Variable Volume Charge Air Cooler for Turbocharged Engine Resonance
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Solution Overview
Problem
Existing air intake circuits for turbocharged engines face challenges in achieving optimal efficiency across a wide range of engine speeds due to the limitations of turbocharger size and resonance frequency, leading to suboptimal performance at both low and high speeds, and existing solutions are complex, bulky, and inefficient.
Innovation Solution
A supercharging air cooler with control means to vary the useful volume, allowing adjustment of the resonance frequency to match engine excitation frequency, thereby optimizing natural filling of combustion chambers without increasing the overall size or complexity of the intake circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large turbocharger is used, then engine efficiency at high speeds is improved, but turbocharger efficiency at low speeds deteriorates due to high inertia
Solution Approach 1:
The patent applies the dynamics principle by making the intermediate portion's volume variable rather than fixed. The intermediate portion can dynamically adjust its volume based on engine operating conditions, allowing the intake circuit to adapt resonance characteristics across different speed ranges. This resolves the contradiction by enabling the system to behave as a large turbocharger at high speeds and a small turbocharger at low speeds, optimizing performance across the entire operating range.
2Productivity
If the resonance frequency of the intake circuit is optimized for a single engine speed, then natural filling at that speed is improved, but performance at other speeds deteriorates
Solution Approach 1:
The patent implements dynamics by providing a variable volume intermediate portion that can adjust the resonance frequency of the intake circuit dynamically. This allows the system to optimize natural filling for different engine speeds as needed, rather than being locked into a single fixed resonance frequency. The variable volume capability enables the intake circuit to adapt to varying operating conditions, maintaining high performance across the entire speed range.
3Productivity
If the volume of the intermediate portion is increased to promote natural filling, then engine performance is improved, but the overall size and complexity of the intake circuit increases
Solution Approach 1:
The patent resolves this contradiction by making the intermediate portion's volume variable rather than permanently large. The intermediate portion can expand to promote natural filling when needed and contract to minimize size when not needed. This dynamic adjustment allows the system to achieve high engine performance during operation while maintaining a compact overall intake circuit design that does not unnecessarily increase size or complexity.
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 enhances engine efficiency by improving turbocharger operation across a wide speed range, reducing the latching speed of the turbocharger, and allowing for easier installation and maintenance, while maintaining high supercharging pressures without leaks.
Implementation Method 1
vary the useful volume (VU) of said cooler (100) so as to vary the resonance frequency of the intake circuit (14) as a function of the excitation frequency of the engine (12)
Implementation Method 2
an exchanger (110); an inlet box (120) to lead the supercharging air from an inlet (101) of the cooler to the exchanger (110); and an outlet box (130) for leading the supercharging air from the exchanger (110)
Data Source
Figure 1~2
Figure 3A~4B
Figure 5A~6B
AI summary
The invention relates to a charge air cooler (100) for an air intake system (14) of an engine (12) supercharged by a turbocharger (18), the cooler (100) comprising: an exchanger (110); an inlet box (120) for guiding the charge air from an inlet (101) of the cooler (100) to the exchanger (110); and an outlet box (130) for guiding the charge air from the exchanger (110) to an outlet (102) of the cooler (100); the inlet box (120), the exchanger (110) and the outlet box (130) defining a filling volume (Vu) designed so as to receive the charge air, the cooler (100) being characterised in that it comprises control means (140) designed so as to vary the filling volume (Vu).