Intake Manifold Sensor Housing for EGR Condensation Control
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Solution Overview
Problem
The freezing of condensed water in manifold pressure sensors due to high temperature and humidity EGR gas and cold external air leads to inaccurate pressure measurements and potential sensor malfunctions in intake manifolds, causing combustion instability and corrosion in engine components.
Innovation Solution
An intake manifold design that includes a sensor housing with an inflow line branching off between the intake and EGR lines, merging into the sensor housing, and an outflow line inclined towards a surge tank, preventing condensed water from reaching the manifold pressure sensor and allowing it to function as a resonator for accurate pressure measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If condensed water is allowed to flow into the manifold pressure sensor, then the sensor can measure pressure in the intake manifold, but the condensed water freezes in cold weather blocking the pressure aperture and deteriorating measurement accuracy
Solution Approach 1:
The patent divides the intake manifold system into separate functional zones: a sensor housing section containing the MAP sensor isolated from condensed water, and a main manifold section where condensation occurs. The sensor housing is connected via an inflow line that branches before the EGR mixing point, creating a segmented pathway that prevents condensed water from reaching the sensor while maintaining pressure measurement capability.
Solution Approach 2:
The sensor housing acts as an intermediary element between the main intake manifold and the MAP sensor. It provides a protected environment for the sensor with proper drainage features (downward inclination, drain hole) that intercept condensed water before it can reach the pressure aperture, thereby mediating between the need for pressure measurement and the hazard of condensation.
2Adaptability or versatility
If the manifold pressure sensor is exposed to high temperature and humidity EGR gas and cold external air, then the sensor can measure the mixed gas conditions, but condensed water generates and freezes on the sensor surface causing malfunction
Solution Approach 1:
The patent extracts the MAP sensor from the harmful environment where EGR gas and cold air mix to form condensed water. By locating the sensor in a separate housing connected upstream of the EGR mixing point, the sensor measures intake pressure indirectly through the sensor housing while being physically removed from the condensation-generating zone, thus eliminating exposure to harmful condensed water.
Solution Approach 2:
The sensor housing and inflow line are designed with preliminary protective features: downward inclination to prevent water accumulation, and a drain hole positioned to exit before condensed water can form. These preliminary design elements proactively prevent condensed water from reaching the sensor before the freezing problem can occur.
3Reliability
If a sensor housing with drainage features is introduced to prevent condensed water from reaching the sensor, then sensor freezing is prevented, but the device complexity increases
Solution Approach 1:
The patent merges the sensor housing function with the existing intake manifold structure. The sensor housing is integrated into the manifold body with inflow and outflow lines that utilize the existing fluid pathways, rather than adding completely separate drainage systems. This merging approach minimizes additional complexity while achieving reliable condensed water prevention.
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 sensor freezing, maintains accurate pressure and temperature measurements, and reduces corrosion by ensuring fresh air flows into the sensor housing before condensation occurs, enhancing the overall engine performance.
Implementation Method 1
allowing it to function as a resonator for accurate pressure measurement
Implementation Method 2
The outflow line may be formed to be downwardly inclined toward the surge tank from the sensor housing
Data Source
AI summary
An intake manifold may include a manifold inlet connected with an intake line into which fresh air flows and a recirculation line into which exhaust gas recirculation (EGR) gas flows; a manifold pressure sensor for measuring pressure of fluid flowing through the manifold inlet; and a sensor housing fluidly communicating with the manifold inlet and including a mounting space in which the manifold pressure sensor is mounted.