Abstract:
A condensation collection system for an internal combustion engine having an exhaust gas recirculation system comprises a condensation collection line, a condensation accumulator, and a condensation expulsion line. The condensation collection line is disposed in fluid communication with an air intake system of an internal combustion engine. The condensation accumulator is in fluid communication with the condensation collection line. The condensation collection line being disposed between the air intake system and the condensation accumulator. The condensation expulsion line is in fluid communication with the condensation accumulator. A portion of the condensation expulsion line is disposed in contact with an engine exhaust pipe. The condensation expulsion line has an opening to vent condensation to the atmosphere.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates to a system for removing condensation from an air intake system of an engine, and more particularly to a system for removing condensation from the air intake system of the engine and venting the condensation to the atmosphere. 
       BACKGROUND 
       [0002]    Many modern diesel engines have an exhaust system that features an exhaust gas recirculation (“EGR”) system that routes a portion of engine exhaust gas into an air intake system, such that a mixture of fresh air and engine exhaust is supplied to a combustion chamber during engine operation. One element of engine exhaust from the combustion of diesel fuel is water vapor. In certain instances, the EGR system additionally includes an EGR cooler that reduces the temperature of the exhaust gas in the EGR system, prior to mixing the exhaust gas with fresh air. However, as EGR levels have increased to meet more stringent environmental concerns and emissions requirements, formation of condensation within the air intake system from the water vapor generated during combustion has increased to a level that can be problematic. The increased level of condensation may cause damage to engine components, or may adversely affect combustion of fuel within the engine. Therefore, a need exists for a system to control an amount of condensation present within the air intake system. 
       SUMMARY 
       [0003]    According to one embodiment, a condensation collection system for an internal combustion engine that has an air intake system, an exhaust system, and an exhaust gas recirculation system is provided. The condensation collection system comprises a first condensation drain line, a first condensation drain line flow valve, a second condensation drain line, a second condensation drain line flow valve, and a condensation discharge port. The first condensation drain line is disposed between an air intake system and an exhaust system of an internal combustion engine. The first condensation drain line is disposed in fluid communication with the air intake system and the exhaust system of the internal combustion engine. The first condensation drain line flow valve is disposed within the first condensation drain line. The first condensation drain line flow valve is positionable between an open position and a closed position. The first condensation drain line flow valve controls fluid communication of the first condensation drain line with the exhaust system. The second condensation drain line is disposed between an exhaust gas recirculation cooler system and the exhaust system. The second condensation drain line is disposed in fluid communication with the exhaust gas recirculation cooler system and the exhaust system. The second condensation drain line flow valve is disposed within the second condensation drain line. The second condensation drain line flow valve is positionable between an open position and a closed position and controls fluid communication of the second condensation drain line with the exhaust system. The condensation discharge port is disposed within the exhaust system and connects at least one of the first condensation drain line and the second condensation drain line to the exhaust system. 
         [0004]    According to another embodiment, a condensation collection system for an internal combustion engine that has an air intake system, an exhaust system, and an exhaust gas recirculation system is provided. The condensation collection system comprises a condensation accumulator, a first condensation drain line, a first condensation drain line flow valve, a second condensation drain line, a second condensation drain line flow valve, a condensation injection line, and a condensation discharge port. The condensation accumulator has a plurality of inputs, a vent output, and a drain output. The vent output is in fluid communication with an exhaust system of an internal combustion engine. The drain output is in fluid communication with an air intake system of the internal combustion engine. The first condensation drain line is disposed between an air intake system and the condensation accumulator. The first condensation drain line is disposed in fluid communication with the air intake system and at least one of the plurality of inputs of the condensation accumulator. The first condensation drain line flow valve is disposed within the first condensation drain line. The first condensation drain line flow valve is positionable between an open position and a closed position and controls fluid communication of the first condensation drain line with the condensation accumulator. The second condensation drain line is disposed between an exhaust gas recirculation cooler system and the condensation accumulator. The second condensation drain line is disposed in fluid communication with the exhaust gas recirculation cooler system and the condensation accumulator. The second condensation drain line flow valve is disposed within the second condensation drain line. The second condensation drain line flow valve is positionable between an open position and a closed position and controls fluid communication of the second condensation drain line with the condensation accumulator. The condensation injection line is disposed between the drain output of the condensation accumulator and the air intake system. The condensation discharge port is disposed within the air intake system. The condensation discharge port connects to the condensation injection line. 
