Charge air cooling adds to power - if you have unlimited fuel to burn.Dr. Acula wrote: ↑18 Aug 2023, 12:50Well, it really isn't that simple.chaoticflounder wrote: ↑08 Aug 2023, 23:20at the base level, intercoolers are removing work (heat) that the system is putting into it via the compressor so they do represent net loss in efficiency
in road cars I know they go a long way to reducing the NOx emissions due to reducing the inlet charge temperature
also, they allow for a denser air charge so you can react more fuel to get more power, but not necessarily more efficiency
What Tommy's saying above is with Direct Injection fuel is introduced at the last possible moment and is not a factor in cooling the charge air like it is for port injection
Let us start and just look at the system before the air enters the cylinder. Yes technically an intercooler removes energy from the system, but the question is how much oxygen you need. By removing heat, you get more oxygen per volume at the same pressure. Or with other words, an intercooler allows you to run with lower boost pressure to get the same amount of oxygen into the cylinder. More boostpressure means more work for the turbo which means even more heat and so on. So overall, an intercooler makes the charge cycle more efficient. The whole point of any charge system is to get more oxygen into the cylinder. You don't need more pressure, that's just an unavoidable side effect.
It really doesn't matter if you have port- or direct injection. The evaporative cooling effect happens all the same. Direct injection can't beat physics and liquids don't burn.
But overall, it really is a question of how high the thermal limits are set. If you don't remove the heat of the compressed air before it reaches the cylinder, the heat will simply end up somewhere else. Which means higher cylinder wall, piston crown, exhaust valve and so on temperature. If all these components can easely deal with that, sure run without an intercooler. But in most cases, you will run into thermal problems somewhere.
Charge air cooling reduces cycle efficiency.
The benefits of fuel evaporative cooling vary depending on whether the evaporation occurs:
a. In the intake system before the valve
b. In cylinder but prior to IVC
c. In cylinder, after IVC but before TDC. . . and at what point in the compression stroke it occurs.
So there is a difference between DI and PFI.