Integrated intercooler for in-line diesel engine
By integrating the intercooler design, the problems of non-compact structure and poor adaptability to low-temperature environments of inline diesel engines are solved, achieving high efficiency and reliability in high dust environments, and meeting the compactness and low-temperature adaptability requirements of diesel engines.
Patent Information
- Application Number
- CN202511723231.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-21
- Publication Date
- 2026-02-03
AI Technical Summary
Inline diesel engines are not compact enough, have poor adaptability to low-temperature environments, and are difficult to meet the working requirements of environments with high dust content.
An integrated intercooler was designed, including an intercooler core, an exhaust shroud, an intake shroud, a heating grille, and an air filter. The heating grille and air filter are integrated into the intercooler exhaust shroud by welding and bolting. The intercooler exhaust port is directly connected to the cylinder head, eliminating the need for an intake manifold. A sealing ring groove is added to ensure sealing performance, and a burst pressure sensor is installed to monitor pressure.
The compact design of the intercooler improves the diesel engine's adaptability to low-temperature environments and its ability to operate under high dust content, while also ensuring high maintainability and reliability.
Smart Images
Figure CN121452061A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of diesel engine turbocharged intercooling technology, and in particular relates to an integrated intercooler for inline diesel engines. Background Technology
[0002] Modern high-power diesel engines generally employ turbocharging and intercooling technology to improve power performance, reduce heat load, and improve emissions. The intercooler, which cools the pressurized air before it enters the cylinder, is an indispensable part of the normal operation of a turbocharged diesel engine. Diesel engine starting performance is one of the important indicators for evaluating the overall performance of a diesel engine. Starting performance not only affects the completion of the engine's tasks but also its emissions and service life. Diesel engine intake air heating is a necessary compensation measure for low-temperature environments and an important component for adapting the diesel engine to all operating conditions. The diesel engine air filter should be able to handle air with high dust content, improving the engine's adaptability to high-dust environments, while also meeting the requirements for good maintainability. Summary of the Invention
[0003] In view of this, the present invention aims to propose an integrated intercooler for inline diesel engines, which solves the problems of diesel engine structure not being compact enough, poor adaptability to low temperature environment, and difficulty in meeting the working requirements of high dust content environment.
[0004] To achieve the above objectives, the technical solution of the present invention is implemented as follows: An integrated intercooler for an inline diesel engine includes an intercooler core, with an intercooler inlet and an intercooler outlet respectively opened on both sides of the intercooler core; The top of the intercooler core is connected to the intercooler exhaust shroud. The intercooler exhaust shroud has several intercooler exhaust ports. Sealing ring grooves are formed around the intercooler exhaust ports. A sensor mounting hole is formed at the intercooler exhaust port on the right side. A second boss is provided in the middle of the intercooler exhaust shroud. A first boss is provided above the second boss. A third boss is provided below the second boss. A heating grille is installed between the second boss and the first boss. An air filter is installed between the second boss and the third boss. The bottom of the intercooler core is connected to the intercooler air intake shroud, and an intercooler air intake port is opened on the side of the intercooler air intake shroud. The bottom of the intercooler air intake shroud is provided with mounting boss one and mounting boss two. The sealing ring is embedded inside the sealing ring groove, and the intercooler outlet is sealed to the inlet of the inline diesel engine cylinder head through the sealing ring groove.
[0005] Furthermore, both the heating grille and the air filter are sealed inside the intercooler exhaust shroud by bolts and sealing strips.
[0006] Furthermore, the heating grille includes grille plates, and the air filter element includes filter paper, both of which are installed by bolts.
[0007] Furthermore, the number of air outlets of the intercooler is matched with the number of cylinders of the inline diesel engine.
[0008] Furthermore, a burst pressure sensor is installed in the sensor mounting hole.
[0009] Furthermore, both mounting boss one and mounting boss two are equipped with brackets, which are located on the side of the inline diesel engine.
[0010] Furthermore, both the intercooler exhaust shroud and the intercooler intake shroud are connected to the intercooler core by welding.
[0011] Furthermore, the heating grid can be preheated by electricity.
