# US 2018/0023522 A1 · System and methods for extracting water from exhaust gases for water injection > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2018/0023522 A1 - Document ID: US20180023522A1 - Status: Published application - Kind: A1 - Application number: 15/217,764 - Filed: 2016-07-22 - Published: 2018-01-25 - Earliest claimed: 2016-07-22 - Assignees: Ford Global Technologies, LLC - Applicants: Ford Global Technologies, LLC - Inventors: Daniel Joseph Styles; Gopichandra Surnilla; Mohannad Hakeem; Brad Alan VanDerWege; Christopher House; Michael Howard Shelby - Web page: https://patentgrep.com/patent/US20180023522A1 ## CPC - F02M 26/35: with means for cleaning or treating the recirculated gases, e.g. catalysts, condensate traps, particle filters or heaters - F02D 41/0025: {Controlling engines characterised by use of non-liquid fuels, pluralities of fuels, or non-fuel substances added to the combustible mixtures} - F02D 41/005: {according to engine operating conditions} - F02D 41/0077: {Control of the EGR valve or actuator, e.g. duty cycle, closed loop control of position (EGR valve position sensor F02M26/48)} - F02M 25/0222: {Water recovery or storage} - F02M 25/0227: {Control aspects; Arrangement of sensors; Diagnostics; Actuators} - F02M 25/028: into the charge intakes - F02M 26/07: Mixed pressure loops, i.e. wherein recirculated exhaust gas is either taken out upstream of the turbine and reintroduced upstream of the compressor, or is taken out downstream of the turbine and reintroduced downstream of the compressor - F02M 26/19: Means for improving the mixing of air and recirculated exhaust gases, e.g. venturis or multiple openings to the intake system - F02M 26/24: with two or more coolers - F02M 26/25: with coolers having bypasses - F02M 35/10157: {Supercharged engines} - F02M 35/10222: {Exhaust gas recirculation [EGR]; Positive crankcase ventilation [PCV]; Additional air admission, lubricant or fuel vapour admission} - F02M 2026/002: {EGR valve being controlled by vacuum or overpressure} - F02M 2026/004: {EGR valve controlled by a temperature signal or an air/fuel ratio (lambda) signal} - Y02T 10/12: Improving ICE efficiencies - Y02T 10/40: Engine management systems - F02M: SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF - F02D: CONTROLLING COMBUSTION ENGINES (vehicle fittings, acting on a single sub-unit only, for automatically controlling vehicle speed B60K31/00; conjoint control of vehicle sub-units of different type or different function, road vehicle drive control systems for purposes other than the control of a single sub-unit B60W) - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract Methods and systems are provided for flowing exhaust through a second cooler, arranged downstream of a first cooler and upstream of an intake in an exhaust gas recirculation passage, and extracting condensate for water injection from condensate in cooled exhaust gas exiting the second cooler. In one example, a method may include adjusting the amount of exhaust gas flowing through the second cooler based on an amount of water stored at a water storage tank of a water injection system and engine operating conditions. Further, the method may include selectively flowing exhaust gas from the second cooler to a location upstream or downstream of a compressor in response to engine operating conditions. ## Claims ### Claim 1 A method, comprising: flowing exhaust gas through a second cooler, the second cooler arranged downstream of a first cooler in a passage disposed between an exhaust and intake of an engine; and selectively directing the flow of exhaust gas from the second cooler to each of the intake upstream of a compressor and the intake downstream of the compressor based on a first operating condition. ### Claim 2 (depends on 1) The method of claim 1, further comprising adjusting the flow of exhaust gas through the second cooler based on a second operating condition and extracting condensate from the exhaust gas flowing through the second cooler. ### Claim 3 (depends on 2) The method of claim 2, wherein extracting condensate include separating condensate entrained within the exhaust gas exiting the second cooler, flowing the extracted condensate to a reservoir of a water injection system, and flowing the exhaust gas to the intake either upstream or downstream of the compressor. ### Claim 4 (depends on 2) The method of claim 2, further comprising storing the extracted condensate in a reservoir and injecting the stored condensate into an intake manifold upstream of cylinders of the engine. ### Claim 5 (depends on 4) The method of claim 4, wherein the second operating condition includes one or more of an amount of the stored extracted condensate and a desired amount of water injection at the intake manifold. ### Claim 6 (depends on 5) The method of claim 5, wherein adjusting the flow of exhaust gas through the second cooler includes actuating one or more valves to increase the flow exhaust gas through the second cooler in response to the amount of stored extracted condensate being below a threshold level. ### Claim 7 (depends on 1) The method of claim 1, wherein the first operating condition includes one or more of an estimated temperature of exhaust gas exiting the second cooler and a compressor surge condition. ### Claim 8 (depends on 7) The method of claim 7, wherein selectively directing the flow of exhaust gas from the second cooler includes directing the flow of exhaust gas to the intake upstream of the compressor and not downstream of the compressor in response to one or more of the estimated