Vehicle Shutter System for Charge Air Cooler Ice Prevention
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Solution Overview
Problem
Existing engine cooling systems and charge air coolers fail to reduce air flow during icing conditions, leading to potential ice formation in charge air cooler components and the air path to the engine, which affects fuel economy and heat rejection.
Innovation Solution
A shutter system with a rear shutter mechanism and actuator, controlled by sensors and a processor, that adjusts air flow to the radiator and intercooler based on intake air, ambient air, and vehicle speed to manage air flow and prevent ice formation, while also optimizing fuel economy and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the charge air cooler system maintains continuous air flow through the intercooler and radiator, then effective heat rejection is achieved, but ice formation occurs in charge air cooler components during icing conditions
Solution Approach 1:
The patent implements dynamic control of air flow through the intercooler and radiator using shutters that adjust their position based on ambient temperature and vehicle operating conditions. During icing conditions, the shutters close to block air flow through the charge air cooler, preventing ice formation while allowing the system to maintain cooling function when conditions permit
Solution Approach 2:
The patent separates the air flow paths for the charge air cooler and radiator using independent shutter mechanisms. This allows the radiator to continue receiving cooling air flow while the intercooler air flow is blocked during icing conditions, extracting the harmful cooling function from the charge air cooler system when it would cause ice formation
2Object-affected harmful factors
If the shutter system closes the rear shutter to prevent air flow through the intercooler during icing conditions, then ice formation is prevented, but heat rejection capability is reduced
Solution Approach 1:
The patent divides the cooling system into separate controllable zones with independent shutter mechanisms - a front shutter controlling air flow to the intercooler and a rear shutter controlling air flow from the intercooler to the radiator. This segmentation allows selective closure of the rear shutter to prevent ice formation in the intercooler while maintaining air flow through the radiator for continued heat rejection
Solution Approach 2:
The rear shutter acts as an intermediary element between the intercooler and radiator, mediating the air flow between these two components. By controlling this intermediate air flow path, the system can prevent ice formation in the intercooler while preserving the radiator's heat rejection function through alternative air flow paths
3Device complexity
If existing cooling systems maintain fixed air flow configuration, then system simplicity is maintained, but adaptability to icing conditions is lost
Solution Approach 1:
The patent transforms the fixed air flow configuration into a dynamic system with electronically controlled shutters that can adjust their position based on sensor input from temperature sensors and control logic. This allows the system to adapt to varying ambient conditions including icing conditions while maintaining a relatively simple mechanical structure
Solution Approach 2:
The patent implements a feedback control system using ambient temperature sensors and intake air temperature sensors that provide input to control logic, which then actuates the shutter mechanisms appropriately. This feedback mechanism enables the system to automatically adapt to icing conditions without requiring complex mechanical redesign
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 shutter system effectively manages air flow to prevent ice formation, improves fuel economy, and limits heat rejection during icing conditions by scavenging air flow from the intercooler to the radiator when necessary, enhancing vehicle performance and safety.
Implementation Method 1
a charge air cooler system having an intercooler for cooling the intake air
Implementation Method 2
an engine cooling system having a radiator for cooling the engine coolant
Data Source
AI summary
A shutter system is provided for a vehicle having an internal combustion engine that receives forced intake air and is cooled by an engine coolant. The vehicle includes a charge air cooler system having an intercooler for cooling the intake air and an engine cooling system. The shutter system includes a shutter positioned downstream of the intercooler and an actuator for moving the shutter between first and second positions. The shutter system further includes a sensor for generating a signal associated with a temperature of the intake air and a processor for comparing the temperature to a threshold. The actuator moves the shutter to the first position in response to receiving the first signal when the temperature is below the threshold. The actuator moves the shutter to the second position in response to receiving the second signal when the temperature is above the threshold.