[0012] Compared with the prior art, the integrated intercooler for inline diesel engines described in this invention has the following advantages: (1) Compared with traditional intercoolers, it effectively solves the problem of large size of auxiliary system of high-strength inline diesel engine. The intercooler outlet is directly connected to cylinder head, reducing intake manifold and meeting the high compact design requirements of high-strength inline diesel engine.
[0013] (2) The intercooler exhaust shroud integrates a heating grille and an air filter to meet the requirements of diesel engine low temperature environment adaptability and high dust content environment operation, while also being easy to maintain and highly reliable. Attached Figure Description
[0014] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a rear view schematic diagram of the integrated intercooler for a diesel engine according to an embodiment of the present invention; Figure 2 This is a longitudinal sectional view of the integrated intercooler for a diesel engine according to an embodiment of the present invention; Figure 3 This is a schematic cross-sectional view of the integrated intercooler for diesel engines according to an embodiment of the present invention; Figure 4 This is a front view schematic diagram of the integrated intercooler for diesel engines according to an embodiment of the present invention.
[0015] Explanation of reference numerals in the attached figures: 1. Intercooler exhaust shroud; 2. Heating grille; 3. Air filter; 4. Intercooler core; 5. Intercooler intake shroud; 6. Bolt 2; 7. Sealing strip; 8. Bolt 1; 9. Boss 1; 10. Boss 2; 11. Boss 3; 12. Intercooler air inlet; 13. Intercooler air outlet; 14. Intercooler water inlet; 15. Intercooler water outlet; 16. Mounting boss 1; 17. Mounting boss 2; 18. Sensor mounting hole; 19. Sealing ring groove. Detailed Implementation
[0016] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.
[0017] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.
[0018] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0019] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.
[0020] like Figures 1 to 4 As shown, it includes an intercooler exhaust shroud 1, a heating grille 2, an air filter element 3, an intercooler core 4, an intercooler intake shroud 5, bolt 1 8, a sealing strip 7, and bolt 2 6.
[0021] In a preferred embodiment of the present invention, the top of the intercooler core 4 is connected to the intercooler exhaust shroud 1. The intercooler exhaust shroud 1 has several intercooler exhaust ports 13, and sealing grooves 19 are formed around the intercooler exhaust ports 13. A sensor mounting hole 18 is formed at the right side of the intercooler exhaust port 13. A second boss 10 is provided in the middle of the intercooler exhaust shroud 1. A first boss 9 is provided above the second boss 10, and a third boss 11 is provided below the second boss 10. A heating grille 2 is installed between the second boss 10 and the first boss 9, and an air filter element 3 is installed between the second boss 10 and the third boss 11. The bottom of the intercooler core 4 is connected to the intercooler intake shroud 5. An intercooler intake port 12 is formed on the side of the intercooler intake shroud 5. The bottom of the intercooler intake shroud 5 is provided with a mounting boss 16 and a mounting... Boss 2 17; a sealing ring is embedded inside the sealing ring groove 19, and the intercooler outlet 13 is sealed to the intake port of the inline diesel engine cylinder head through the sealing ring groove 19; the heating grille 2 and the air filter element 3 are both sealed to the inside of the intercooler outlet shroud 1 by bolt 1 8 and sealing strip 7; the heating grille 2 includes grille plates, and the air filter element 3 includes filter paper, and the grille plates and filter paper are both installed by bolt 2 6; the number of intercooler outlets 13 matches the number of cylinders of the inline diesel engine; the sensor mounting hole 18 is used to install a burst pressure sensor; both mounting boss 16 and mounting boss 2 17 are equipped with brackets, and the brackets are located on the side of the inline diesel engine; the intercooler outlet shroud 1 and the intercooler intake shroud 5 are both connected to the intercooler core 4 by welding; the heating grille 2 can be preheated by electricity.In this embodiment, the intercooler core 4 is the core component of the intercooler. Its top is welded to the intercooler exhaust shroud 1, and its bottom is welded to the intercooler intake shroud 5. It is a key structure for achieving compressed air cooling. Cooling water flows into the intercooler core 4 from the intercooler inlet 14 and flows out from the intercooler outlet 15. Through heat exchange between the internal air and the external medium (water cooling), the intake