High-efficiency aluminum plate-fin type diesel engine turbocharged air cooler

Abstract

This utility model discloses a high-efficiency aluminum plate-fin type turbocharged air cooler for diesel engines, comprising a cooler body, an inlet support at one end of the cooler body, and an outlet support at the other end of the cooler body. The inlet support has an inlet port, and the outlet support has an outlet port. A gas outlet is located at the upper end of the cooler body, and a gas inlet is located at the lower end of the cooler body. A patch is installed on the outer side of the lower end of the cooler body. This high-efficiency aluminum plate-fin type turbocharged air cooler for diesel engines, through a rationally designed flow channel layout, can achieve efficient heat exchange in a relatively small space. Its modular design allows for flexible adjustment of size and shape according to different engine compartment spaces and heat dissipation requirements, facilitating installation and integration into various power systems and providing greater convenience for the overall layout design of vehicles and mechanical equipment.

Description

Technical Field

[0001] This utility model relates to the field of air coolers, and in particular to a high-efficiency aluminum plate-fin type turbocharged air cooler for diesel engines. Background Technology

[0002] The turbocharged air cooler lowers the temperature of the boosted air and increases its density, allowing more air to enter the cylinder and supplying sufficient oxygen for complete fuel combustion, greatly improving charging efficiency. In the complex system of a diesel engine, the turbocharged air cooler plays a crucial role. With increasingly stringent requirements for diesel engine performance, efficiency, and environmental protection, the importance of the turbocharged air cooler is becoming increasingly prominent. The unique fin structure design of the aluminum plate-fin intercooler effectively disturbs airflow, enhancing the convective heat transfer between the air and the fin surface, significantly improving the heat transfer coefficient. Compared to traditional intercoolers, its heat transfer efficiency can be increased by 30%-50%, quickly cooling high-temperature compressed air to the ideal temperature, providing the engine with sufficient and low-temperature intake air to ensure engine power output. The aluminum plate-fin intercooler has advantages such as compact structure and light weight. Its heat transfer area per unit volume is large, typically reaching 1000-1500㎡ / m³, achieving efficient heat dissipation while occupying little space. Because it uses aluminum alloy, its weight can be reduced by 40% - 60% compared to steel intercoolers. For weight-sensitive applications such as automotive and aerospace engines, this not only contributes to lightweight design of the entire vehicle or aircraft but also reduces energy consumption and improves fuel economy. It features a compact structure and light weight; the main structural types of intercoolers are tube-fin, plate-fin, and tube-strip. Materials are typically copper, steel, and aluminum; currently, aluminum plate-fin intercoolers mainly use air cooling, achieving forced convection heat transfer through a fan. With continuous technological advancements, the manufacturing process requirements for turbocharged air coolers are becoming increasingly stringent.

[0003] Existing turbocharged air coolers have certain drawbacks. Plate-fin air-to-air intercoolers have low heat exchange efficiency, large size, and are greatly affected by ambient temperature. They cannot meet the growing demands for improved engine performance and efficient heat dissipation. Tube-fin water-to-air intercoolers have a simple structure, low cost, and mature manufacturing process, offering good heat dissipation performance and reliability, and are widely used. However, they have relatively high air resistance, as well as large size and weight. Tube-strip air-to-air intercoolers have good heat dissipation performance, relatively low air resistance, and a certain degree of flexibility, allowing them to adapt to some installation deformation. However, the manufacturing process of tubes and strips is relatively complex, and the cost is also high. Air-cooled intercoolers rely on high-power fans for forced cooling, and the noise generated by the fan operation disrupts the quiet driving environment and increases maintenance costs and risks associated with fan failure. Therefore, we propose a high-efficiency aluminum plate-fin diesel engine turbocharged air cooler. Utility Model Content

[0004] Technical problem solved: In view of the shortcomings of the prior art, this utility model provides a high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler. Through the rational design of the flow channel layout, it can achieve efficient heat exchange in a small space. Its modular design features allow it to be flexibly adjusted in size and shape according to the space and heat dissipation requirements of different engine compartments, which is convenient for installation and integration into various power systems. It provides greater convenience for the overall layout design of vehicles and mechanical equipment and can effectively solve the problems in the background art.

