Intercooler lower cavity assembly
Through the design of the intercooler lower chamber assembly and the use of a wire mesh water blocker and automatic drain valve structure, the problem of liquid water entering the generator set is solved, thereby improving the purity of the combustion process and the operating stability of the generator set.
Patent Information
- Application Number
- CN202423175892.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-23
- Publication Date
- 2025-10-17
- Estimated Expiration
- 2034-12-23
AI Technical Summary
Existing technologies fail to effectively prevent liquid water from entering the generator set during low-concentration gas power generation, leading to problems such as deterioration of combustion conditions, lubricating oil contamination, and decreased operating efficiency.
The intercooler lower chamber assembly, including a wire mesh water blocker and a float-type automatic drain valve, is designed with an eccentric air outlet layout and an inclined bottom plate. Combined with the automatic drain valve structure, this ensures that condensed water is gathered and safely discharged under the action of gravity.
Effectively prevent condensed water from entering the engine's air intake system, improve the purity of the combustion process, reduce the probability of equipment failure, extend maintenance cycles, and improve the performance and stability of the generator set.
Smart Images
Figure CN223447129U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of gas generator set air intake, in particular to an intercooler lower cavity component. Background Art
[0002] During low-concentration gas power generation, liquid water can have numerous adverse effects on the generator set. Once in the generator set, liquid water reduces the effective calorific value of the gas, making it difficult for the spark plug to ignite and worsening combustion. Furthermore, when the fuel, mixed with significant amounts of water vapor, is compressed and produced in the cylinder, the water rapidly vaporizes, occupying the cylinder's effective stroke. This increases wasted work and reduces the generator set's operating efficiency. Furthermore, large amounts of liquid water in the gas can severely contaminate the generator set's lubricating oil system, causing rapid deterioration in lubricating oil quality and requiring frequent replacement.
[0003] Existing technologies focus on the dehydration of low-concentration gas in the transmission pipeline, such as the use of mechanical cyclone dehydration and the addition of electric refrigeration dehydration devices. However, existing technologies generally ignore the necessity of further dehydration when the gas and air are mixed and enter the generator set. As a result, despite the dehydration treatment in the early stage, many of the above-mentioned problems still exist in the subsequent intake process. Although an automatic condensate discharge device has been designed in the intake pipe, due to the high-speed flow of the low-concentration gas mixture in the intake pipe, some condensate will still enter the engine cylinder with the airflow, which cannot fundamentally solve the problem. At this stage, a lower chamber assembly of the intercooler is needed. Utility Model Content
[0004] In order to solve the problem that liquid water enters the generator set and causes the performance of the generator set to deteriorate, the utility model provides an intercooler lower chamber component.
[0005] In the first aspect, the present invention provides an intercooler lower chamber assembly, which adopts the following technical solutions:
[0006] An intercooler lower chamber assembly, comprising:
[0007] The intercooler lower chamber, the wire mesh water blocker and the automatic drain valve, the wire mesh water blocker is installed inside the air outlet cavity of the intercooler lower chamber, the bottom of the intercooler lower chamber is provided with a water storage part, the water storage part is connected to the bottom plate of the intercooler lower chamber, the bottom plate is installed obliquely to the bottom of the intercooler lower chamber, the automatic drain valve is installed to the side of the water storage part, the intercooler lower chamber includes an air outlet and an air outlet cavity, the central axis of the air outlet is located above the central axis of the air outlet cavity, and the air outlet is connected to the throttle.
[0008] Furthermore, the automatic drain valve adopts a float type automatic drain valve.
[0009] Further, the automatic drain valve comprises a valve body, a valve cover, a hollow floating ball and a valve seat, the top of the valve body is provided with external threads, the valve body is connected to the valve cover through the external threads, the hollow floating ball is installed to the internal cavity of the valve body, and the valve seat is installed to the bottom of the valve body at the drain port.
[0010] Further, the valve body is internally provided with a snap spring, the two ends of the snap spring are connected with the support shaft of the hollow floating ball and the clamping groove of the inner wall of the valve body respectively, and the snap spring is used for providing vertical movement guidance of the hollow floating ball.
[0011] Further, the internal inlet of the valve body is provided with a filter screen, and the filter screen is connected with the valve body in a welding mode.
[0012] Further, the top of the valve seat is provided with an opening, and the area of the opening is the same as the bottom end of the hollow floating ball.
[0013] Further, the automatic drain valve further comprises a drain flange connected with the valve seat, the drain flange is connected with a drain elbow, and the connection position of the drain flange and the drain elbow is provided with a rubber sealing ring.
