Intercooler condensate to sump or positive crankcase ventilation flow

• US 9,181,853 B2
• Filed: 12/06/2012
• Issued: 11/10/2015
• Est. Priority Date: 12/06/2012
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Leone, Thomas G., Czekala, Michael Damian
• Primary Examiner(s): Trieu, Thai Ba
• Assistant Examiner(s): KEBEA, JESSICA L
• Application Number:
  US13/707,468
• Publication Number:
  US 20140158096A1
• Time in Patent Office: 1,069 Days
• Field of Search: 605/99, 123572-574, 123/563
• US Class Current: 1/1
• CPC Class Codes: F01M 13/00 Crankcase ventilating or breathing
• CPC Class Codes: F01M 13/028 of positive pressure
• CPC Class Codes: F02B 29/0468 Water separation or drainage means
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Methods and systems are provided for removing condensate from a charge air cooler. Condensate may be drained from the charge air cooler and introduced into a positive crankcase ventilation flow or an engine oil sump. Introducing condensate into the engine oil sump may be controlled based on conditions of the engine oil sump and stored condensate.

Claims

1. An engine method for removing condensate from a charge air cooler, comprising:

automatically draining water condensate from the charge air cooler to a liquid storage reservoir;

adjusting a drain valve in the liquid storage reservoir in response to conditions of the liquid storage reservoir and an engine oil sump to introduce drained condensate to the engine oil sump; and

evaporating at least a portion of the drained condensate in the liquid storage reservoir and directing the evaporated portion to a PCV flow.

2. The method of claim 1, wherein the liquid storage reservoir is positioned adjacent to a block of the engine.

3. The method of claim 1, wherein the liquid storage reservoir is positioned adjacent to an exhaust manifold.

4. The method of claim 1, further comprising directing the PCV flow into the engine.

5. The method of claim 4, further comprising adjusting the drain valve based on at least one of a pressure difference between the liquid storage reservoir and the engine oil sump, a liquid condensate level in the liquid storage reservoir, an oil temperature, a fluid level in the engine oil sump, and an estimated rate of evaporation in the engine oil sump.

6. An engine method for removing condensate from a charge air cooler, comprising:

automatically draining water condensate from the charge air cooler to a liquid storage reservoir; and

adjusting a drain valve in the liquid storage reservoir in response to conditions of the liquid storage reservoir and an engine oil sump, where the conditions include a fluid level in the engine oil sump, a liquid condensate level in the liquid storage reservoir, an oil temperature in the engine oil sump, and a pressure difference between the liquid storage reservoir and the engine oil sump.

7. The method of claim 6, wherein the adjusting includes controlling an opening of the drain valve to a flow rate of fluid into the engine oil sump.

8. The method of claim 7, wherein the flow rate is determined based on at least one of the fluid level in the engine oil sump, the oil temperature in the engine oil sump, an evaporation rate of fluid in the engine oil sump, and an amount of liquid condensate in the liquid storage reservoir.

9. The method of claim 6, wherein the adjusting includes opening the drain valve responsive to the liquid condensate level in the liquid storage reservoir being greater than a first threshold level, the oil temperature being greater than a threshold temperature, the pressure difference between the liquid storage reservoir and the engine oil sump being within a threshold range, and the fluid level in the engine oil sump being less than a threshold fluid level.

10. The method of claim 9, further comprising, closing the drain valve when one or more of the liquid condensate level in the liquid storage reservoir reaches a second threshold level, the fluid level in the engine oil sump reaches the threshold fluid level, and the pressure difference between the liquid storage reservoir and the engine oil sump is outside the threshold range.

11. The method of claim 9, wherein the threshold temperature is based on an oil temperature at which drained condensate evaporates.

12. The method of claim 9, wherein the threshold range of pressure difference between the liquid storage reservoir and the engine oil sump corresponds to a threshold flow rate of fluid into the engine oil sump, the threshold flow rate of fluid based on the fluid level in the engine oil sump, the oil temperature in the engine oil sump, and an estimated fluid evaporation rate in the engine oil sump.

13. The method of claim 9, wherein the threshold fluid level is based on one or more of the oil temperature in the engine oil sump and an estimated fluid evaporation rate in the engine oil sump.

14. The method of claim 13, wherein the threshold fluid level increases with one or more of increasing oil temperature in the engine oil sump and an increasing estimated fluid evaporation rate in the engine oil sump.

15. An engine system for removing condensate from a charge air cooler, comprising:

an engine including a cylinder head, an engine block, and an engine oil sump;

a positive crankcase ventilation system, with a positive crankcase ventilation flow path leading into an engine intake manifold;

the charge air cooler with an automatic drain tube to drain water condensate from the charge air cooler to a liquid storage reservoir,

the liquid storage reservoir positioned adjacent to the engine block for storing liquid condensate in the liquid storage reservoir and evaporating a portion of the drained liquid water condensate into water vapor directed to the positive crankcase ventilation flow path;

a drain valve, connected between the liquid storage reservoir and engine oil sump; and

a controller with non-transitory computer readable executable instructions to adjust a position of the drain valve to control flow of liquid from the liquid storage reservoir into the engine oil sump responsive to a fluid level in the engine oil sump.

16. The system of claim 15, wherein the executable instructions further include executable instructions to adjust the position of the drain valve responsive to a liquid condensate level in the liquid storage reservoir.