Variable Charge Air Cooler Volume Control for Compressor Surge
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Solution Overview
Problem
Turbocharged and supercharged engines face issues with compressor surge, leading to noise disturbances and performance problems, and existing compressor recirculation valve solutions do not provide adequate surge control and reduce engine output.
Innovation Solution
A charge air cooler with a valve that selectively reduces its volume during compressor surge conditions to maintain operation outside the surge region, routing intake air through a subset of the cooler's volume to increase air flow velocity and prevent surge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compressor recirculation valve is opened to control surge, then compressor surge is reduced, but engine output is reduced
Solution Approach 1:
The charge air cooler is divided into multiple passages that can be selectively opened or closed. By closing some passages, the effective volume of the cooler is reduced, which prevents compressor surge without requiring the recirculation valve to open fully, thus maintaining engine output.
Solution Approach 2:
The charge air cooler volume is made dynamically adjustable through the valve mechanism. The system transitions from a fixed-volume cooler to one that can change its effective volume based on operating conditions, allowing optimization between surge prevention and engine performance.
2Reliability
If charge air cooler volume is decreased to prevent surge, then compressor surge is prevented, but cooling efficiency is reduced
Solution Approach 1:
The charge air cooler operates with variable volume based on demand. During surge-prone conditions, the volume is reduced to prevent surge. During normal operation, the full volume is available for optimal cooling. This dynamic adjustment resolves the contradiction between surge prevention and cooling efficiency.
Solution Approach 2:
The effective volume parameter of the charge air cooler is changed based on operating conditions. By modulating the valve position, the system changes the cooler's volume parameter to match the compressor's operational requirements, preventing surge when needed while maintaining cooling efficiency when possible.
3Temperature
If intake air flows through entire charge air cooler, then cooling is maximized, but air flow velocity is reduced and condensation accumulates
Solution Approach 1:
The charge air cooler passages are segmented and can be selectively closed. By closing certain passages, the air flow is concentrated through remaining open passages, increasing velocity and reducing condensation accumulation while still providing adequate cooling through the active passages.
Solution Approach 2:
The potential harm of condensation accumulation is converted into a benefit by using the valve to increase air flow velocity through selected passages. The higher velocity air flow not only prevents condensation but also enhances cooling efficiency in the active passages, turning a potential problem into an advantage.
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 approach effectively prevents compressor surge, maintains engine performance, and reduces condensation accumulation, thereby avoiding torque disturbances and combustion instability.
Implementation Method 1
By routing the intake air through only a portion of the volume of the charge air cooler instead of the entire volume during surge conditions, intake air flow velocity increases and compressor surge may be avoided
Implementation Method 2
charge air cooler downstream of a compressor may include a valve positioned in the inlet of the charge air cooler that may selectively reduce the volume of the charge air cooler
Data Source
AI summary
Embodiments for a charge air cooler are provided. In one example, an engine method comprises during a first mode, decreasing a volume of a charge air cooler in response to a compressor operation upstream of the charge air cooler. In this way, compressor surge may be prevented.