CONDENSATION CONTROL SYSTEM FOR INTERNAL COMBUSTION ENGINE
20170350353 · 2017-12-07
Assignee
Inventors
Cpc classification
F02B37/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M35/10157
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M31/205
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02M35/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M31/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An engine assembly with an air intake system and a turbocharger device in fluid communication with the air intake system includes an electronic control unit in communication with the air intake system and turbocharger device. A CAC system is in downstream fluid communication with the turbocharger device and in upstream fluid communication with the air intake system and includes at least one flow adjustment mechanism in communication with the electronic control unit and selectively positionable between a first position and one or more second positions to adjust velocity of air from the turbocharger device flowing through the CAC system and to manage condensation buildup in the CAC system and/or to open a bypass duct in order for some or all of the turbo airflow to bypass the CAC system to reduce or eliminate condensation buildup in the CAC system at warm ambient conditions and ice buildup at cold ambient conditions.
Claims
1. An internal combustion engine assembly, comprising: an air intake system; a turbocharger device in fluid communication with the air intake system; an electronic control unit in communication with the air intake system and turbocharger device; and a charge air cooler system in downstream fluid communication with the turbocharger device and in upstream fluid communication with the air intake system, wherein the charge air cooler system includes at least one flow adjustment mechanism in communication with the electronic control unit and selectively positionable between a first position and one or more second positions to adjust velocity of air from the turbocharger device flowing through the charge air cooler system and to manage condensation buildup in the charge air cooler system.
2. The internal combustion engine assembly of claim 1, wherein the at least one flow adjustment mechanism of the charge air cooler system further comprises a valve selectively positionable between the first position and a second substantially closed position restricting the flow of air from the turbocharger device therethrough.
3. The internal combustion engine assembly of claim 2, wherein the valve is disposed on an induction duct in fluid communication with an exhaust portion of the charge air cooler system and an air intake manifold of the air intake system.
4. The internal combustion engine assembly of claim 2, wherein the valve is integrally formed to an opening in the exhaust portion of the charge air cooler system and in fluid communication with the air intake manifold of the air intake system through the induction duct.
5. The internal combustion engine assembly of claim 1, wherein the at least one flow adjustment mechanism of the charge air cooler system further comprises a flap disposed within the charge air cooler system and adjacent to the exhaust portion that is selectively positionable between the first position and one or more second actuated positions to restrict the flow of air through the turbocharger device to the air intake system.
6. The internal combustion engine assembly of claim 1, wherein the at least one flow adjustment mechanism of the charge air cooler system further comprises a flap disposed within the charge air cooler system and adjacent to an intake portion that is selectively positionable between the first position and one or more second actuated positions to restrict the flow of air through the turbocharger device to the air intake system.
7. The internal combustion engine assembly of claim 1 wherein the electronic control unit is in communication with one or more sensors in the engine assembly, including: a manifold absolute pressure sensor operatively coupled to the intake manifold such that the manifold absolute pressure sensor is capable of monitoring an intake manifold pressure; a manifold airflow sensor operatively coupled to the air cleaner or clean air duct such that the manifold airflow sensor is capable of monitoring mass airflow into the turbocharger device; and a manifold air temperature sensor operatively coupled to the intake manifold such that the manifold air temperature sensor is capable of monitoring an intake manifold temperature.
8. An internal combustion engine assembly having an engine block, comprising: an exhaust system including an exhaust manifold in fluid communication with the engine block to receive and expel exhaust gases therefrom; a throttle body creating a pressure gradient when the internal combustion engine is in an on-state; an air intake system including an intake manifold in downstream fluid communication with the throttle body, a turbocharger device in fluid communication with the air intake system and configured to provide compressed airflow thereto; an electronic control unit in communication with the air intake system and turbocharger device; and a charge air cooler system in downstream fluid communication with the turbocharger device and in upstream fluid communication with the air intake system, wherein the charge air cooler system includes at least one flow adjustment mechanism in communication with the electronic control unit and selectively positionable between a first position and one or more second positions to adjust velocity of air from the turbocharger device flowing through the charge air cooler system to manage condensation buildup in the charge air cooler system.
