Intercooler Condensate Discharge via Ejector Airflow
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Solution Overview
Problem
In turbo intercooler engines, accumulated condensate in the outlet tank can lead to engine failure and sensor malfunction due to excessive condensate introduction into the combustion chamber and acidification, causing corrosion.
Innovation Solution
A condensate discharge device with an ejector hose, housing, and nozzle system that injects high-pressure air into the outlet tank to frequently discharge condensate in small amounts, preventing accumulation and acidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If condensate is discharged frequently in small amounts, then engine reliability is improved, but device complexity increases due to addition of ejector components
Solution Approach 1:
The ejector system utilizes the existing high-pressure air flow from the turbocharger compressor to discharge condensate automatically without requiring external power sources, control systems, or additional actuators. The kinetic energy of the compressed air itself drives the condensate discharge process, making the system self-powered and eliminating complex control mechanisms while improving engine reliability through frequent condensate removal
Solution Approach 2:
The ejector housing serves multiple functions simultaneously: it acts as a condensate collection chamber, a discharge nozzle system, and an integration point for the condensate inlet from the outlet tank. This multi-functionality reduces the need for separate components for each function, thereby improving reliability through frequent discharge while minimizing the increase in device complexity
2Device complexity
If condensate accumulates in outlet tank, then device complexity is reduced, but harmful effects increase due to engine failure and sensor malfunction
Solution Approach 1:
The ejector system employs pneumatic principles by using the high-pressure air flow from the turbocharger compressor to create a vacuum effect that draws condensate from the outlet tank through the condensate inlet, and then propels it through the ejector housing to the discharge location. This pneumatic mechanism enables automatic condensate discharge without mechanical moving parts, maintaining simplicity while preventing harmful effects of condensate accumulation such as engine failure and sensor malfunction
Solution Approach 2:
The ejector housing acts as an intermediary device between the outlet tank and the engine intake system. It intercepts the condensate that would otherwise be discharged directly into the engine, and uses the high-pressure air flow as a mediator to transport the condensate to a safe discharge location, thereby preventing harmful effects while adding minimal complexity to the system
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 engine damage and sensor malfunction by regularly discharging condensate, reducing the risk of excessive condensate introduction and acidification, thereby maintaining engine and component integrity.
Implementation Method 1
an ejector nozzle disposed in the ejector housing and configured to inject the air introduced from the ejector hose into an inner space of the outlet tank
Implementation Method 2
a cooler core disposed between an inlet tank and an outlet tank and configured to cool air introduced from the inlet tank and discharge the cooled air to the outlet tank
Implementation Method 3
The moisture and the water which are introduced into the intercooler are cooled while passing through an interior of a core of the intercooler. When the moisture and the water are cooled in the core, the moisture and the water are condensed due to a temperature difference with respect to the outside of the core thus causing condensate to be generated.
Data Source
AI summary
A condensate discharge device of an intercooler for a vehicle is provided to remove condensate collected inside an intercooler. The device includes an ejector hose that is disposed between an inlet tank and an outlet tank to form a flow path for an air flow between the inlet tank and the outlet tank. An ejector housing is disposed on one side of the outlet tank. The condensate collected in the outlet tank is introduced into the ejector housing. An ejector nozzle is disposed in the ejector housing and injects the air introduced from the ejector hose into an inner space of the outlet tank. When injecting the air, to inject the condensate, which is introduced from the outlet tank into the ejector housing, injecting the inner space of the outlet tank with the air.