Abstract: A system and method for controlling an internal combustion engine to reduce or eliminate formation of EGR condensate monitor current ambient and operating conditions to determine whether conditions are favorable for condensation of EGR gases, and control the engine accordingly to avoid condensation, preferably by increasing the intake manifold temperature. The intake manifold temperature may be increased by redirecting some or all of the EGR flow to avoid the EGR cooler. Alternatively, or in combination, some or all of the charge air may be redirected to bypass the charge air cooler and/or redirected from the outlet of the turbocharger compressor to the intake, effectively increasing the intake air temperature and resulting in a corresponding increase of the intake manifold temperature. Conditions favorable for condensation may be determined based on engine speed and load, ambient temperature, manifold pressure, scheduled or actual EGR flow rate and scheduled or actual air/fuel ratio.

Abstract: An exhaust gas recirculation system for a compression ignition engine is provided wherein the exhaust gas recirculation is shut off depending upon the sensed or calculated humidity in the intake manifold relative to the dew point of the exhaust/intake air mixture. The humidity of the exhaust/intake air mixture may be measured in the intake manifold, charge air mixer or the ambient humidity may be sensed. If humidity is measured in the air charge mixer or in the ambient air, other factors such as engine speed and load, intake manifold pressure, EGR flow and air/fuel ratio may be used to calculate the humidity in the intake manifold. When the temperature of the mixture in the intake manifold is less than the dew point of the mixture, the engine control strategy may be shut off the EGR to prevent condensation in the exhaust gas recirculation system or engine.

Abstract: A system and method for controlling an internal combustion engine to reduce or eliminate formation of EGR condensate monitor current ambient and operating conditions to determine whether conditions are favorable for condensation of EGR gases, and control the engine accordingly to avoid condensation, preferably by increasing the intake manifold temperature. The intake manifold temperature may be increased by redirecting some or all of the EGR flow to avoid the EGR cooler. Alternatively, or in combination, some or all of the charge air may be redirected to bypass the charge air cooler and/or redirected from the outlet of the turbocharger compressor to the intake, effectively increasing the intake air temperature and resulting in a corresponding increase of the intake manifold temperature. Conditions favorable for condensation may be determined based on engine speed and load, ambient temperature, manifold pressure, scheduled or actual EGR flow rate and scheduled or actual air/fuel ratio.