Turbocharged Engine Intake System Condensate Control
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Solution Overview
Problem
Supercharged internal combustion engines face challenges with condensate formation in the intake system due to exhaust gas recirculation, leading to increased noise emissions, potential damage to compressor impellers, and reduced efficiency, especially at lower ambient temperatures and engine speeds.
Innovation Solution
Incorporating an electrically operated heating device in the coolant circuit upstream of a heat exchanger in the intake system to increase the coolant temperature beyond the charge-air temperature, thereby reducing condensate formation by heating the charge air through the heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If exhaust gas recirculation is used to reduce emissions, then pollutant emissions are reduced, but condensate forms in the intake system causing noise and potential compressor damage
Solution Approach 1:
The patent applies preliminary anti-action by heating the charge air before it enters the intake system. The heating device pre-heats the charge air to a temperature above the dew point, preventing condensate formation before it can occur. This proactive approach counteracts the harmful effect of exhaust gas recirculation that would otherwise cause condensation and subsequent noise/compressor damage.
Solution Approach 2:
The patent changes the temperature parameter of the charge air by introducing a heating device that raises the charge air temperature above the dew point. This parameter change (from cold to heated charge air) fundamentally alters the thermodynamic conditions in the intake system, preventing the phase change that leads to condensate formation while maintaining the emission-reducing benefits of exhaust gas recirculation.
2Quantity of substance
If charge air is cooled to increase density and improve charging, then charge air density increases, but condensate formation risk increases at lower temperatures
Solution Approach 1:
The patent modifies the temperature parameter of the charge air by heating it before intake. This parameter change prevents the charge air temperature from dropping below the dew point during cooling and recirculation processes, thereby eliminating condensate formation risk while preserving the benefits of charge air cooling for increased density and improved charging.
Solution Approach 2:
The heating device acts as an intermediary element between the charge air cooling system and the intake system. It mediates the temperature of the charge air, ensuring it remains above the dew point despite cooling processes, thus preventing condensate formation while allowing the cooling system to maintain high charge air density.
3Object-affected harmful factors
If electric heating device is added to prevent condensate formation, then condensate formation is reduced, but device complexity and energy consumption increase
Solution Approach 1:
The heating device is integrated into the existing charge air system and can serve multiple functions: preventing condensate formation, controlling charge air temperature, and potentially assisting with cold start conditions. This multi-functionality reduces the need for separate dedicated heating systems, thereby limiting the increase in device complexity despite adding heating capability.
4Object-affected harmful factors
If heating device is used to maintain charge air temperature, then condensate formation is prevented, but fuel consumption increases due to additional energy requirement
Solution Approach 1:
The heating device can utilize waste heat from the exhaust gas recirculation system or other thermal sources within the engine system to heat the charge air. This self-service approach reduces the need for additional energy input by recycling thermal energy that would otherwise be wasted, thereby preventing condensate formation with minimal additional fuel consumption.
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 solution effectively mitigates condensate formation and noise emissions, reduces the risk of compressor impeller degradation, and maintains engine efficiency across various operating conditions, including cold starts and low ambient temperatures.
Implementation Method 1
an electrically operated heating device (11) which is arranged in the coolant circuit (10a) upstream of the heat exchanger (7) and with which the temperature of the coolant can be increased
Implementation Method 2
a heat exchanger (7) which is arranged upstream of the first junction point (6′) in the intake system (2) and is incorporated into the coolant circuit (10a) and serves for transferring heat between the charge air and the coolant
Implementation Method 3
at least one compressor (5a) which is arranged for the purposes of compressing the charge air in the intake system (2)
Implementation Method 4
The hot exhaust-gas flow is fed to the turbine and expands in the turbine with a release of energy, as a result of which the shaft is set in rotation
Data Source
AI summary
Methods and systems are provided for a heating device. In one example, a system comprises a heat exchanger and an air filter arranged in a common housing, wherein the heat exchanger is configured to receive coolant from a heating device. In one example, the heating device is an electric heating device.