Air Charge System and Method for an Internal Combustion Engine

An air charge system for an internal combustion engine, the air charge system comprising:

• a charge path having an inlet configured to receive air from ambient, and an outlet configured to be connected to an intake of the internal combustion engine to convey air from the inlet to the intake of the internal combustion engine;
• a first compressor in the charge path connected to receive air from the inlet;
• a first charge cooler in the charge path connected to receive air from the first compressor;
• a second compressor in the charge path connected to receive air from the first charge cooler;
• a first variable bypass valve connected to divert at least a portion of the air from the charge path upstream of the first compressor, convey none, some or all of the air around at least one of the first compressor and the first charge cooler, and back to the charge path;
• and
• a controller connected to the first variable bypass valve for varying an amount of air flowing therethrough to maintain optimal operation of the internal combustion engine.

A method for providing charge air to an internal combustion engine, the method comprising:

• conveying ambient air through a charge path from an inlet of the charge path to an intake of the internal combustion engine;
• activating a first compressor in the charge path, the first compressor being driven by a motor and configured to compress the air in the charge path to increase a temperature, pressure and mass flow rate of the air in the charge path;
• measuring charge air conditions in the charge path;
• and
• modulating a volumetric flow of the air to the intake by at least one of diverting none, some or all of the air leaving the first compressor from the charge path and modulating a speed of the motor.