System and methods for engine air path condensation management

Patent metadata

Field	Value
Publication number	US-2016160744-A1
Application number	US-201615044984-A
Country	US
Kind code	A1
Filing date	Feb 16, 2016
Priority date	Dec 20, 2013
Publication date	Jun 9, 2016
Grant date	—

Abstract

A system and methods for routing condensate collected in a heat exchanger reservoir to either an air intake system or a position in the engine exhaust based on the type of contaminate in the condensate and operating parameters of the engine or the catalyst are described. In one particular example, condensate is routed to a first position along the engine air intake system in a first mode of operation, and a second position upstream of the catalyst along the engine exhaust in a second mode of operation, and a third position downstream of the catalyst along the engine exhaust in a third mode of operation. When substantially no contaminates are detected, the condensate may be routed into the engine exhaust upstream of the catalyst in order to cool the catalyst.

First claim

1 . A method, comprising:
routing air through a heat exchanger and into one or more combustion chambers of an engine via an air intake system comprising an air intake coupled to an intake manifold which is coupled to one or more intake runners each of which is coupled to one of said combustion chambers; forming a condensate in said heat exchanger; and routing said condensate to either said combustion chamber or a position in an engine exhaust based upon a contaminate in said condensate and operating parameters of the engine or a catalyst coupled to the engine exhaust, said condensate routed to a first position along said engine air intake system in a first mode of operation, a second position along the engine exhaust in a second mode of operation, and a third position along the engine exhaust in a third mode of operation.

2 . The method recited in claim 1 , wherein said first mode of operation comprises engine operation at a high load with said contaminate including engine oil.

3 . The method recited in claim 1 , wherein said first mode of operation comprises engine operation under fuel enrichment conditions with said contaminate including engine oil.

4 . The method recited in claim 1 , wherein said second position along the engine exhaust is upstream of the catalyst and said second mode of operation comprises engine operation at a high load with said contaminate being substantially free of engine oil.

5 . The method recited in claim 1 , wherein said second mode of operation comprises the catalyst operating at a temperature inferred to be above a predetermined temperature with said contaminate being substantially free of engine oil.

6 . The method recited in claim 5 , wherein catalyst temperature is inferred from one or more of the following variables: combustion air/fuel ratio, exhaust gas recirculation, engine speed, ignition timing, and airflow through the engine.

7 . The method recited in claim 1 , further comprising reducing power to the engine when said contaminate includes engine coolant.

8 . The method recited in claim 1 , wherein said third position along the engine exhaust is downstream of the catalyst and said third mode of operation comprises engine operation at a low load and no significant engine oil is detected in said condensate.

9 . The method recited in claim 8 , wherein said third mode of operation with said condensate routed to said third position occurs more often than said second mode of operation with said condensate routed to said second position or said first mode of operation with said condensate routed to said first position.

10 . The method of claim 1 , wherein said heat exchanger comprises an air to air heat exchanger and includes a reservoir to collect said condensate.

11 . The method recited in claim 1 , wherein said heat exchanger comprises a liquid to air heat exchanger and said condensate is collected from said intake manifold.

12 . A method, comprising:
routing air through a heat exchanger and into one or more combustion chambers of an engine; forming a condensate in said heat exchanger; and routing said condensate to either said combustion chamber or a position in an engine exhaust based upon a contaminate in said condensate and operating parameters of the engine or a catalyst coupled to the engine exhaust, said heat exchanger comprising a liquid to air heat exchanger and said condensate collected from an intake manifold of an air intake system.

13 . The method of claim 12 , wherein the air intake system further comprises an air intake coupled to the intake manifold which is coupled to one or more intake runners each of which is coupled to one of said combustion chambers.

14 . The method recited in claim 12 , further comprising reducing power to the engine when said contaminate includes engine coolant.

15 . An engine system having an engine air intake and a light off catalyst coupled to an engine exhaust, comprising:
a turbocharger having a compressor driven by a turbo coupled to the engine exhaust upstream of the catalyst; a heat exchanger having an input coupled to the compressor and an outlet coupled to the air intake; a reservoir coupled to a bottom of the heat exchanger to collect condensate formed by the heat exchanger; and a controller to route the condensate to a first position along the engine air intake in a first mode of operation, a second position along the engine exhaust in a second mode of operation, and a third position along the engine exhaust in a third mode of operation.

16 . The system recited in claim 15 , further comprising:
a first metering valve coupled between the reservoir and the air intake; a second metering valve coupled between the reservoir and the engine exhaust upstream of the catalyst and downstream of the turbo; and a third metering valve coupled between the reservoir and the engine exhaust downstream of the catalyst.

17 . The system recited in claim 16 , wherein the first mode of operation comprises engine operation at a high load with the contaminate including engine oil, and wherein the controller activates the first metering valve during the first mode of operation.

18 . The system recited in claim 16 , wherein the second position along the engine exhaust is upstream of the catalyst and the second mode of operation comprises engine operation at a high load with the contaminate being substantially free of engine oil, and wherein the controller activates the second metering valve during the second mode of operation.

19 . The system recited in claim 16 , wherein the third position along the engine exhaust is downstream of the catalyst and the third mode of operation comprises engine operation at a low load and no significant engine oil is detected in the condensate, and wherein the controller activates the third metering valve during the third mode of operation.

20 . The system recited in claim 16 , wherein the controller activates the first metering valve when the engine is operating at a low or moderate load.

Assignees

• Ford Global Tech Llc

Inventors

• Wicks Christopher Donald
• Maceroni Karen Elizabeth
• Madin Mark Michael

Classifications

• F02B37/00

  Engines characterised by provision of pumps driven at least for part of the time by exhaust · CPC title

• F02B29/0468 Primary

  Water separation or drainage means · CPC title

• F02M35/10268

  Heating, cooling or thermal insulating means (air coolers F02B29/04; thermal treatment of combustion-air, fuel or fuel-air mixture F02M31/00; details of the throttle valve housing F02D9/1035) · CPC title

• F02D41/0025

  Controlling engines characterised by use of non-liquid fuels, pluralities of fuels, or non-fuel substances added to the combustible mixtures · CPC title

• F02M25/028

  into the charge intakes · CPC title