Two-Stage Supercharged Engine Charge Air Cooling

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Solution Overview

Problem

Supercharged combustion engines face challenges in supplying an optimum amount of air, which is essential for efficient combustion and performance, due to the high temperature of compressed air after two-stage compression, making it difficult for air-cooled charge air coolers to cool the air to a temperature close to the surroundings without increasing their size.

Innovation Solution

A separate cooling system with a first coolant-cooled charge air cooler and a second air-cooled charge air cooler, where the coolant is pre-cooled using a radiator element cooled by surrounding air, allows for efficient cooling of compressed air to a temperature near the surroundings, and an EGR system with a separate cooling circuit for recirculating exhaust gases to reduce nitrogen oxide content.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If air is compressed in two stages by two compressors, then the amount of air that can be supplied to the combustion engine is increased, but the temperature of the compressed air becomes too high for effective cooling in air-cooled charge air coolers

Engineering Contradiction:

Improveamount of airVSAvoidtemperature of compressed air

Core Design Contradiction:

Quantity of substanceVSTemperature

Solution Approach 1:

The cooling process is segmented into three distinct stages: first coolant-cooled charge air cooler between compressors, second coolant-cooled charge air cooler after second compressor, and air-cooled charge air cooler. This segmentation allows each cooling stage to handle specific temperature ranges effectively, preventing the air temperature from becoming too high for effective cooling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Coolant serves as an intermediary medium to transfer heat from the compressed air. The coolant circulates through the coolant-cooled charge air coolers, absorbing heat from the compressed air and transferring it to the cooling system, thereby controlling the air temperature without direct air-to-air cooling.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If the dimensions of the air-cooled charge air cooler are increased to cool compressed air to a temperature close to the temperature of the surroundings, then the cooling effectiveness is improved, but the device complexity and space requirements increase

Engineering Contradiction:

Improvetemperature of compressed airVSAvoiddimensions of charge air cooler

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling function is segmented across multiple cooler components with different cooling mechanisms. The coolant-cooled charge air coolers handle the bulk of the cooling load using the vehicle's existing cooling system, while the air-cooled charge air cooler handles residual heating. This distribution allows each component to be more compact than if a single large air-cooled cooler were used.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coolant-cooled charge air coolers serve dual purposes: cooling the compressed air and utilizing the vehicle's existing cooling system infrastructure. This multi-functionality reduces the need for dedicated large-scale air-cooled cooling components, as the same cooling system serves both engine cooling and air cooling functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 arrangement enables a larger amount of air to be compressed and cooled efficiently, improving engine performance and reducing nitrogen oxide emissions by ensuring both air and exhaust gases are cooled to a temperature close to the surroundings, facilitating optimal combustion.

Implementation Method 1

a first coolant-cooled charge air cooler adapted to cooling the compressed air when it has been compressed in the first stage

Methodology Applied