Air Intake Modules with Integrated Indirect Charge Air Coolers

Abstract

Gasoline downsizing and turbocharging has become a key contributor to respect future legislation regarding CO2 emissions and engine dynamics. In turbocharged engines, increasing charge pressure will cause rising charge air temperatures. Increased charge air temperatures also increase the thermal strain on charge air cooler and air intake module, and have a negative effect on combustion. As a result, the engine’s response characteristics and torque output will deteriorate, accompanied by increased fuel consumption. By cooling the charge air, combustion is improved significantly, and the tendency to knocking decreases. At full load, the spark can be advanced, and combustion can be more efficient. Due to the higher mass flow, the turbocharger will also respond more readily. At lower engine speeds, this will lead to improved dynamics and torque. At high speed and load, the cooled charge air will also reduce the requirements for overfueling and thus fuel consumption. We have investigated the effects of charge air temperature on combustion in a 1.2 L three-cylinder gasoline engine. Our results show improvements in consumption, torque and dynamics. At increasing specific and absolute engine performance, even higher potentials can be expected.