         [0005]    According to a further embodiment, a condensation collection system for an internal combustion engine that has an air intake system, an exhaust system, and an exhaust gas recirculation system is provided. The condensation collection system comprises a condensation accumulator, a first condensation drain line, a first condensation drain line flow valve, a second condensation drain line, a second condensation drain line flow valve, a condensation injection line, and a condensation discharge port. The condensation accumulator has plurality of inputs, a vent output, and a drain output. The vent output is in fluid communication with an exhaust system of an internal combustion engine. The drain output is in fluid communication with an exhaust gas recirculation system of the internal combustion engine. The first condensation drain line is disposed between an air intake system and the condensation accumulator. The first condensation drain line is disposed in fluid communication with the air intake system and at least one of the plurality of inputs of the condensation accumulator. The first condensation drain line flow valve is disposed within the first condensation drain line. The first condensation drain line flow valve is positionable between an open position and a closed position. The first condensation drain line flow valve controls fluid communication of the first condensation drain line with the condensation accumulator. The second condensation drain line is disposed between an exhaust gas recirculation cooler system and the condensation accumulator. The second condensation drain line is disposed in fluid communication with the exhaust gas recirculation cooler system and the condensation accumulator. The second condensation drain line flow valve is disposed within the second condensation drain line. The second condensation drain line flow valve is positionable between an open position and a closed position and controls fluid communication of the second condensation drain line with the condensation accumulator. The condensation injection line is disposed between the drain output of the condensation accumulator and the exhaust gas recirculation system. The condensation discharge port is disposed within the exhaust gas recirculation system. The condensation discharge port connects to the condensation injection line. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a schematic diagram showing an engine having an exhaust system with an EGR system and an air intake system with a condensation controlling system according to one embodiment. 
           [0007]      FIG. 2  is a schematic diagram showing an engine having an exhaust system with an EGR system and an air intake system with a condensation controlling system according to another embodiment. 
           [0008]      FIG. 3  is a schematic diagram showing an engine having an exhaust system with an EGR system and an air intake system with a condensation controlling system according to a further embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0009]      FIG. 1  shows an engine  10  having an exhaust system  12 . The exhaust system  12  comprises a first turbine  14   a  and a second turbine  14   b  such as, for example, for turbochargers. the exhaust system  12  also has an exhaust gas recirculation (EGR) system  16 . The EGR system  16  has an EGR cooler  18  that reduces the temperature of exhaust within the EGR system  16 . 
         [0010]    The EGR system  16  additionally comprises an EGR connection  22  that delivers exhaust from the EGR system  16  to an air intake system  24 . The air intake system  24  delivers fresh air as well as exhaust gas that has passed through the EGR cooler  18  to the engine  10  for use during combustion. The air intake system  24  includes fresh air input  20  that provides fresh air to the engine  10  that may be mixed with the exhaust gas from the EGR system  16 . The air intake system comprises a first compressor  26   a,  and a second compressor  26   b,  such as from turbochargers, and a charge air cooler  28  that reduces the temperature of intake air within the air intake system  24 . 
         [0011]    The air intake system  24  additionally has a condensation drain  30  that connects to a first condensation drain line  32 . The first condensation drain  32  line is disposed between the air intake system  24  and the exhaust system  12 . The first condensation drain line  32  is in fluid communication with the air intake system  24  and the exhaust system  12 . 
         [0012]    A first condensation drain line flow valve  34  is disposed within the first condensation drain line  32 . The first condensation drain line flow valve  34  is positionable between an open position and a closed position to control fluid communication between the air intake system  24  and the exhaust system  12  through the first condensation drain line  32 . 
