Condensation control system for engine

A system for controlling condensation of water within an intake manifold of an engine is disclosed. The system may have a humidity sensor. The humidity sensor may be configured to generate a signal indicative of a humidity of intake air. The system may also have a controller communicably coupled to the humidity sensor. The controller may be configured to receive the signal indicative of the humidity of the intake air. The controller may be also configured to control an operational parameter of at least one of the engine and an engine component to maintain the humidity of the intake air within the intake manifold below a predetermined threshold.

CLAIM FOR PRIORITY

This application claims benefit of priority of European Patent Application No. 14175997.7, filed Jul. 7, 2014, which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to condensation control in an engine system, and more specifically to control condensation within an intake manifold of the engine.

BACKGROUND

An internal combustion engine employing a turbocharger may additionally employ an aftercooler arrangement. During high power condition of the engine and high humidity of intake air, moisture present in the intake air may condense within the intake manifold. Further, the condensation of the moisture may occur within the aftercooler itself or downstream of the aftercooler with respect to a flow direction of the intake air in the system.

The condensed moisture may affect the health of one or more engine components. For example, the condensed moisture may mix with depositions present in the engine components and may form unwanted compounds detrimental to health of the engine components. These unwanted compounds may destroy the engine components such as, the aftercooler, mixers, tubes, and other such devices.

Hence, there is a need for a system to control condensation of the moisture within the engine.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a system for controlling condensation of water within an intake manifold of an engine is provided. The system includes a humidity sensor configured to generate a signal indicative of a humidity of intake air. The system also includes a controller communicably coupled to the humidity sensor. The controller is configured to receive the signal indicative of the humidity of the intake air. The controller is also configured to control an operational parameter of at least one of the engine and an engine component to maintain the humidity of the intake air within the intake manifold below a predetermined threshold.

In another aspect of the present disclosure, a method for controlling condensation of water within an intake manifold of an engine is provided. The method includes receiving a signal indicative of a humidity of intake air. The method also includes controlling an operational parameter of at least one of the engine and an engine component to maintain the humidity of the intake air within the intake manifold below a predetermined threshold.

DETAILED DESCRIPTION

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts. Referring toFIG. 1, an exemplary engine system100is illustrated. The engine system100includes an engine102. The engine102is embodied as an internal combustion engine powered by diesel fuel. In other embodiments, the engine102may be powered by any other fuel such as, gasoline, natural gas, a combination thereof and so on. In yet other embodiments, the engine102may be a gas turbine engine.

The engine system100includes a turbocharger104provided in fluid communication with the engine102. More specifically, the turbocharger104is provided upstream of the engine102with respect to a flow direction of intake air. Further, the turbocharger104is provided in fluid communication with an intake manifold106associated with the engine102. The turbocharger104includes a compressor108drivably coupled to a turbine110. The turbine110is driven by exhaust gas exiting from an exhaust manifold112associated with the engine102which in turn drives the compressor108. The compressor108is configured to compress and increase a density of the intake air before being supplied to the intake manifold106.

Further, the engine system100includes an engine component114such as, an aftercooler116, provided downstream of the turbocharger104with respect to the flow direction of the intake air. The aftercooler116is provided in fluid communication with the compressor108and the intake manifold106. The aftercooler116is configured to reduce a temperature of the intake air downstream of the compressor108before being supplied to the intake manifold106. In other embodiments, the engine component114may be an intercooler (not shown). The intercooler may be provided within the turbocharger104, and more specifically, between consecutive stages of compression of the intake air. For the purpose of explanation of the disclosure, the engine component114considered hereinafter is the aftercooler116. It should be noted that the disclosure may apply to the intercooler or a combination thereof without any limitations.

The engine system100includes a controller118. The controller118may be positioned internal or external to the engine102. The controller118is communicably coupled to the engine102and/or the aftercooler116and will be explained in detail with reference toFIG. 2. The controller118may embody a single microprocessor or multiple microprocessors for receiving signals from components of the condensation control system200. Numerous commercially available microprocessors may be configured to perform the functions of the controller118. It should be appreciated that the controller118may embody a machine microprocessor capable of controlling numerous machine functions. A person of ordinary skill in the art will appreciate that the controller118may additionally include other components and may also perform other functions not described herein.

