Charge air cooling control for boosted engines to actively maintain targeted intake manifold air temperature

An engine method, comprising:

• setting a target manifold charge air temperature based on condensate formation and combustion stability;
• determining a difference between a charge air cooler inlet air temperature and the set target manifold charge air temperature;
• determining a difference between the set target manifold charge air temperature and a temperature of a charge air cooler cooling medium, where the temperature of the charge air cooler cooling medium is one of an under-hood air temperature and a charge air cooler inlet coolant temperature;
• adjusting one of a coolant pump speed of a charge air cooler coolant pump or a charge air cooler fan speed of a charge air cooler fan based on a local cooling percentage, the local cooling percentage determined based on the determined difference between the charge air cooler inlet air temperature and the set target manifold charge air temperature and a cooling capacity of a charge air cooler;
• and
• adjusting a grille shutter position by a first amount and an engine cooling fan speed of an engine cooling fan by a second amount, the first and second amounts based on an external cooling percentage and vehicle operating conditions, the external cooling percentage determined based on the determined difference between the set target manifold charge air temperature and the temperature of the charge air cooler cooling medium.

An engine system, comprising:

• an engine including an intake manifold;
• a compressor coupled to the intake manifold upstream of a throttle;
• a water-to-air charge air cooler coupled downstream of the compressor;
• a coolant pump coupled to a water side of the charge air cooler;
• an engine cooling fan coupled to a radiator;
• grille shutters positioned at a vehicle front end, forward of the engine cooling fan, water-to-air charge air cooler, and radiator;
• and
• a controller with computer readable instructions for:
• determining each of a difference between a target manifold charge air temperature and a charge air cooler inlet coolant temperature, a difference between a charge air cooler inlet air temperature and the target manifold charge air temperature, a difference between a target coolant temperature and the charge air cooler inlet coolant temperature, and a difference between a measured manifold charge air temperature and the target manifold charge air temperature;
• adjusting one or more of an opening of the grille shutters and a speed of the engine cooling fan based on the determined difference between the target manifold charge air temperature and the charge air cooler inlet coolant temperature;
• and
• adjusting a speed of the coolant pump based on the determined difference between the charge air cooler inlet air temperature and the target manifold charge air temperature, the determined difference between the target coolant temperature and the charge air cooler inlet coolant temperature, a mass air flow of charge air flowing from the compressor and through the water-to-air charge air cooler, and the determined difference between the measured manifold charge air temperature and the target manifold charge air temperature.