air temperature is reduced, and engine efficiency is improved. The intercooler exhaust shroud 1 is a key component of the intercooler. It collects the compressed air cooled by the intercooler core 4 and delivers it to the engine cylinder through the exhaust port. It integrates a heating grille 2 and an air filter element 3. The heating grille 2 preheats the low-temperature air, improving the low-temperature environment of the diesel engine. Adaptability: The air filter element 3 filters air impurities to meet the operating requirements of diesel engines in high-dust environments. The intercooler exhaust shroud 1 connects directly to the intake port of the inline diesel engine cylinder head through the intercooler exhaust port 13, eliminating the need for an intake manifold. Compressed air enters the cylinder directly, thus improving the compactness of the diesel engine. The sealing ring groove 19 around the intercooler exhaust port 13 is used to embed the sealing ring, thereby ensuring sealing performance. In the intercooler exhaust shroud 1, bosses 1-9, 10-11, and 11-11 are used to fix the heating grille 2 and the air filter element 3, preventing bolts and nuts from falling into the air chamber and ensuring the components are installed securely. The intercooler intake shroud 5 is one of the key components of the intercooler and is located in the intercooler core 4. The bottom section receives high-temperature compressed air from the turbocharger and guides it into the intercooler core 4 for cooling. Compressed air is received through the intercooler intake port 12 on the side and guided into the intercooler core 4 for heat exchange, reducing the intake air temperature. A mounting boss is provided at the bottom for fixing it to the side of the engine with a bracket, ensuring the overall stability of the intercooler. It is welded to the intercooler core 4 to form a sealed channel, preventing air leakage. Serving as the "inlet end" of the intercooler, it works in conjunction with the top intercooler exhaust shroud 1 to form the compressed air cooling process (intake → core cooling → exhaust to engine cylinders). The heated grille 2 is an electrically powered device installed inside the intercooler exhaust shroud 1. The preheating device is used to increase the intake air temperature of the diesel engine in low-temperature environments, enhance the engine's low-temperature starting performance and operational stability, and solve the problem of reduced combustion efficiency caused by excessively low intake air temperature in low-temperature environments. It heats up when energized at low temperatures to preheat the compressed air flowing through it, and stops heating after the engine runs stably, thereby optimizing combustion efficiency and reducing emissions. The air filter element 3 is a filter component integrated into the exhaust shroud 1 of the diesel engine intercooler. Its core function is to filter impurities in the air entering the engine. It intercepts dust and particulate matter through filter paper and other materials to meet the working requirements of the diesel engine in high dust content environments. At the same time, it works with the heated grille 2 to improve low-temperature adaptability and ensure clean engine intake air and efficient operation.
[0022] Example 1: The integrated intercooler for inline diesel engines is constructed by welding together the intercooler exhaust shroud 1, the intercooler core 4, and the intercooler intake shroud. The intercooler exhaust shroud 1 houses the heating grille 2 and the air filter element 3. The heating grille 2 and air filter element 3 are sealed to the intercooler exhaust shroud 1 by tightening bolt 2 6 and installing a sealing strip 7. Bolt 1 8 secures the grille to the heating grille 2 and the filter paper to the air filter element 3. Three layers of protrusions are designed in the middle and on both sides of the intercooler exhaust shroud 1 cavity. These protrusions are identified as protrusion 1 9, protrusion 2 10, and protrusion 3 11, used to secure the heating grille 2 and air filter element 3 and prevent bolt 1 8 from falling into the air chamber.
[0023] The intercooler exhaust shroud 1 is designed with intercooler exhaust ports 13. The number of exhaust ports depends on the number of cylinders in the inline diesel engine. These ports are directly installed at the intake ports of the cylinder head and sealed with rubber rings. A sealing ring groove 19 is designed, eliminating the need for an intake manifold. A sensor mounting hole 18 is machined at the rightmost exhaust port of the intercooler exhaust shroud 1 for mounting a pressure sensor. The bottom surface of the intercooler intake shroud 5 is designed with mounting boss 16 and mounting boss 2 17 for mounting brackets to support the intercooler on the side of the inline diesel engine.