         [0013]    The EGR system  16  additionally has a condensation drain  36  that connects to a second condensation drain line  38 . The second condensation drain line  38  is disposed between the EGR system  16  and the exhaust system  12 . The second condensation drain line  38  is in fluid communication with the EGR system  16  and the exhaust system  12 . As shown in  FIG. 1 , the condensation drain  36  of the EGR system  16  is disposed on the EGR cooler  18 , but it is also contemplated that the condensation drain  36  may be elsewhere on the EGR system  16 . 
         [0014]    A second condensation drain line flow valve  40  is disposed within the second condensation drain line  38 . The second condensation drain line flow valve  40  is positionable between an open position and a closed position to control fluid communication between the EGR system  16  and the exhaust system  12  through the second condensation drain line  38 . 
         [0015]    A condensation discharge port  42  is additionally provided within the exhaust system  12 . As shown in  FIG. 1 , the condensation discharge port  42  connects to the first condensation drain line  32  and the second condensation drain line  38 , however, it is contemplated that a separate condensation discharge port may be provided for the first condensation drain line  32  and the second condensation drain line  38 . 
         [0016]      FIG. 2  depicts an engine  110  having an exhaust system  112 . The exhaust system  112  comprises a first turbine  114   a  and a second turbine  14   b  such as, for example, for turbochargers. The exhaust system  12  also has an exhaust gas recirculation (EGR) system  116 . The EGR system  116  has an EGR cooler  118  that reduces the temperature of exhaust within the EGR system  116 . 
         [0017]    The EGR system  116  additionally comprises an EGR connection  122  that delivers exhaust from the EGR system  116  to an air intake system  124 . The air intake system  124  delivers fresh air as well as exhaust gas that has passed through the EGR cooler  118  to the engine  110  for use during combustion. The air intake system  124  includes fresh air input  120  that provides fresh air to the engine  110  that may be mixed with the exhaust gas from the EGR system  116 . The air intake system  124  comprises a first compressor  126   a,  and a second compressor  126   b,  such as from turbochargers, and a charge air cooler  128  that reduces the temperature of intake air within the air intake system  124 . 
         [0018]    The air intake system  124  additionally has a condensation drain  130  that connects to a first condensation drain line  132 . The first condensation drain line  132  is disposed between the air intake system  124  and a condensation accumulator  150 . The first condensation drain line  132  is in fluid communication with the air intake system  124  and the at least one input  152  of the condensation accumulator  150 . 
         [0019]    A first condensation drain line flow valve  134  is disposed within the first condensation drain line  132 . The first condensation drain line flow valve  134  is positionable between an open position and a closed position to control fluid communication between the air intake system  124  and the condensation accumulator  150  through the first condensation drain line  132 . The first condensation drain line flow valve  134  additionally is a backflow valve, in that it prevents fluid flow from the condensation accumulator to the condensation drain  130  of the air intake system  124 . 
         [0020]    The EGR system  116  additionally has a condensation drain  136  that connects to a second condensation drain line  138 . The second condensation drain line  138  is disposed between the EGR system  116  and at least a second input  154  of the condensation accumulator  150 . The second condensation drain line  138  is in fluid communication with the EGR system  116  and the condensation accumulator  150 . As shown in  FIG. 2 , the condensation drain  136  of the EGR system  116  is disposed on the EGR cooler  118 , but it is also contemplated that the condensation drain  136  may be elsewhere on the EGR system  116 . 
         [0021]    A second condensation drain line flow valve  140  is disposed within the second condensation drain line  138 . The second condensation drain line flow valve  140  is positionable between an open position and a closed position to control fluid communication between the EGR system  116  and the condensation accumulator  150  through the second condensation drain line  138 . 
         [0022]    The condensation accumulator  150  additionally has a vent output  156 , and a drain output  158 . The vent output  156  connects via a vent line  160  to the exhaust system  112 . A vent control valve  162  may be provided within the vent line  160  to control fluid communication between the condensation accumulator  150  and the exhaust system  112 . The drain output  158  is connected via a condensation injection line  164  to the air intake system  124 . The condensation injection line  164  connects to the air intake system  124  at a condensation discharge port  166 . A condensation injection pump  168  is depicted within the condensation injection line  164  between the condensation accumulator  150  and the condensation discharge port  166 . The condensation injection pump  168  delivers condensation collected within the condensation accumulator  150  to the condensation discharge port  166  such that the condensation may be injected into the air intake system  124 . It is contemplated that gravity may be used to introduce condensation from the condensation accumulator  150  into the condensation discharge port  166  in place of the condensation injection pump  168 . 