temperature of the exhaust gas exiting the second cooler being above a first threshold and an indication of compressor surge at the compressor. ### Claim 9 (depends on 7) The method of claim 7, wherein selectively directing the flow of exhaust gas from the second cooler includes directing the flow of exhaust gas to the intake downstream of the compressor and not upstream of the compressor in response to the estimated temperature of the exhaust gas exiting the second cooler being below a first threshold, where the first threshold is a temperature below which condensate forms at the compressor. ### Claim 10 A method, comprising: extracting condensate from exhaust gases flowing through a second cooler, the second cooler arranged downstream of a first cooler in a passage disposed between and exhaust and intake of an engine, and storing the extracted condensate; injecting the extracted condensate at an intake manifold; and adjusting one or more of an amount of the exhaust gases flowing through the second cooler and an amount of coolant flow through the second cooler based on an amount of stored extracted condensate. ### Claim 11 (depends on 10) The method of claim 10, wherein adjusting one or more of the amount of the exhaust gases flowing through the second cooler and the amount of coolant flow through the second cooler includes one or more of increasing the amount of exhaust gases flowing through the second cooler and increasing the amount of coolant flow through the second cooler in response to the amount of stored condensate being below a first threshold level. ### Claim 12 (depends on 11) The method of claim 11, wherein adjusting one or more of the amount of the exhaust gases flowing through the second cooler and the amount of coolant flow through the second cooler includes one or more of increasing the amount of exhaust gases flowing through the second cooler and increasing the amount of coolant flow through the second cooler in response to each of the amount of stored condensate being above the first threshold level and below a second threshold level, the second threshold level greater than the first threshold level, and a desired water injection amount at the intake manifold being above a first water injection threshold amount. ### Claim 13 (depends on 12) The method of claim 12, wherein adjusting one or more of the amount of the exhaust gases flowing through the second cooler and the amount of coolant flow through the second cooler includes one or more of decreasing the amount of exhaust gases flowing through the second cooler and decreasing the amount of coolant flow through the second cooler in response to the amount of stored condensate being above the second threshold level. ### Claim 14 (depends on 12) The method of claim 12, wherein adjusting one or more of the amount of the exhaust gases flowing through the second cooler and the amount of coolant flow through the second cooler includes one or more of decreasing the amount of exhaust gases flowing through the second cooler and decreasing the amount of coolant flow through the second cooler in response to each of the amount of stored condensate being above the first threshold level and below the second threshold level and the desired water injection amount being below the first water injection threshold amount. ### Claim 15 (depends on 10) The method of claim 10, further comprising adjusting a flow of exhaust gases from the second cooler to the intake based on a desired amount of exhaust gas recirculation (EGR) flow from the exhaust to the intake and a desired intake air temperature. ### Claim 16 (depends on 15) The method of claim 15, wherein adjusting the flow of exhaust gases from the second cooler to the intake includes diverting a first portion of exhaust gases from the second cooler to the exhaust, downstream of the passage disposed between the exhaust and intake, and flowing a remaining, second portion of exhaust gases from the second cooler to the intake. ### Claim 17 (depends on 16) The method of claim 16, wherein the first portion increases and the second portion decreases as the desired intake air temperature increases and the desired EGR flow decreases. ### Claim 18 A system for an engine, comprising: an intake including an intake manifold arranged upstream of cylinders of the engine; an exhaust gas recirculation (EGR) passage arranged between the intake and an exhaust of the engine, the EGR passage including a first EGR cooler and a second EGR cooler disposed downstream of the first EGR cooler; a bypass passage coupled to the EGR passage, between the first and second EGR coolers, and to the intake; and a controller including non-transitory memory with instructions for: during a first condition, flowing exhaust gases to the intake via the first EGR cooler and second EGR cooler; during a second condition, flowing a first portion of the exhaust gases to the intake via the first EGR cooler and second EGR cooler while flowing a remaining, second portion of the exhaust gases to the intake via the first cooler only and the bypass passage; and during both the first and second conditions, extracting condensate from the exhaust flow at the second cooler. ### Claim 19 (depends on 18) The system of claim 18, further comprising: a cyclonic separator coupled to an outlet of the second EGR cooler and a water reservoir; and a water injector coupled to the intake manifold and fluidly coupled to the water reservoir via a fluid passage. ### Claim 20 (depends on 18) The system of claim 18, wherein the first portion is based on a fluid level in the water reservoir.