9. The internal combustion engine assembly of claim 8, wherein the at least one flow adjustment mechanism of the charge air cooler system further comprises a valve selectively positionable between the first position and a second substantially closed position restricting the flow of air from the turbocharger device therethrough.
10. The internal combustion engine assembly of claim 9, wherein the valve is disposed on an induction duct in fluid communication with an exhaust portion of the charge air cooler system and an air intake manifold of the air intake system.
11. The internal combustion engine assembly of claim 9, wherein the valve is integrally formed to an opening in the exhaust portion of the charge air cooler system and in fluid communication with the air intake manifold of the air intake system through the induction duct.
12. The internal combustion engine assembly of claim 8, wherein the at least one flow adjustment mechanism of the charge air cooler system further comprises a flap disposed within the charge air cooler system and adjacent to the exhaust portion that is selectively positionable between the first position and one or more second actuated positions to restrict the flow of air through the turbocharger device to the air intake system.
13. The internal combustion engine assembly of claim 8, wherein the at least one flow adjustment mechanism of the charge air cooler system further comprises a flap disposed within the charge air cooler system and adjacent to an intake portion that is selectively positionable between the first position and one or more second actuated positions to restrict the flow of air through the turbocharger device to the air intake system.
14. The internal combustion engine assembly of claim 8 wherein the electronic control unit is in communication with one or more sensors in the engine assembly, including: a manifold absolute pressure sensor operatively coupled to the intake manifold such that the manifold absolute pressure sensor is capable of monitoring an intake manifold pressure; a manifold airflow sensor operatively coupled to the intake manifold such that the manifold airflow sensor is capable of monitoring mass airflow in the intake manifold; and a manifold air temperature sensor operatively coupled to the intake manifold such that the manifold air temperature sensor is capable of monitoring an intake manifold temperature.
15. A charge air cooler system in fluid communication with an air intake system and turbocharger device of an internal combustion engine assembly comprising: an electronic control unit in communication with the air intake system and turbocharger device; a housing having an inlet portion at a first end in fluid communication with the turbocharger device, an exhaust portion in an opposing second end in fluid communication with the air intake system and a cavity defined therebetween; and at least one flow adjustment mechanism in communication with the electronic control unit and selectively positionable between a first position and one or more second positions to adjust velocity of air from the turbocharger device flowing through the charge air cooler system to manage condensation buildup in the charge air cooler system.
16. The charge air cooler system of claim 15, wherein the at least one flow adjustment mechanism of the charge air cooler system further comprises a valve selectively positionable between the first position and a second substantially closed position restricting the flow of air from the turbocharger device therethrough.
17. The charge air cooler system of claim 16, wherein the valve is disposed on an induction duct in fluid communication with an exhaust portion of the charge air cooler system and an air intake manifold of the air intake system.
18. The charge air cooler system of claim 16, wherein the valve is integrally formed to an opening in the exhaust portion of the charge air cooler system and in fluid communication with the air intake manifold of the air intake system through the induction duct.
19. The charge air cooler system of claim 15, wherein the at least one flow adjustment mechanism of the charge air cooler system further comprises a flap disposed within the charge air cooler system and adjacent to the exhaust portion that is selectively positionable between the first position and one or more second actuated positions to restrict the flow of air through the turbocharger device to the air intake system.
20. The charge air cooler system of claim 15, wherein the at least one flow adjustment mechanism of the charge air cooler system further comprises a flap disposed within the charge air cooler system and adjacent to an intake portion that is selectively positionable between the first position and one or more second actuated positions to restrict the flow of air through the turbocharger device to the air intake system.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0031] Reference will now be made in detail to several embodiments of the disclosure that are illustrated in the accompanying drawings. Whenever possible, the same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms such as top, bottom, left, right, up, over, above, below, beneath, rear, and front, may be used with respect to the drawings. These and similar to directional terms are not to be construed to limit the scope of the disclosure in any manner.
[0032] Referring to the drawings, wherein like reference numbers refer to like components throughout the several views,
[0033] The internal combustion engine assembly 10 may be provided in a motorized vehicle, such as, but not limited to, standard passenger cars, sport utility vehicles, light trucks, heavy duty vehicles, minivans, buses, transit vehicles, bicycles, robots, farm implements, sports-related equipment or any other transportation device. Engine assembly 10 may include an engine block, crankcase and cylinder head, indicated collectively at 12, equipped with a turbocharging or supercharging device, represented herein by a turbocharger device 14, and a CAC system 16.