[0005] Technical Solution: To achieve the above objectives, the technical solution adopted by this utility model is as follows: a high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler, comprising a cooler body, an inlet support installed at one end of the cooler body, an outlet support installed at the other end of the cooler body, an inlet port provided on the inlet support, an outlet port provided on the outlet support, a gas outlet provided at the upper end of the cooler body, a gas inlet provided at the lower end of the cooler body, a patch installed on the outer side of the lower end of the cooler body, a corner bracket installed on the side of the patch, and a turbocharger positioned at the bottom of the cooler body.

[0006] Preferably, a return tank is installed at the outlet, a pump body is installed at the bottom of the return tank, an inlet tank is installed at the inlet, a cooling water cooler is installed at the top of the inlet tank, a return pipe is connected between the pump body and the cooling water cooler, and a filter screen is installed on the side of the inlet tank.

[0007] Preferably, both ends of the pressurization device are positioned with elastic frames, an elastic component is positioned between the cooler body and the elastic frames, an intercooler is installed inside the cooler body, and heat exchange fins are positioned on the intercooler.

[0008] Preferably, the liquid inside the return tank is driven by a pump and enters the cooling water cooler through the return pipe for cooling before returning to the inlet tank for recycling.

[0009] Preferably, the pressurization device is slightly movable at the gas inlet position at the bottom of the cooler body via an elastic frame and elastic components.

[0010] Preferably, the bottom of the cooler body is installed using patches and corner brackets. Coolant enters the cooler body from the inlet and flows out from the outlet. Pressurized air enters the cooler body from the gas inlet and is ejected from the gas outlet.

[0011] Beneficial effects: Compared with the prior art, this utility model provides a high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler, which has the following beneficial effects: This high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler, through a reasonable design of the flow channel layout, can achieve efficient heat exchange in a small space. Its modular design features allow it to flexibly adjust its size and shape according to the space and heat dissipation requirements of different engine compartments, making it easy to install and integrate into various power systems, and providing greater convenience for the overall layout design of vehicles and mechanical equipment; Because of its relatively independent coolant circulation system, the water-cooled plate-fin intercooler performs exceptionally well in complex environments. Whether in extreme heat or cold, or under conditions unfavorable to air cooling such as frequent vehicle starts and stops or low-speed driving, it maintains stable heat dissipation performance, ensuring the engine remains within its optimal operating temperature range and enhancing engine reliability and durability. Water-cooled plate-fin intercoolers do not rely on high-power fans for forced cooling like air-cooled intercoolers, reducing the noise generated by fan operation and helping to create a quieter and more comfortable driving environment. They also reduce the maintenance costs and risks caused by fan failure. The air fins feature high heat exchange efficiency, optimized structural design, and low flow resistance. The product has tapered ends to resist high thermal stress, with a design temperature up to 265℃. The all-aluminum alloy design results in lighter weight. Diesel engine fuel efficiency is improved by 3%. The inlet and outlet temperature difference of the boosted air is 150℃. The inlet and outlet pressure drop of the boosted air is less than 1.65Kpa, and the water-side pressure drop is less than 50Kpa. The entire boosted air cooler has a simple structure, is easy to operate, and performs better than traditional methods. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the overall structure of the high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler of this utility model.

[0013] Figure 2 This is a schematic diagram of the overall bottom structure of the high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler of this utility model.

[0014] Figure 3 This is a schematic diagram of the other end of the high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler of this utility model.

[0015] Figure 4 This is a structural schematic diagram of the main view of the high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler of this utility model.