The present disclosure relates to a condensation control system200for the engine102. Referring toFIG. 2, a block diagram of the condensation control system200is illustrated. The condensation control system200is configured to control condensation of water within a component associated with the engine102such as, the intake manifold106. The condensation control system200includes a humidity sensor202associated with the engine102. The humidity sensor202is positioned within the engine102. More specifically, the humidity sensor202is positioned within the intake manifold106. The humidity sensor202is configured to generate a signal indicative of humidity of the intake air within the intake manifold106. This humidity of the intake air may be an estimate of a relative humidity of the intake present within the intake manifold106.

The condensation control system200includes the controller118communicably coupled to the humidity sensor202. Accordingly, the controller118is configured to receive the signal indicative of the humidity of the intake air. Based on the received signal indicative of the humidity of the intake air, the controller118is configured to control an operational parameter of at least one of the engine102and the aftercooler116to maintain the humidity of the intake air within the intake manifold106below a predetermined threshold. The predetermined threshold may be a value of a threshold relative humidity. The controller118may be configured to retrieve a value of the predetermined threshold by referring to a map or a lookup table stored in a database204communicably coupled to the controller118. In other embodiments, the value of the predetermined threshold may be stored in a memory (not shown) of the controller118.

For example, when the predetermined threshold may be 100%, the controller118may be configured to control the operational parameter of the at least one of the engine102and the aftercooler116to maintain the humidity of the intake air below 100%. It should be noted that the value of the predetermined threshold described herein is merely exemplary and may vary as per system design and configuration. More specifically, a temperature of the intake air within the intake manifold106may be altered to modify the humidity of the intake air.

The operational parameter of the engine102may include at least one of a speed of the engine102and a power output of the engine102such as, a torque output of the engine102. For example, when the humidity of the intake air within the intake manifold106may be approximately equal or higher than the predetermined threshold, the engine102may be de-rated to reduce the power output and/or the speed of the engine102. The de-rating of the engine102may reduce a pressure within the intake manifold106. The reduction of pressure within the intake manifold106may in turn lower the humidity of the intake air below the predetermined threshold. Further, the de-rating of the engine102may be stopped when the humidity of the intake air within the intake manifold106may fall below the predetermined threshold. It should be noted that the operational parameter of the engine102may be controlled in numerous ways known to one skilled in the art. The techniques of controlling the operational parameter of the engine102described herein are exemplary and do not limit the scope of the disclosure.

The operational parameter of the aftercooler116may be at least one of a state of the aftercooler116and a temperature of the aftercooler116. For example, when the humidity of the intake air within the intake manifold106may be approximately equal or higher than the predetermined threshold, the aftercooler116may be temporarily switched off to raise the temperature of the intake air. Raising the temperature of the intake air may lower the humidity of the intake air. Further, the aftercooler116may be switched on when the humidity of the intake air may fall below the predetermined threshold. In other embodiments, the temperature of the aftercooler116may be modified in order to change the temperature, and thus the humidity, of the intake air within the intake manifold106. It should be noted that the aftercooler116may be controlled in numerous ways known to one skilled in the art. The techniques of controlling the aftercooler116described herein are exemplary and do not limit the scope of the disclosure.

In another configuration of the condensation control system200, the condensation control system200may include at least one intake air parameter sensor206, hereinafter referred to as the IAP sensor206. The IAP sensor206is configured to generate a signal indicative of at least one parameter of the intake air. The IAP sensor206includes a pressure sensor208. The pressure sensor208is positioned within the intake manifold106associated with the engine102. The pressure sensor208is configured to generate a signal indicative of a pressure of the intake air within the intake manifold106.

In other embodiments, the pressure of the intake air within the intake manifold106may be determined by the controller118from the operational parameters of the engine102including, but not limited to, the speed of the engine102, the power output of the engine102, and a load on the engine102. In such a situation, the controller118may determine the pressure of the intake air within the intake manifold106based on a pre-calibrated data set. The pre-calibrated data set may include a lookup table. The lookup table may be stored in the database204communicably coupled to the controller118or the memory (not shown) of the controller118. In other embodiments, the pre-calibrated data set may include a reference map stored in the database204or the memory of the controller118.

The lookup table and/or the reference map may include predetermined readings of the pressure of the intake air within the intake manifold106corresponding to different values of the operational parameters of the engine102. In yet other embodiments, the pre-calibrated data set may be a predetermined mathematical equation, relation, model or known algorithm. For example, a multiple polynomial regression model, a physics based model, a neural network model, any other model or algorithm, or a combination thereof known in the art.

