Venturi-Based Charge Air Cooler Condensate Drain System
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Solution Overview
Problem
Internal combustion engines face issues with water ingestion due to condensate accumulation in charge air coolers, leading to potential misfires and hydro-lock conditions when large amounts of water are ingested during acceleration, necessitating a system to reduce condensate to small droplets or amounts acceptable for engine intake.
Innovation Solution
A charge air cooler drain system incorporating a Venturi device that draws condensate from a collection reservoir and introduces it into the intake manifold as a mist, utilizing a bypass loop and valves to control fluid communication and pressure differentials to prevent large water ingestion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a charge air cooler is used to cool compressed intake air, then the air intake temperature decreases and engine power increases, but condensate accumulates in the cooler which can cause misfire or hydro-lock when ingested
Solution Approach 1:
The patent extracts the harmful condensate from the charge air cooler system by providing a dedicated drain path that removes water before it can be ingested by the engine, thereby separating the cooling function from the water accumulation problem
Solution Approach 2:
The patent introduces an intermediary component (drain system with valve and reservoir) between the charge air cooler and the engine intake to intercept and manage condensate, preventing direct contact between water and the engine combustion process
2Reliability
If condensate is completely removed from the charge air cooler, then water ingestion is prevented, but the system complexity and cost increase
Solution Approach 1:
The drain system is designed to be self-regulating, using pressure differentials and gravity to automatically drain condensate without requiring complex active control systems, sensors, or external power sources
Solution Approach 2:
The patent utilizes changes in pressure and flow parameters to control the draining process, where the valve responds to pressure differentials between the charge air cooler and atmosphere to automatically open or close, eliminating the need for complex electronic control
3Power
If the charge air cooler is sized to maximize cooling efficiency, then engine power output increases, but the volume of condensate produced increases
Solution Approach 1:
The patent converts the harmful effect of condensate accumulation into a manageable byproduct by designing a drain system that efficiently removes water, allowing the charge air cooler to operate at maximum cooling efficiency without penalty from water accumulation
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 system effectively reduces condensate to small droplets, preventing engine misfires and hydro-lock conditions by ensuring that only a mist of condensate is introduced into the engine, allowing for peak performance without risking water ingestion, thus maintaining engine efficiency and preventing damage.
Implementation Method 1
a Venturi device in a bypass loop around the throttle. A motive inlet of the Venturi device is in fluid communication upstream of the throttle, a discharge outlet of the Venturi device is in fluid communication downstream of the throttle
Implementation Method 2
Under operating conditions that activate the Venturi device, the suction port draws condensate from the condensate collection reservoir and introduces the condensate into the intake manifold as a mist
Implementation Method 3
The condensate collection reservoir is in fluid communication with air flow upstream of the compressor and a check valve controls the fluid communication therebetween
Data Source
AI summary
An internal combustion engine having an intake manifold, a compressor in fluid communication with the intake manifold, a charge air cooler in fluid communication with and between the compressor and the intake manifold, a throttle controlling fluid communication between the air charge cooler and the intake manifold, and a condensate collection reservoir that collects condensate from the air charge cooler and is in fluid communication with a suction port of a Venturi device in a bypass loop around the throttle. A motive inlet of the Venturi device is in fluid communication upstream of the throttle and a discharge outlet is in fluid communication downstream of the throttle, and under operating conditions that provide an adequate pressure drop across the Venturi device, the suction port draws condensate from the condensate collection reservoir and introduces the condensate into the intake manifold as a mist.