Methods and systems are provided for a charge air cooling system of an engine. In one example, a turbocharger arrangement includes an internal combustion engine, a turbocharger for supercharging the internal combustion engine, a charge-air intercooler located in an intake tract between the turbocharger and the internal combustion engine, and an auxiliary cooling system including a first feed line for supplying a first coolant to the charge-air intercooler, the first feed line positioned upstream of the charge-air intercooler and downstream of a cooling element, the first feed line including a heat recovery element. The heat recovery element may exchange heat between the first coolant and a heat transfer medium, the heat transfer medium including one of engine coolant or exhaust gas.

A chamber for absorbing condensate formed in a charge-air-cooler of a turbocharged engine system. The chamber may include desiccant to absorb the moisture. The chamber may also include a valve that is controlled by the vehicle control module to open to allow airflow to pass by the desiccant and absorb the moisture from the desiccant or to place in a closed position to allow the desiccant to absorb the condensate formed in the charge-air-cooler.

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.

The invention relates to a charge air cooler (5) for fuel engine comprising: a casing having an inlet (16) and an outlet (20), a heat exchanger (10) within the casing between the inlet (16) and the outlet (20), a thermally responsive draining mechanism (50, 60) for draining condensates, the draining mechanism (50, 60) being configured to drain condensates when temperature within the charge air cooler (5) is below a defined temperature, draining mechanism comprising a drain port (58, 68), a valve (51, 61, 52, 62, 53, 63) arranged on the drain port (58, 68), an actuation device (53, 63, 64) for moving the valve between an opened state and a closed state,
wherein the actuation device includes a phase change material.

A gas-liquid separator includes an inlet pipe and an inner pipe. The inlet pipe includes a swirling flow generating member therewithin, and a first drain port through which the liquid exits. The inner pipe includes an opening at an end which is inserted into an end of the inlet pipe. The swirling flow generating member includes a vane supporting portion extending along an axis line of the inlet pipe, and stator vanes provided on an outer circumferential surface of the vane supporting portion. The vane supporting portion has a conical shape whose diameter gradually increases from a fluid entering side to a fluid exiting side of the gas-liquid two-phase fluid. The stator vanes surround the outer circumference with inclining relative to the axis line of the inlet pipe.

An air cooler assembly includes an air cooler having an air inlet manifold, an air outlet manifold, and a heat exchanger core connected at a first end thereof to the air inlet manifold and at a second end thereof to the air outlet manifold. A water separator includes a chamber having a first end and an opposed second end, an air inlet proximate the first end and connected to the air outlet manifold, and an air outlet proximate the second end. A water outlet is formed in a bottom surface of the chamber, and a channel is positioned beneath the water outlet. A condensate outlet is positioned on a bottom surface of the channel. A helical blade has a first end and a second end, and is positioned within the chamber between the air inlet and the air outlet.

An intake device for an internal combustion engine includes: a main pipe having an upstream end forming a suction port and a downstream end configured to be connected to an intake port of an internal combustion engine main body; a compressor of a supercharger provided in the main pipe; an intercooler provided in the main pipe at a position downstream of the compressor and including a cooling part, an upstream header provided upstream of the cooling part, and a downstream header provided downstream of the cooling part; a throttle valve disposed in the main pipe at a position downstream of the intercooler; a bypass pipe having a first end and a second end, the bypass pipe being connected to a part of the main pipe between the cooling part and the throttle valve; and a catch tank provided in the bypass pipe and configure to catch condensed water.

An air cooler assembly includes an air cooler having an air inlet manifold, an air outlet manifold, and a heat exchanger core connected at a first end thereof to the air inlet manifold and at a second end thereof to the air outlet manifold. A water separator includes a chamber having a first end and an opposed second end, an air inlet proximate the first end and connected to the air outlet manifold, and an air outlet proximate the second end. A water outlet is formed in a bottom surface of the chamber, and a channel is positioned beneath the water outlet. A condensate outlet is positioned on a bottom surface of the channel. A helical blade has a first end and a second end, and is positioned within the chamber between the air inlet and the air outlet.

An apparatus for removing condensed water of an intercooler includes a collecting portion for collecting condensed water, the collecting portion being provided at a lower end of the intercooler; and an ultrasonic wave vibrator provided in the collecting portion, the ultrasonic wave vibrator being operated to introduce the condensed water collected in the collecting portion toward an engine so that the condensed water is vaporized, thereby removing or significantly reducing an amount of condensed water in the intercooler. The apparatus for removing condensed water of the intercooler can prevent engine damage and ignition failure due to the presence of the condensed water in the intercooler.

An air cooler assembly includes an air cooler having an air inlet manifold, an air outlet manifold, and a heat exchanger core connected at a first end thereof to the air inlet manifold and at a second end thereof to the air outlet manifold. A water separator includes a chamber having a first end and an opposed second end, an air inlet proximate the first end and connected to the air outlet manifold, and an air outlet proximate the second end. A water outlet is formed in a bottom surface of the chamber, and a channel is positioned beneath the water outlet. A condensate outlet is positioned on a bottom surface of the channel. A helical blade has a first end and a second end, and is positioned within the chamber between the air inlet and the air outlet.