Further, the IAP sensor206includes a temperature sensor210. In one embodiment, the temperature sensor210may be positioned at an inlet of the aftercooler116. Accordingly, the temperature sensor210may be configured to generate a signal indicative of a temperature of the intake air prior to entering the aftercooler116. In another embodiment, the temperature sensor210may be positioned at an inlet of the compressor108of the turbocharger104. Accordingly, the temperature sensor210may be configured to generate a signal indicative of the temperature of the intake air prior to entering the turbocharger104.

The condensation control system200also includes the humidity sensor202associated with the engine102. The humidity sensor202may be positioned at any location within or external to the engine102based on the position of the temperature sensor210. For example, in one embodiment, when the temperature sensor210may be positioned at the inlet of the aftercooler116, the humidity sensor202may also be positioned at the inlet of the aftercooler116. In another embodiment, when the temperature sensor210may be positioned at the inlet of the turbocharger104, the humidity sensor202may also be positioned at the inlet of the turbocharger104. It should be noted that the location of the humidity sensor202is merely exemplary and may vary as per system design and configuration. The humidity sensor202is configured to generate the signal indicative of humidity of the intake air.

The condensation control system200includes an intake manifold temperature sensor212, hereinafter referred to as the IMT sensor212. The IMT sensor212is positioned within the intake manifold106. The IMT sensor212is configured to generate a signal indicative of a current temperature of the intake air within the intake manifold106.

The condensation control system200includes the controller118communicably coupled to the humidity sensor202, the pressure sensor208and the temperature sensor210. Accordingly, the controller118is configured to receive the signal indicative of the humidity, the pressure and the temperature of the intake air respectively.

The controller118is further communicably coupled to the IMT sensor212. Accordingly, the controller118is configured to receive the signal indicative of the current temperature of the intake air within the intake manifold106. It should be noted that in other embodiments, the controller118may determine the current temperature of the intake air within the intake manifold106by any other methods known in the art. For example, the controller118may derive the current temperature of the intake air within the intake manifold106from the operational parameters of the engine102, such as, the speed of the engine102, the power output of the engine102, and so on.

In such a situation, the controller118may determine the current temperature of the intake air within the intake manifold106based on a pre-calibrated data set. The pre-calibrated data set may include a lookup table. The lookup table may be stored in the database204communicably coupled to the controller118or the memory (not shown) of the controller118. In other embodiments, the pre-calibrated data set may include a reference map stored in the database204or the memory of the controller118.

The lookup table and/or the reference map may include predetermined readings of the current temperature of the intake air within the intake manifold106corresponding to different values of the operational parameters of the engine102. In yet other embodiments, the pre-calibrated data set may be a predetermined mathematical equation, relation, model or known algorithm. For example, a multiple polynomial regression model, a physics based model, a neural network model, any other model or algorithm, or a combination thereof known in the art.

Based on the received signals, the controller118is configured to compare the humidity, the pressure, and the temperature of the intake air with a pre-calibrated dataset. Based, on the comparison, the controller118is further configured to determine a predetermined threshold to control the operational parameter of the at least one of the engine102and the aftercooler116. In such a situation, the predetermined threshold is a dew point temperature of the intake air within the intake manifold106.

In one embodiment, the pre-calibrated data set may include a lookup table. The lookup table may be stored in the database204communicably coupled to the controller118or a memory (not shown) of the controller118. In other embodiments, the pre-calibrated data set may include a reference map stored in the database204or the memory of the controller118.

The lookup table and/or the reference map may include predetermined readings of the dew point temperature corresponding to different values of the pressure of the intake air, the temperature of the intake air, and the humidity of the intake air. In yet other embodiments, the pre-calibrated data set may be a predetermined mathematical equation, relation, model or known algorithm. For example, a multiple polynomial regression model, a physics based model, a neural network model, any other model or algorithm, or a combination thereof known in the art.

Based on the determined dew point temperature, the controller118is further configured to control the operational parameter of the at least one of the engine102and the aftercooler116to maintain the current temperature of the intake air within the intake manifold106above the dew point temperature. The operational parameter of the engine102may include at least one of the speed of the engine102and the power output of the engine102such as, the torque output of the engine102. The operational parameter of the aftercooler116may be at least one of the state of the aftercooler116and the temperature of the aftercooler116.

