmful effects of cold air on the valve's durability while maintaining the fuel efficiency benefits of EGR mixing.
3Temperature
If coolant is continuously circulated through the radiator, then engine cooling is maintained, but heating of intake air cannot be achieved when engine is cold
Solution Approach 1:
When the engine is cold, the control system directs coolant flow through the intercooler to preheat the intake air before combustion. This preliminary heating action prepares the air for efficient combustion while the engine is warming up, improving cold-start performance without preventing the engine from reaching operating temperature.
Solution Approach 2:
The coolant circulation system dynamically redirects flow paths based on engine temperature. During cold operation, coolant flows through the intercooler for heating; during normal operation, it flows through the radiator for cooling. This dynamic switching allows the system to achieve both heating and cooling functions using the same coolant circulation infrastructure.
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
Prevents swirl control valve malfunctions and durability issues by heating low-temperature air using the intercooler, improving engine performance without the need for additional heating apparatuses, thus reducing production costs and environmental impact.
Implementation Method 1
an intercooler configured to heat-exchange a coolant and air
Implementation Method 2
a radiator configured to cool a coolant heated in an engine through heat-exchange with air
Implementation Method 3
a low temperature radiator configured to cool the coolant of the intercooler
Data Source
AI summary
A cooling system may include an intercooler configured to heat-exchange a coolant and air, a radiator configured to cool a coolant heated in an engine through heat-exchange with air, a low temperature radiator configured to cool the coolant of the intercooler, a thermostat selectively fluid-connected to the radiator or the intercooler to supply the coolant from the radiator or the intercooler to the engine, a first control valve configured to selectively supply the coolant which has passed through the intercooler to the radiator, a second control valve configured to selectively supply the coolant which has passed through the engine to the intercooler or the first control valve, and a controller configured to control operations of the thermostat, the first control valve, and the second control valve according to a temperature of the coolant of the engine and a temperature of intake air.