Predictive EGR Cooler Cooling Control for Transient Engine Operations
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Solution Overview
Problem
During transient operations of an internal combustion engine, the low temperature coolant circuit's EGR cooler experiences a temporary decrease in cooling performance due to delayed coolant flow, leading to insufficient dehumidification of EGR gas and potential condensate water production in the intercooler, which can cause corrosion.
Innovation Solution
A predictive control system that adjusts the coolant flow rate into the EGR cooler and the radiator fan's air rate, along with an inhibition control to prevent EGR gas backflow, to maintain optimal cooling performance and prevent condensate water formation during deceleration and subsequent acceleration phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coolant flow rate into the EGR cooler is increased during deceleration, then the cooling performance of the EGR cooler is maintained, but the temperature difference between the coolant and EGR gas decreases, reducing dehumidification efficiency
Solution Approach 1:
The control unit predicts future cooling performance degradation before it occurs by monitoring coolant temperature trends during deceleration. When the predicted inlet temperature to the EGR cooler exceeds a threshold, the control unit preemptively increases the coolant flow rate to maintain cooling effectiveness, rather than waiting for actual performance degradation to occur
Solution Approach 2:
The system dynamically adjusts the coolant flow rate based on real-time operating conditions and predicted future states. The flow rate is increased only when prediction indicates cooling performance will fall short, allowing the system to adapt to changing thermal conditions while minimizing unnecessary energy consumption
2Temperature
If the coolant flow rate is increased to maintain cooling performance, then the coolant temperature rise is restricted, but the flow delay from EGR cooler to radiator causes temporary temperature increase
Solution Approach 1:
The control unit continuously monitors coolant temperature at multiple points in the circuit and uses this feedback to predict future temperature conditions. By comparing current temperature readings with expected temperature trends, the system determines when to adjust the coolant flow rate to compensate for the time delay in the thermal response
Solution Approach 2:
The system performs preliminary temperature prediction based on current operating conditions and coolant flow patterns. When the prediction indicates that coolant temperature will rise above acceptable levels due to flow delay, the control unit preemptively adjusts the flow rate to prevent temperature excursions before they occur
3Object-affected harmful factors
If EGR gas flow is inhibited during transient operation, then condensate water production is prevented, but the EGR function is temporarily reduced
Solution Approach 1:
The control unit acts as an intermediary between the EGR valve and the cooling system, coordinating EGR gas flow with coolant temperature conditions. Rather than simply inhibiting EGR flow, the system uses the cooling capacity of the low temperature coolant circuit to enable EGR operation under conditions where it would normally produce condensate, thus maintaining EGR function while preventing harmful effects
Solution Approach 2:
The system changes the operational parameters of the EGR valve based on predicted cooling performance. When prediction indicates sufficient cooling capacity, the EGR valve opening degree is increased to maintain or enhance EGR function. When cooling performance is insufficient, the valve opening is reduced to prevent condensate formation, thus dynamically optimizing the balance between EGR productivity and condensate 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
The solution effectively restricts the rise in coolant temperature, ensuring sufficient dehumidification of EGR gas and preventing condensate water production in the intercooler, thereby maintaining the EGR cooler's cooling performance and preventing corrosion.
Implementation Method 1
an EGR cooler cooling the EGR gas
Implementation Method 2
an intercooler cooling an intake gas of the internal combustion engine
Implementation Method 3
a radiator
Data Source
AI summary
A low temperature cooling device applied to an internal combustion engine includes an EGR device, a low temperature coolant circuit, a prediction unit predicting whether an EGR cooler falls into a state where a cooling performance falls short according to at least one of an operating state of an internal combustion engine and an outside air environment while a control that dehumidifies an EGR gas by cooling the EGR gas in the EGR cooler is performed, and a control unit performing at least one of a first increase control that increases a flow rate of a coolant flowing into the EGR cooler, a second increase control that increases an air rate of a radiator fan cooling a radiator, and an inhibition control that inhibits the EGR gas from flowing back when the prediction unit predicts that the EGR cooler falls into the state where the cooling performance falls short.