[0034] Notably, the engine block, crankcase and cylinder head 12, turbocharger device 14, and CAC system 16 shown in
[0035] With continued reference to
[0036] The engine assembly 10 also includes an air intake system, which is represented herein by an intake manifold or inlet manifold 40 in downstream fluid communication with a throttle body 42. The throttle body 42 is operable to control the amount of air flowing into the engine, normally in response to driver input. The intake manifold 40, on the other hand, is responsible for supplying the fuel/air mixture to the variable volume combustion chambers. The throttle body 42 creates a pressure gradient when the engine assembly 10 is in an on-state.
[0037] The turbocharger device 14 is in fluid communication with the engine assembly 10. More specifically, the turbocharger device 14 includes a turbine portion 18 and a compressor portion 20. The turbine portion 18 has a turbine housing 22, which is in fluid communication with the exhaust manifold 30 via exhaust line 38. The turbine housing 22 redirects the flowing exhaust stream to spin a turbine blade or impeller, shown hidden in
[0038] The compressor portion 20 has a compressor housing 24 with a compressor blade, shown hidden in
[0039] Air compressed by the compressor portion 20 is communicated by compressor output duct or CAC inlet duct 46 to the CAC system 16, the compressor housing 24 being in upstream fluid communication with the CAC system 16. Those skilled in the art will recognize that the disclosure may incorporate a single turbocharger, twin turbochargers, staged turbochargers, or various other engine turbocharging or supercharging devices without departing from the intended scope of the disclosure.
[0040] Still referring to
[0041] The charge air output is routed from the compressor portion 20 of the turbocharger device 14 through the CAC or aftercooler system 16 before entering the intake manifold 40. To this regard, the CAC system 16 is positioned in downstream fluid communication with the turbocharger device 14, and in upstream fluid communication with the air intake system, including the air intake manifold 40 and throttle body 42. The CAC system 16 is configured to extract heat from compressed airflow or cool the air charge exiting the turbocharger device 14. Although condensate buildup is a phenomena normally associated with air-to-air charge air cooler devices, the CAC system 16 may also be of the air-to-liquid type heat exchanger.
[0042] The engine intake manifold 40 may include a MAP sensor 50 monitors intake manifold absolute pressure and ambient barometric pressure within the intake manifold. Preferably the MAP sensor 50 may be configured to monitor positive and negative pressures, and is thus able to monitor boost pressure in the intake manifold 40. A MAT sensor 52 monitors intake manifold air temperature. Other sensors and monitoring schemes may be employed for purposes of control and diagnostics. For example, exhaust gas sensors may monitor one or more exhaust gas parameters, e.g., air/fuel ratio, and exhaust gas constituents, and may be used as feedback for control and diagnostics and a combustion pressure sensor may be configured to monitor cylinder pressure, from which a mean-effective pressure or another suitable combustion parameter may be determined.
[0043] The CAC system 16 includes a CAC tank or housing 54 having an inlet portion at a first end 58 in fluid communication with the turbocharger device 14, an outlet portion in an opposing second end 60 in fluid communication with the air intake manifold 40 and a cavity defined therebetween. The cavity may be configured to receive a heat exchange core assembly 56 between the first end 58 and second end 60 of the housing 54. The first end 58 of the housing 54 may also be referred to as the “hot-end” or “upstream-end”, while the second end 60 of the housing 54 may also be referred to as the “cold-end” or “downstream-end.” The upstream or first end 58 provides a transition to allow the intake air from the turbocharger device 14 to flow from the compressor output duct 46 into the inner cooling tubes of the heat exchange core assembly 56 of the CAC system 16. The pressure of air at an inlet of the throttle 42 may be measured using a throttle inlet air pressure (TIAP) sensor 62. The TIAP sensor 62 may be located downstream from the throttle 42.