[0014] Further, the outlet end of the drain elbow is sleeved on one end of a drain hose, the outlet end of the drain elbow is fixed around one end of the drain hose through a hose clamp, and the other end of the drain hose is used for guiding the condensed water to the bottom of the generator set chassis.
[0015] Further, one end of the bottom plate is connected to the lower cavity wall surface of the intercooler, the other end of the bottom plate is connected to the side edge of the water storage part, the one end of the bottom plate connected to the lower cavity wall surface of the intercooler is higher than the other end connected to the side edge of the water storage part, and an inclination angle is formed to stably return the condensed water to the water storage part under the action of gravity.
[0016] Further, a flange with a metal sealing gasket is arranged at the connection position of the air outlet and the throttle valve, and the air outlet is connected to the throttle valve through the flange.
[0017] In conclusion, the automatic drain valve has the beneficial technical effects as follows.
[0018] 1. The lower cavity air outlet of the intercooler is closely connected to the throttle valve and is arranged upward and eccentrically, the bottom inclination design is combined, the condensed water flow path is changed from the root, the condensed water is prevented from being mixed into the air outlet airflow, the purity of the mixed gas entering the engine intake system is ensured, high-quality gas sources are provided for subsequent combustion, the combustion process is optimized, and the overall performance and stability are improved.
[0019] 2. The automatic drain valve has simple structure and only contains a single movable part, i.e., the hollow floating ball, the number of vulnerable parts is greatly reduced, the parts are made of high-quality materials, have high manufacturing precision, are tightly matched, the fault probability is significantly reduced, and the maintenance cycle and service life are prolonged.
[0020] 3. The present invention installs a wire mesh water blocker inside the air outlet cavity, which can effectively intercept condensed water and prevent it from entering downstream components, thereby reducing the risk of subsequent throttle valve, intake pipe and cylinder being corroded and interfered with by liquid water, reducing the probability of equipment failure caused by moisture, and improving the continuity and reliability of system operation. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Figure 1 It is a schematic diagram of the overall connection between the lower chamber of the intercooler and other components in an embodiment of the present utility model.
[0022] Figure 2 It is an overall structural diagram of the lower chamber of the intercooler of an embodiment of the present utility model.
[0023] Figure 3 It is a cross-sectional view of an intercooler lower chamber assembly taken along line AA of an intercooler lower chamber assembly according to an embodiment of the present invention.
[0024] Figure 4 It is a structural schematic diagram of a water storage portion in a lower chamber assembly of an intercooler according to an embodiment of the present utility model.
[0025] Figure 5 It is a structural schematic diagram of an automatic drain valve in a lower chamber assembly of an intercooler according to an embodiment of the present utility model.
[0026] Among them, 1. flame arrester; 2. upper cavity of intercooler; 3. intercooler; 4. lower cavity of intercooler; 41. air outlet; 42. air cavity; 43. wire mesh water arrester; 44. automatic drain valve; 441. valve body; 442. valve cover; 443. filter screen; 444. retaining ring; 445. hollow float; 446. valve seat; 447. locking nut; 448. drain elbow; 449. drain hose; 45. water storage part; 46. bottom plate; 5. throttle valve; 6. second flame arrester; 7. intake pipe. DETAILED DESCRIPTION
[0027] The present invention will be described in further detail below with reference to the accompanying drawings.
[0028] Example 1
[0029] Reference Figure 1 , an intercooler lower chamber assembly of this embodiment includes:
[0030] The lower cavity of the intercooler, the wire mesh water stopper and the automatic drain valve, the wire mesh water stopper is installed inside the air outlet cavity of the lower cavity of the intercooler, the bottom of the lower cavity of the intercooler is provided with a water storage part, the water storage part is connected with the bottom plate of the lower cavity of the intercooler, the bottom plate is obliquely installed at the bottom of the lower cavity of the intercooler, the automatic drain valve is installed at the side of the water storage part, the lower cavity of the intercooler comprises an air outlet and an air outlet cavity, the central axis of the air outlet is above the central axis of the air outlet cavity, and the air outlet is connected with the throttle valve.
[0031] Specifically,
[0032] As Figure 1 shown, the mixed gas of low concentration gas and air is first subjected to pressure boosting treatment and then enters the flame arrester 1, the core function of the flame arrester 1 is to prevent the spread of possible flames, and its working principle is that when the flame in the mixed gas tries to pass through, the heat is quickly absorbed and dispersed by the specially designed structure and material, such as multi-layer metal wire mesh or passage filled with flame-retardant material, so that the flame is extinguished, thereby ensuring the safety of subsequent equipment and systems.
