The role of intercooler on supercharged engine


When the air is compressed by the supercharger, the temperature rises, which is a basic physical principle. How much does the gas temperature increase after pressurization? This depends on the operating conditions of the supercharger. The higher the speed, the greater the boost pressure, the higher the temperature rise, and generally it can rise 40-60. About °C, plus the original temperature of the air, the pressurized gas has been very hot.

The reason why the intercooler and the supercharger are facing dry air is because the intercooler will increase the air resistance, so that the pressure of the pressurized air will drop, leading to a reduction in the supercharging effect and a slower engine response, but this effect is comparable to The effect of the cooler on the power of the engine is insignificant.

The impact of high-temperature gas on the engine is mainly in two points: First, the air volume is large, which means that the amount of air sucked by the engine becomes less; and the second point is more important, high-temperature air is particularly unfavorable for the engine combustion, power will be reduced, Emissions will deteriorate. Under the same combustion conditions, the engine power drops by about 3%-5% for every 10°C increase in charge air temperature. This problem is very serious. The increased power will eventually be offset by high air temperatures. To solve these problems, we need to re-cool the pressurized air and send it to the engine. The component that bears this heavy responsibility is the intercooler. The principle and structure of the intercooler are similar to those of household refrigerators and air conditioners.

Air cooling and water cooling

To cool the air, there are nothing more than two methods. One is to cool down through the cold air that hits the surface when the vehicle is driving, and the other is to use water cooling. The principle of the former is the same as that of our domestic refrigerators and air conditioners. It is to let the air pass through a root pipe, increase the contact area between the pipe and the surrounding air, and then cool it by the surrounding air.

Water cooling is just the opposite of wind cooling. Is a cooler, shape and principle and air-cooled intercooler basically the same into the intake pipe, so that the pressurized hot air flow. In the cooler, there is constant flow of cooling water, which takes away the heat of the pressurized air.

Side effects: Engine response slows, turbo lag becomes serious

In general, the larger the intercooler, the smaller the airflow loss and the higher the cooling efficiency. The longer the airflow stays inside the intercooler, the better the cooling effect. However, an intercooler is like an increase in the volume of the intake pipe. The compressed air produced by the supercharger must first fill this volume before it can produce supercharging effect. If used on turbocharger, the direct performance effect is that the turbo lag becomes serious; even mechanical supercharged machines will cause the engine to respond slowly.

On the other hand, because the pressurized air has to flow through various pipes, the resistance increases, and its boost pressure is sure to be weakened. However, this weakening occurs only for a short period of time after the accelerator is pressed, because the pressurized air is weakened and the pressure is re-established in the sealed space between the intercooler and the intake valve until the pressure is relieved. The valve opens. Therefore, the final performance is still the engine response becomes slower, turbocharged hysteresis will become serious.

The intercooler will make the turbo hysteresis more obvious, but it can not be installed, so how to balance the cooling efficiency and pressure maintenance is the most troublesome problem for engineers. One of the most fundamental methods is to reduce the volume of the entire intake pipe, reduce the resistance of the pipe, and shorten the intake line. Therefore, the intercoolers we see are often close to the engine and not far away from the engine like the radiator tank. In this case, the overall engine will be more compact.

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