A Controllable Water Cooled Charge Air Cooler (WCCAC) for Diesel Trucks

Water-cooled charge air cooling is being considered as part of various technology solutions in response to 2007 US, 2010 US, EU4 and EU5 emissions standards. As manufacturers determine appropriate engine and vehicle solutions to meet the upcoming emissions standards, charge air cooling requirements are increasing due to higher turbocharger outlet temperatures and pressures, higher EGR rates, and requests for intake manifold temperature control to manage combustion and exhaust temperatures. Valeo and EMP have collaborated on the development and testing of a water cooled charge air cooler (WCCAC), controlled by a 12 volt brushless motor coolant pump. The system design addresses material temperature limitations of air-air aluminum CAC's and has the potential to simplify the packaging of the air induction system. Test results from the first prototype system show the ability of the system to increase intake manifold temperature under cold conditions, decrease the charge side system pressure loss by 79%, and control the intake manifold temperature under transient conditions and ambient temperature changes. The system nearly met the base cooling system performance in high ambient and high load conditions.