[0044] The upstream or first end 58 may be in upstream fluid communication with the downstream or second end 60 of the housing 54. The downstream end tank 60 provides a transition to allow the intake air to flow from the tubes of the CAC system 16 to an induction duct 48, for transfer to the throttle body 42. The throttle body 42 creates a pressure gradient when the engine assembly 10 is in an on-state. “Engine misfire” is a phenomena that may occur when a threshold volume of water condensation builds up inside of the CAC system 16, which is then ingested in undesirable volumes into the intake manifold 40 due a sudden increase in turbocharger airflow and air pressure, in response to the driver requesting a sudden acceleration of the vehicle.
[0045] Referring now to
[0046]
[0047] First flow path 70 and second flow path 72 in the housing 54 direct air flow from the CAC system 16 toward the first and second vents 66, 68. Induction duct 48 may include first and second channels 74, 76 respectively that are in fluid communication with the first and second vents 66, 68 to direct the air flow to the throttle 42. The CAC system 16, as also illustrated in
[0048] The at least one flow adjustment mechanism illustrated in
[0049] Alternatively, as is illustrated in
[0050] Referring now to
[0051] Referring now to
[0052] As is shown in greater detail in
[0053] Referring now to
[0054] The flap 96 shown in
[0055] The ECU, in response to information collected by one or more sensors, is in communication with and operably connected to the at least one flow adjustment mechanism to selectively position the flow adjustment mechanism in response to the sensor output. For example, the ECU may be in communication with a MAP sensor operatively coupled to the intake manifold such that the MAP sensor is capable of monitoring an intake manifold pressure. The ECU may be in communication with a MAF sensor operatively coupled to the air cleaner or clean air duct such that the MAF sensor is capable of monitoring mass airflow into the turbocharger.
[0056] Alternatively, the ECU may be in communication with a mass airflow sensor disposed between the engine air inlet and filter and the turbocharger device to measure air or ambient temperature and ambient humidity conditions. Further, the ECU may be in communication with a MAT sensor operatively coupled to the intake manifold such that the MAT sensor is capable of monitoring an intake manifold temperature.
[0057] Condensation may gather inside a CAC system in a high humidity environment as detected by the mass airflow sensor and where the air flow is reduced through the CAC system as a result of continuous low engine airflow as detected by the MAF sensor. The moisture resulting from condensation may create a potential engine misfire if the engine output is increased in response to a vehicle acceleration condition. An icing condition may exist in a CAC system where the ambient temperature of the environment in which the engine operates is below about minus ten (−10) degrees Celsius as detected by the mass airflow sensor and where the engine PCV system is venting crankcase moisture into the turbocharger and CAC system. Moisture from the PCV system may then freeze inside the CAC, increasing CAC internal air pressure drop and eventually causing a turbo underboost condition.
[0058] In one embodiment of the disclosure, the ECU will selectively position the at least one flow adjustment mechanism to a position which allows turbocharger airflow to completely bypass the CAC system. The ECU will detect an icing condition when the ambient air temperature detected by the mass airflow sensor is below about minus ten (−10) degrees Celsius. Upon detection of this condition, the ECU will then determine if the MAT sensor or air temperature from the TIAP sensor is detected below about zero degrees Celsius and if the MAP sensor detects a pressure above which the PCV system vents crankcase moisture into the CAC system, the ECU will adjust the at least one flow adjustment mechanism to a position which substantially bypasses the CAC system.
[0059] Alternatively, the ECU will selectively position the at least one flow adjustment mechanism in a substantially closed position to reduce the number of active cooling tubes in the heat exchange core assembly to adjust the air velocity and to manage condensation inside the CAC system when a condensation condition may exist. The ECU will detect a condensation condition when the ambient air temperature detected by the mass airflow sensor is above zero (0) degrees Celsius and the engine air inlet humidity or ambient humidity is high. Upon detection of this condition, if the MAF sensor detects that engine airflow is low and the MAT sensor or air temperature from the TIAP sensor is detected below about thirty-five (35) degrees Celsius, the ECU will adjust the at least one flow adjustment mechanism to a substantially closed position.
[0060] The detailed description and the drawings or figures are supportive and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims. Furthermore, the embodiments shown in the drawings or the characteristics of various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each of the characteristics described in one of the examples of an embodiment can be combined with one or a plurality of other desired characteristics from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the scope of the appended claims.