[0016] In the diagram: 1. Cooler body; 2. Liquid outlet support; 3. Liquid outlet; 4. Angle bracket; 5. Patch; 6. Liquid inlet support; 7. Liquid inlet; 8. Gas inlet; 9. Gas outlet; 10. Return tank; 11. Pump body; 12. Return pipe; 13. Radiator; 14. Liquid inlet tank; 15. Filter screen; 16. Pressurization device; 17. Heat exchange fins; 18. Flexible frame; 19. Flexible component; 20. Intercooler. Detailed Implementation

[0017] The technical solution of this utility model will be clearly and completely described below with reference to the accompanying drawings and specific embodiments. However, those skilled in the art will understand that the embodiments described below are only some embodiments of this utility model, not all embodiments, and are only used to illustrate this utility model, and should not be regarded as limiting the scope of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall be followed. Where the manufacturers of reagents or instruments are not specified, they are all conventional products that can be purchased commercially.

[0018] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model 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 this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0019] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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 can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0020] like Figure 1-4As shown, a high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler includes a cooler body 1, with a liquid inlet support 6 installed at one end of the cooler body 1 and a liquid outlet support 2 installed at the other end. The liquid inlet support 6 is provided with a liquid inlet 7, and the liquid outlet support 2 is provided with a liquid outlet 3. A gas outlet 9 is provided at the upper end of the cooler body 1, and a gas inlet 8 is provided at the lower end of the cooler body 1. A patch 5 is installed on the outer side of the lower end of the cooler body 1, and a corner bracket 4 is installed on the side of the patch 5. A turbocharger 16 is positioned at the bottom of the cooler body 1. Through a reasonable design of the flow channel layout, efficient heat exchange can be achieved in a small space. Its modular design features allow for flexible adjustment of size and shape according to the space and heat dissipation requirements of different engine compartments, facilitating installation and integration into various power systems and providing greater convenience for the overall layout design of vehicles and mechanical equipment.

[0021] Furthermore, a return tank 10 is installed at the outlet 3, a pump body 11 is installed at the bottom of the return tank 10, an inlet tank 14 is installed at the inlet 7, a cooling water cooler 13 is installed at the top of the inlet tank 14, a return pipe 12 is connected between the pump body 11 and the cooling water cooler 13, and a filter screen 15 is installed on the side of the inlet tank 14.

[0022] Furthermore, elastic frames 18 are positioned at both ends of the booster device 16, and an elastic component 19 is positioned between the cooler body 1 and the elastic frame 18. An intercooler 20 is installed inside the cooler body 1, and heat exchange fins 17 are positioned on the intercooler 20.

[0023] Furthermore, the liquid inside the return tank 10 is driven by the pump body 11 and enters the heat dissipation water cooler 13 through the return pipe 12 for cooling before returning to the inlet tank 14 for recycling.

[0024] Furthermore, the pressurization device 16 moves slightly at the gas inlet 8 at the bottom of the cooler body 1 via the elastic frame 18 and the elastic component 19.

[0025] Furthermore, the bottom of the cooler body 1 is installed with the patch 5 and the corner bracket 4. The coolant enters the cooler body 1 from the inlet 7 and flows out from the outlet 3. The pressurized air enters the cooler body 1 from the gas inlet 8 and is sprayed out from the gas outlet 9.

[0026] By simulating heat exchange conditions using specialized selection software and combining it with CFD analysis, the design of the water chamber and flow channels is optimized to reduce system resistance. The air side utilizes newly developed high-density fins, optimized through CFD and combined with wind tunnel testing, to provide a high heat transfer coefficient, a higher heat transfer area per unit area, and lower resistance. The water chamber is made of high-performance aluminum alloy castings, offering excellent corrosion resistance, lightweight construction for cost reduction, and an aesthetically pleasing appearance, making it suitable for mass production. Furthermore, the product undergoes wind tunnel performance testing, engine bench testing, pressure testing, temperature cycling testing, pressure cycling testing, burst testing, and vibration testing to ensure its reliability and durability.

