Turbocharged engine water vapor ingestion control techniques determine a dew point of a charge air cooler (CAC) in an induction system of the engine based on measured humidity and temperature of a mixture of (i) air drawn into the induction system and (ii) exhaust gas produced by the engine that is cooled and recirculated by a low pressure cooled exhaust gas recirculation (LPCEGR) system of the engine back into the induction system. When the mixture temperature is less than the CAC dew point, a condensate accumulation in the CAC is determined. When the CAC condensate accumulation does not satisfy a set of one or more thresholds, the mixture temperature is increased. When the CAC condensate accumulation satisfies the set of one or more thresholds, an amount of the exhaust gas that is cooled and recirculated by the LPCEGR system is decreased until the mixture temperature meets the CAC dew point.

An intercooler assembly includes: a cooler main body having a heat exchange unit; an upper tank including an intake receiving portion connected to the heat exchange unit, and coupled to an upper portion of the cooler main body; a lower tank including an intake discharge portion connected to the heat exchange unit, and coupled to an lower portion of the cooler main body; a bypass receiving portion connected to a valve mounting portion, and forming a passage partitioned separately from the intake receiving portion; a bypass line portion that is provided at an exterior of the cooler main body and includes: an inlet connected to the bypass receiving portion and an outlet connected to the intake discharge portion; and a valve unit connected to the intake receiving portion and the bypass receiving portion.

An intercooler assembly includes: a cooler body having a heat exchanger; an upper tank formed at an intake air inlet connected to the heat exchanger and coupled to an upper portion of the cooler body; a lower tank coupled to the lower portion of the cooler body to form an intake air discharge part connected to the heat exchanger; a bypass unit connected to the intake discharge part separately from the intake inlet; and a valve unit connected to the intake air inlet and the bypass unit and selectively introducing intake air supplied through a turbocharger into the intake air inlet and the bypass unit.

An air compression system includes an internal combustion engine operable to produce a power output in response to combustion of a fuel-air mixture, and an air compressor driven by the internal combustion engine and operable to draw in atmospheric air and discharge a mixed flow of compressed air and water. A water injection system supplies water to the fuel-air mixture and into the internal combustion engine, a separator assembly in communication with the air compressor separates a portion of the water from the compressed air, and a water passageway interconnects the separator assembly and the water injection system such that the air compressor supplies water to the water injection system.

Embodiments for controlling condensate in a charge air cooler are provided. In one example, a charge air cooler comprises an inlet to admit charge air, a plurality of heat exchange passages to remove heat from the charge air, an outlet configured to discharge the charge air from the heat exchange passages to an intake passage upstream of an intake manifold of an engine, and a dispersion element extending at least partially across the outlet.

A method of forming an integral drain for a heat exchanger is provided. The method includes forming a plurality of passage walls to define a plurality of passages with an additive manufacturing process, each of the passage walls having a non-linear portion. The method also includes integrally forming a drain wall with at least one of the passage walls with the additive manufacturing process to define a drain for each of the plurality of passages, the drain wall located proximate the non-linear portion of each of the plurality of passage walls.

An air intake passage (30) has a third passage (37) that connects an intercooler (36) and a bottom portion of a surge tank (38) such that the intercooler (36) is positioned below the surge tank (38). A pair of wall portions (71, 72) configured to catch moisture is formed in a section from an upstream end portion of the third passage (37) to a connected portion between said third passage (37) and the surge tank (38).

An intercooler for cooling air exiting a turbocharger for delivery to an internal combustion engine can include an inlet, an outlet, a condensate collection space and a filter. The inlet can be configured to be in fluid communication with the turbocharger. The outlet can be configured to be in fluid communication with the internal combustion engine. The condensate collection space can be located between the inlet and the outlet. The filter can be located between the condensate collection space and the outlet such that water vapor in the air that condenses in the intercooler flows through the filter and into the condensate collection space in a first direction and condensed water flowing from the condensate collection space toward the outlet passes through the filter in a second direction before exiting through the outlet, and the second direction is different from the first direction.

An intercooler for cooling air exiting a turbocharger for delivery to an internal combustion engine can include an inlet, an outlet, a condensate collection space and a filter. The inlet can be configured to be in fluid communication with the turbocharger. The outlet can be configured to be in fluid communication with the internal combustion engine. The condensate collection space can be located between the inlet and the outlet. The filter can be located between the condensate collection space and the outlet such that water vapor in the air that condenses in the intercooler flows through the filter and into the condensate collection space in a first direction and condensed water flowing from the condensate collection space toward the outlet passes through the filter in a second direction before exiting through the outlet, and the second direction is different from the first direction.

A condensate discharge device of an intercooler for a vehicle is provided to remove condensate collected inside an intercooler. The device includes an ejector hose that is disposed between an inlet tank and an outlet tank to form a flow path for an air flow between the inlet tank and the outlet tank. An ejector housing is disposed on one side of the outlet tank. The condensate collected in the outlet tank is introduced into the ejector housing. An ejector nozzle is disposed in the ejector housing and injects the air introduced from the ejector hose into an inner space of the outlet tank. When injecting the air, to inject the condensate, which is introduced from the outlet tank into the ejector housing, injecting the inner space of the outlet tank with the air.