Air-Liquid Intercooler Layout for Compact Engine Bay Packaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in designing an aerodynamically improved motor vehicle with an internal combustion engine is to efficiently integrate auxiliary devices like intercoolers without compromising the distribution of dimensions and weight, while maintaining efficient engine operation.
Innovation Solution
The motor vehicle incorporates an internal combustion engine with a crankcase and cylinders, featuring an air/liquid intercooler arrangement that is strategically positioned behind the engine along the roll axis and aligned with the gearbox, allowing for compact placement and reduced overall dimensions, thereby enabling the design of aerodynamic channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the intercooler is positioned in a conventional location, then the engine cooling function is achieved, but the vehicle dimensions and aerodynamic performance are compromised
Solution Approach 1:
The intercooler is repositioned from a conventional longitudinal arrangement to a lateral arrangement beside the compression assembly, utilizing the lateral dimension of the engine bay. This dimensional repositioning allows the intercooler to be integrated into the side profile of the engine compartment, reducing the overall vehicle width and improving aerodynamic channels while maintaining adequate cooling surface area through optimized fin-and-tube configuration
2Volume of moving object
If the intercooler is positioned to improve aerodynamics, then vehicle dimensions are reduced, but the cooling efficiency may be compromised
Solution Approach 1:
The intercooler employs locally optimized thermal management features including variable pitch fins, strategically positioned bypass passages, and selective insulation zones. These local quality enhancements ensure that despite the compact lateral positioning, the critical cooling zones receive adequate airflow and heat dissipation capacity is maintained through localized structural variations rather than uniform design
3Weight of moving object
If auxiliary devices are compactly arranged, then vehicle weight and dimensions are reduced, but the complexity of integration increases
Solution Approach 1:
The intercooler is merged with the compression assembly into a integrated thermal management module, where the intercooler housing serves dual purposes as both the cooling device enclosure and the compression assembly mounting structure. This merging eliminates separate mounting brackets, fasteners, and alignment mechanisms, thereby reducing overall weight and part count while simplifying the integration process despite the compact arrangement
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration minimizes the vehicle's dimensions, allowing for improved aerodynamics and efficient placement of auxiliary devices, enhancing performance and reducing weight while maintaining efficient engine operation.
Implementation Method 1
at least one intercooler downstream of the compression assembly, wherein the intercooler is an air/liquid type intercooler
Data Source
AI summary
A motor vehicle is described, the former including an internal combustion engine, an intake assembly with an intake manifold and at least one intake line for conveying air to the intake manifold, wherein the intake line has a compression assembly configured to increase the pressure of the air conveyed to the intake manifold and at least one intercooler downstream of the compression assembly, wherein the compression assembly is arranged behind the internal combustion engine according to a roll axis of the vehicle, wherein the intercooler is of the air/liquid type and is arranged side by side with the compression assembly.