[0027] Working Principle: This utility model includes a cooler body 1, a liquid outlet support 2, a liquid outlet 3, a bracket 4, a patch 5, a liquid inlet support 6, a liquid inlet 7, a gas inlet 8, a gas outlet 9, a return tank 10, a pump body 11, a return pipe 12, a radiator 13, a liquid inlet tank 14, a filter screen 15, a pressurization device 16, heat exchange fins 17, an elastic frame 18, an elastic component 19, and an intercooler 20. The product has an air passage and a coolant passage. The coolant passage has inlet and outlet chambers on both sides for introducing and transporting coolant. A flange is provided on the air side for installation on the engine. Both the air side and the coolant side use high-efficiency heat exchange fins, which can effectively disturb the fluid, enhance the convective heat transfer effect, and greatly improve the heat transfer coefficient. The pressurized air is located on the air side. After entering the heat exchanger from the inlet end, it exchanges heat with the coolant through the heat exchange fins and dividers, and the air temperature drops significantly before entering the engine intake end. After absorbing heat from the pressurized air, the coolant's temperature rises. It is then discharged into the radiator to cool down before being recycled. The intercooler uses cross-flow heat exchange, which is easy to pipe and install; The product features a special elastic design at both ends of the air side, allowing the ends to interact freely under thermal stress, thus preventing thermal stress damage. The maximum air inlet temperature can reach 260℃. The water chamber is designed with high-performance cast aluminum alloy, taking into account fluid mechanics, materials science and structural strength. The flow channel design needs to reduce eddies, pressure drop and dead volume.

[0028] It should be noted that, in this document, relational terms such as first and second (number one, number two), etc., are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0029] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model.

Claims

1. A high-efficiency aluminum plate-fin type turbocharged air cooler for diesel engines, comprising a cooler body (1), characterized in that: One end of the cooler body (1) is equipped with a liquid inlet support (6), and the other end of the cooler body (1) is equipped with a liquid outlet support (2). The liquid inlet support (6) is provided with a liquid inlet (7), and the liquid outlet support (2) is provided with a liquid outlet (3). The upper end of the cooler body (1) is provided with a gas outlet (9), and the lower end of the cooler body (1) is provided with a gas inlet (8). A patch (5) is installed on the outer side of the lower end of the cooler body (1), and a corner bracket (4) is installed on the side of the patch (5). A pressurizing device (16) is positioned at the bottom of the cooler body (1).

2. The high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler according to claim 1, characterized in that: A return tank (10) is installed at the outlet (3). A pump body (11) is installed at the bottom of the return tank (10). An inlet tank (14) is installed at the inlet (7). A heat dissipation water cooler (13) is installed at the top of the inlet tank (14). A return pipe (12) is connected between the pump body (11) and the heat dissipation water cooler (13). A filter screen (15) is installed on the side of the inlet tank (14).

3. The high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler according to claim 1, characterized in that: Both ends of the booster device (16) are positioned with elastic frames (18), and an elastic component (19) is positioned between the cooler body (1) and the elastic frame (18). An intercooler (20) is installed inside the cooler body (1), and heat exchange fins (17) are positioned on the intercooler (20).

4. The high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler according to claim 2, characterized in that: The liquid inside the return tank (10) is driven by the pump body (11) and enters the heat dissipation water cooler (13) through the return pipe (12) for cooling and then returns to the inlet tank (14) for recycling.

5. The high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler according to claim 3, characterized in that: The pressurizing device (16) moves slightly at the gas inlet (8) at the bottom of the cooler body (1) via the elastic frame (18) and elastic component (19).

6. The high-efficiency aluminum plate-fin type diesel engine turbocharged air cooler according to claim 1, characterized in that: The bottom of the cooler body (1) is installed by a patch (5) and a corner bracket (4). The coolant enters the cooler body (1) from the inlet (7) and flows out from the outlet (3). The pressurized air enters the cooler body (1) from the gas inlet (8) and is sprayed out from the gas outlet (9).

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