[0033] The mixed gas passing through the flame arrester 1 then enters the upper cavity of the intercooler 2 and then flows into the intercooler 3, the intercooler 3 exchanges heat with the mixed gas by using a cooling medium (such as air or circulating water), so that the temperature of the mixed gas is greatly reduced from 150℃ to below 50℃, and in this cooling process, the water vapor in the mixed gas changes phase due to the temperature reduction and condenses into liquid water, the cooled mixed gas carrying condensed water enters the lower cavity of the intercooler 4, in the lower cavity of the intercooler 4, the components work cooperatively to treat the condensed water and optimize the quality of the mixed gas.
[0034] The wire mesh water stopper 43 plays a blocking role, the wire mesh water stopper 43 installed in the air outlet cavity 42 of the lower cavity of the intercooler 4, the stainless steel wire mesh demister material has a unique microstructure, when the mixed gas with condensed water impacts the wire mesh, gas molecules can pass through the small gaps smoothly, while liquid condensed water is blocked on the surface of the wire mesh due to surface tension and intermolecular forces, this separation method based on physical properties ensures that the condensed water is effectively intercepted when the mixed gas passes through the wire mesh water stopper 43, thereby preliminarily purifying the mixed gas.
[0035] As Figure 2 , Figure 3 shown, one end of the bottom plate 46 of the lower cavity of the intercooler 4 is connected with the cavity wall surface, the other end is connected with the side edge of the water storage part 45, and the end connected with the cavity wall surface is higher than the end connected with the water storage part 45, forming a 5-degree inclination angle, the condensed water intercepted by the wire mesh water stopper 43 is gathered to the water storage part 45 along the inclined bottom plate 46 under the action of gravity, the water storage part 45 serves as a temporary storage area for condensed water and can accommodate the condensed water generated within a certain period of time, preventing water overflow from affecting system operation.
[0036] AsFigure 4 As shown, the automatic drain valve 44 installed on the side of the water storage part 45 is of a float type structure, and its working principle is based on the balance between buoyancy and gravity. The hollow floating ball 445 inside the valve body 441 plays a key role when the condensate water level changes. When the condensate water level in the water storage part 45 rises, the liquid flows into the valve body 441, and the hollow floating ball 445 gradually floats up under the action of buoyancy. The hollow floating ball 445 is fixed by the snap spring 444, which is installed inside the valve body and tightly fits with the hollow floating ball 445 support shaft and the inner wall of the valve body 441 at both ends. This structure provides stable vertical movement guidance for the hollow floating ball 445, limits its horizontal displacement, and ensures that the hollow floating ball 445 accurately rises and falls in the valve body under the action of buoyancy and gravity, maintaining the accuracy and reliability of the sealing or opening of the drain action of the valve seat 446. The valve cover 442 at the top of the valve body 441 is tightly connected with the valve body 441 through external threads and ensures good sealing with the help of rubber sealing gaskets to prevent leakage.
[0037] As the hollow floating ball 445 rises, when the buoyancy overcomes the weight of the hollow floating ball 445 itself and the sealing force of the valve seat 446, the hollow floating ball 445 separates from the valve seat 446. The opening area at the top of the valve seat 446 is accurately matched with the bottom end of the hollow floating ball 445, ensuring good sealing and drainage effect. When the locking nut 447 is tightened, it applies uniform axial pressure to the valve seat 446, causing the valve seat 446 to tightly fit with the sealing surface between the valve body 441, forming a high-efficiency sealing barrier to prevent condensate water from leaking from the joint gap between the valve seat 446 and the valve body 441. The locking nut 447 is installed on the outside of the bottom of the valve body 441, surrounding the bottom circumference of the valve seat 446. The bottom of the valve body 441 is processed with external threads, which are adapted with the internal threads of the locking nut 447. During installation, first, the valve seat 446 is inserted into the bottom drain of the valve body 441 to ensure the correct installation direction and preliminary positioning of the valve seat 446. Then, the locking nut 447 is screwed from the bottom of the valve body 441. At this time, the condensate water flows out from the opening of the valve seat 446 through the drain flange, and the rubber sealing ring at the connection between the drain flange and the drain elbow 448 ensures the sealing of the connection. The drain elbow 448 guides the water flow to the drain hose 449, which stably directs the condensate water to the bottom of the generator set chassis under the tightening action of the hose clamp, achieving safe drainage.