[0024] In low-temperature environments, the heating grille 2 is first energized for preheating. After preheating, the engine is started. Air enters the intake shroud through the intercooler intake port 12 and passes through the intercooler core 4. During the initial engine start-up, the coolant temperature is higher than the air temperature, heating the air. After being filtered by the air filter 3, the heated air, after being heated by the heating grille 2, directly enters the engine cylinders through the intercooler outlet 13. Heating of the heating grille 2 can be stopped once the engine speed stabilizes.
[0025] The pressurized, high-temperature air first enters the intake shroud through the intercooler inlet 12, is cooled by the intercooler core 4, and is then filtered by the air filter element 3 installed on the intercooler outlet shroud 1. After passing through the heated grille 2 (heating stops when power is off), the air directly enters the engine cylinder through the intercooler outlet 13. Cooling water flows into the intercooler core 4 from the intercooler inlet 14, exchanges heat with the high-temperature air, and then flows out from the intercooler outlet 15.
[0026] Advantages and beneficial effects of the present invention: (1) Compared with traditional intercoolers, it effectively solves the problem of large size of auxiliary system of high-strength inline diesel engine. The intercooler outlet is directly connected to cylinder head, reducing intake manifold and meeting the high compact design requirements of high-strength inline diesel engine.
[0027] (2) The intercooler exhaust shroud integrates a heating grille and an air filter to meet the requirements of diesel engine low temperature environment adaptability and high dust content environment operation, while also being easy to maintain and highly reliable.
[0028] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. An integrated intercooler for an inline diesel engine, characterized in that: It includes an intercooler core (4), with an intercooler inlet (14) and an intercooler outlet (15) respectively opened on both sides of the intercooler core (4); The top of the intercooler core (4) is connected to the intercooler exhaust shroud (1). The intercooler exhaust shroud (1) has several intercooler exhaust ports (13). A sealing ring groove (19) is opened around the intercooler exhaust port (13). A sensor mounting hole (18) is opened at the intercooler exhaust port (13) on the right side. A boss two (10) is provided in the middle of the intercooler exhaust shroud (1). A boss one (9) is provided above the boss two (10). A boss three (11) is provided below the boss two (10). A heating grille (2) is installed between the boss two (10) and the boss one (9). An air filter (3) is installed between the boss two (10) and the boss three (11). The bottom of the intercooler core (4) is connected to the intercooler air intake shroud (5). The intercooler air intake shroud (5) has an intercooler air intake port (12) on its side. The bottom of the intercooler air intake shroud (5) is provided with mounting boss one (16) and mounting boss two (17). The sealing ring groove (19) is embedded with a sealing ring, and the intercooler outlet (13) is sealed to the inlet of the cylinder head of the inline diesel engine through the sealing ring groove (19).
2. The integrated intercooler for an inline diesel engine according to claim 1, characterized in that: The heating grille (2) and the air filter (3) are both sealed inside the intercooler outlet cover (1) by bolts (8) and sealing strips (7).
3. The integrated intercooler for an inline diesel engine according to claim 1, characterized in that: The heating grille (2) includes grille plates, and the air filter (3) includes filter paper. Both the grille plates and the filter paper are installed by bolts (6).
4. The integrated intercooler for an inline diesel engine according to claim 1, characterized in that: The number of intercooler outlets (13) is matched with the number of cylinders in the inline diesel engine.
5. The integrated intercooler for an inline diesel engine according to claim 1, characterized in that: The explosion pressure sensor is installed in the sensor mounting hole (18).
6. The integrated intercooler for an inline diesel engine according to claim 1, characterized in that: Both mounting boss one (16) and mounting boss two (17) are equipped with brackets, which are located on the side of the inline diesel engine.
7. The integrated intercooler for an inline diesel engine according to claim 1, characterized in that: The intercooler exhaust shroud (1) and the intercooler intake shroud (5) are both connected to the intercooler core (4) by welding.
8. The integrated intercooler for an inline diesel engine according to claim 1, characterized in that: The heating grid (2) can be preheated by electricity.