For example, when the current temperature of the intake air within the intake manifold106may be approximately equal or lower than the dew point temperature, the aftercooler116may be temporarily switched off to raise the current temperature of the intake air above the dew point temperature. Further, the aftercooler116may be switched on when the current temperature of the intake air may rise above the dew point temperature. In other embodiments, the temperature of the aftercooler116may be modified in order to change the current temperature of the intake air within the intake manifold106. It should be noted that the aftercooler116may be controlled in numerous ways known to one skilled in the art. The techniques of controlling the aftercooler116described herein are exemplary and do not limit the scope of the disclosure.

In other embodiments, the controller118is configured to control the operational parameter of the engine102based on a pre-calibrated data set. In one embodiment, the pre-calibrated data set may include a lookup table. The lookup table may be stored in the database204communicably coupled to the controller118or the memory of the controller118. Accordingly, the pre-calibrated data set may include a reference map stored in the database204or the memory of the controller118. The lookup table and/or the reference map may include predetermined readings of the operational parameter of the engine102corresponding to different values of the current temperature of the intake air within the intake manifold106.

In yet other embodiments, the pre-calibrated data set may be a predetermined mathematical equation, relation, model or known algorithm. For example, a multiple polynomial regression model, a physics based model, a neural network model, any other model or algorithm, or a combination thereof known in the art. The controller118may retrieve the readings from the database204and compare the readings with the current temperature within the intake manifold106and the dew point temperature in order to control the speed or power output of the engine102. It should be noted that the methods described herein to maintain the current temperature within the intake manifold106above the dew point temperature are exemplary and do not limit the scope of the present disclosure.

INDUSTRIAL APPLICABILITY

The present disclosure relates to controlling condensation of water within the component associated with the engine such as, the intake manifold. The controller may control the operational parameter of the at least one of the engine and the engine component in order to maintain the humidity and/or the current temperature of the intake air within the intake manifold above the predetermined threshold. By maintaining the humidity and/or the current temperature of the intake air within the intake manifold above the predetermined threshold, the quantity of the water present in the intake air that may condense may be decreased, minimized or prevented as the case may be.

Referring toFIG. 3, a flowchart of the method300is illustrated. At step302, the controller118receives the signal indicative of the humidity of the intake air from the humidity sensor202. At step304, based on the received signal, the controller118controls the operational parameter of the at least one of the engine102and the aftercooler116to maintain the humidity of the intake air within the intake manifold106above the predetermined threshold. In such a situation, the predetermined threshold is the value of the threshold relative humidity.

The controller118controls the operational parameter of the at least one of the engine102and the aftercooler116based on the pre-calibrated data set. The operational parameter of the engine102may include the at least one of the speed of the engine102and the power output of the engine102. The operational parameter of the aftercooler116may include at least one of the state of the aftercooler116and the temperature of the aftercooler116.

In other embodiments, along with the signal indicative of the humidity of the intake air, the controller118also receives the signal indicative of the pressure of the intake air within the intake manifold106from the pressure sensor208. In other embodiments, the controller118may determine the pressure of the intake air within the intake manifold106from the operational parameters of the engine102including, but not limited to, the speed of the engine102, the power output of the engine102and the load on the engine102. Also, the controller118receives the signal indicative of the temperature of the intake air from the temperature sensor210.

Further, the controller118receives the signal indicative of the current temperature of the intake air within the intake manifold106from the IMT sensor212. In other embodiments, the controller118may determine the current temperature of the intake air within the intake manifold106from the operational parameters of the engine102, such as, the speed of the engine102, the power output of the engine102, and so on.

Based on the received signals, the controller118compares the humidity, the temperature, and the pressure of the intake air with the pre-calibrated data set. Based on the comparison, the controller118determines the predetermined threshold to control the operational parameter of at least one of the engine102and the engine component114. The engine component114may be at least one of the aftercooler116and the intercooler. In such a situation, the predetermine threshold is the dew point temperature of the intake air within the intake manifold106.

Based on the determined dew point temperature, the controller118controls the operational parameter of the engine102and/or the aftercooler116to maintain the current temperature of the intake air within the intake manifold106above the dew point temperature based on the pre-calibrated dataset. The operational parameter of the engine102may include at least one of the speed of the engine102and the power output of the engine102. The operational parameter of the aftercooler116may be at least one of the state of the aftercooler116and the temperature of the aftercooler116.