[0038] As shown, Figure 5 When the condensate water level in the water storage part 45 decreases, the buoyancy on the hollow floating ball 445 decreases, and it falls back to the bottom of the valve body 441 under the action of gravity, re-tightly fitting with the valve seat 446 to form a reliable water seal, effectively preventing gas leakage. The filter screen 443 at the inlet inside the valve body 441 is firmly fixed by welding, and its high filtration precision can intercept possible impurity particles, protecting the sealing surface of the hollow floating ball 445 and the valve seat 446 and the drainage channel from wear and blockage, ensuring long-term stable operation of the automatic drain valve 44.
[0039] The outlet 41 of the middle cooler lower cavity 4 is eccentric 20mm above the axis of the outlet cavity 42, when the mixture flows from the outlet 41 to the throttle valve 5, the eccentric structure uses the principle of gravity, so that the small amount of condensate water possibly remaining is left at the bottom of the outlet cavity 42 under the action of gravity, further reducing the possibility of the condensate water being taken out into the throttle valve 5, the subsequent second flame arrester 6 and the intake pipe 7 and the cylinder, the outlet 41 and the throttle valve 5 are connected through a flange with a metal sealing gasket, the metal sealing gasket is elastically deformed under the action of the bolt pre-tightening force, filling the small gap of the connecting surface, ensuring that the connecting part maintains an airtight state when the mixture flows at high speed and the system pressure changes, preventing the mixture from leaking, ensuring the stability of the engine air intake, optimizing the combustion process, and improving the overall performance and efficiency of the generator set.
[0040] The above are preferred embodiments of the utility model, and do not limit the protection scope of the utility model, so: equivalent changes made according to the structure, shape and principle of the utility model should be covered in the protection scope of the utility model.
Claims
1. An intercooler lower chamber assembly, characterized in that: include: The intercooler lower chamber, the wire mesh water blocker and the automatic drain valve, the wire mesh water blocker is installed inside the air outlet cavity of the intercooler lower chamber, the bottom of the intercooler lower chamber is provided with a water storage part, the water storage part is connected to the bottom plate of the intercooler lower chamber, the bottom plate is installed obliquely to the bottom of the intercooler lower chamber, the automatic drain valve is installed to the side of the water storage part, the intercooler lower chamber includes an air outlet and an air outlet cavity, the central axis of the air outlet is located above the central axis of the air outlet cavity, and the air outlet is connected to the throttle.
2. The intercooler lower chamber assembly according to claim 1, characterized in that: The automatic drain valve adopts a float type automatic drain valve.
3. The intercooler lower chamber assembly according to claim 2, characterized in that: The automatic drain valve includes a valve body, a valve cover, a hollow float and a valve seat. The top of the valve body is provided with an external thread. The valve body is connected to the valve cover via the external thread. The hollow float is installed in the internal chamber of the valve body. The valve seat is installed at the drain outlet at the bottom of the valve body.
4. The intercooler lower chamber assembly according to claim 3, characterized in that: A retaining spring is provided inside the valve body, and two ends of the retaining spring are respectively connected to the support shaft of the hollow float and the retaining groove on the inner wall of the valve body, so as to provide a vertical movement guide for the hollow float.
5. The intercooler lower chamber assembly according to claim 4, characterized in that: A filter screen is provided at the internal inlet of the valve body, and the filter screen is connected to the valve body by welding.
6. The intercooler lower chamber assembly according to claim 3, characterized in that: The top of the valve seat is provided with an opening, and the area of the opening is the same as that of the bottom end of the hollow float.
7. The intercooler lower chamber assembly according to claim 1, characterized in that: The automatic drain valve further comprises a drain flange connected to the valve seat, the drain flange is connected to the drain elbow, and a rubber sealing ring is provided at the connection between the drain flange and the drain elbow.
8. The intercooler lower chamber assembly according to claim 7, characterized in that: The outlet end of the drainage elbow is sleeved on one end of the drainage hose, and the outlet end of the drainage elbow is surrounded and fixed to one end of the drainage hose by a hose clamp, and the other end of the drainage hose is used to guide the condensed water to the bottom of the generator set chassis.
9. The intercooler lower chamber assembly according to claim 1, characterized in that: One end of the bottom plate is connected to the wall of the lower cavity of the intercooler, and the other end of the bottom plate is connected to the side edge of the water storage part. The end of the bottom plate connected to the wall of the lower cavity of the intercooler is higher than the other end connected to the side edge of the water storage part, forming an inclination angle for the condensed water to flow back to the water storage part stably under the action of gravity.
10. The intercooler lower chamber assembly according to claim 1, characterized in that: A flange with a metal sealing gasket is provided at the connection between the air outlet and the throttle valve, and the air outlet is connected to the throttle valve through the flange.