         [0023]    Turning now to  FIG. 3 , an engine  210  having an exhaust system  212  is shown. The exhaust system  212  comprises a first turbine  214   a  and a second turbine  214   b  such as, for example, for turbochargers. The exhaust system  12  also has an exhaust gas recirculation (EGR) system  216 . The EGR system  216  has an EGR cooler  218  that reduces the temperature of exhaust within the EGR system  216 . 
         [0024]    The EGR system  216  additionally comprises an EGR connection  222  that delivers exhaust from the EGR system  216  to an air intake system  224 . The air intake system  224  delivers fresh air as well as exhaust gas that has passed through the EGR cooler  218  to the engine  210  for use during combustion. The air intake system  224  includes fresh air input  220  that provides fresh air to the engine  210  that may be mixed with the exhaust gas from the EGR system  216 . The air intake system  224  comprises a first compressor  226   a,  and a second compressor  226   b,  such as from turbochargers, and a charge air cooler  228  that reduces the temperature of intake air within the air intake system  224 . 
         [0025]    The air intake system  224  additionally has a condensation drain  230  that connects to a first condensation drain line  232 . The first condensation drain line  232  is disposed between the air intake system  224  and a condensation accumulator  250 . The first condensation drain line  232  is in fluid communication with the air intake system  224  and the at least one input  252  of the condensation accumulator  250 . 
         [0026]    A first condensation drain line flow valve  234  is disposed within the first condensation drain line  232 . The first condensation drain line flow valve  234  is positionable between an open position and a closed position to control fluid communication between the air intake system  224  and the condensation accumulator  250  through the first condensation drain line  232 . The first condensation drain line flow valve  234  additionally is a backflow valve, in that it prevents fluid flow from the condensation accumulator  250  to the condensation drain  230  of the air intake system  224 . 
         [0027]    The EGR system  216  additionally has a condensation drain  236  that connects to a second condensation drain line  238 . The second condensation drain line  238  is disposed between the EGR system  216  and at least a second input  254  of the condensation accumulator  250 . The second condensation drain line  238  is in fluid communication with the EGR system  216  and the condensation accumulator  250 . As shown in  FIG. 3 , the condensation drain  236  of the EGR system  216  is disposed on the EGR cooler  218 , but it is also contemplated that the condensation drain  236  may be elsewhere on the EGR system  216 . 
         [0028]    A second condensation drain line flow valve  240  is disposed within the second condensation drain line  238 . The second condensation drain line flow valve  240  is positionable between an open position and a closed position to control fluid communication between the EGR system  216  and the condensation accumulator  250  through the second condensation drain line  238 . It is contemplated that the second condensation drain line flow valve  240  is also a backflow valve. 
         [0029]    The condensation accumulator  250  additionally has a vent output  256 , and a drain output  258 . The vent output  256  connects via a vent line  260  to the exhaust system  212 . A vent control valve  262  may be provided within the vent line  260  to control fluid communication between the condensation accumulator  250  and the exhaust system  212 . The drain output  258  is connected via a condensation injection line  264  to the exhaust system  212 . The condensation injection line  264  connects to the exhaust system  212  at a condensation discharge port  266 . The condensation discharge port  266  is shown as being upstream of the EGR system  216 , but it is also contemplated that the condensation discharge port  266  may be located downstream of the location the EGR system  216  connects to the exhaust system  212 . A condensation injection pump  268  is depicted within the condensation injection line  264  between the condensation accumulator  250  and the condensation discharge port  266 . The condensation injection pump  268  delivers condensation collected within the condensation accumulator  250  to the condensation discharge port  266  such that the condensation may be injected into the exhaust system  212 . It is contemplated that gravity may be used to introduce condensation from the condensation accumulator  250  into the condensation discharge port  266  in place of the condensation injection pump  268 .