Engine Oil Cooler Backflush Valve Assembly Design
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Solution Overview
Problem
Diesel engine oil coolers often become restricted due to debris, leading to increased oil temperatures and potential component failure, requiring costly replacement, with existing solutions lacking a mechanism for cleaning without removing the EGR coolant supply cover.
Innovation Solution
A backflush valve assembly that serves as a permanent replacement for the EGR coolant supply cover, allowing for selective backflushing of the engine oil cooler without removing the cover, incorporating a manually activated valve and increased volume for improved coolant flow, enabling debris removal and monitoring of coolant temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the oil cooler is cleaned by removing the EGR coolant supply cover, then debris can be removed from the oil cooler, but the process becomes time-consuming and requires repeated disassembly and reassembly
Solution Approach 1:
The patent incorporates a cleanout port and T-handle mechanism into the valve assembly during manufacturing, enabling users to perform backflushing operations without removing the EGR coolant supply cover. This preliminary design integration eliminates the need for repeated disassembly and reassembly, reducing cleaning time from potentially hours to minutes while maintaining effective debris removal capability
Solution Approach 2:
The patent introduces a T-handle and valve mechanism as an intermediary tool that provides access to the oil cooler's internal passages through the valve assembly. This intermediary mechanism allows debris to be flushed out through dedicated ports without requiring removal of the EGR coolant supply cover, serving as a mediator between the user and the confined internal passages
2Reliability
If the oil cooler passages are restricted with debris, then coolant flow is reduced and oil temperature increases, but replacement of the oil cooler is expensive
Solution Approach 1:
The patent enables oil cooler owners to perform their own maintenance through the integrated backflushing system with T-handle and valve assembly. Users can independently clean debris from coolant passages using the external cleanout ports, eliminating the need for professional service or expensive replacement. The system empowers end-users to restore full coolant flow and maintain reliability at minimal cost
Solution Approach 2:
The patent allows for recovery and reuse of the oil cooler by removing accumulated debris through the backflushing mechanism. Instead of discarding the entire oil cooler assembly when debris restricts passages, the system enables selective removal and flushing of contaminants while retaining the functional heat exchanger components, significantly reducing replacement costs
3Ease of operation
If the EGR coolant supply cover is made removable for cleaning, then access to oil cooler passages is enabled, but the risk of loss or misplacement of the cover increases
Solution Approach 1:
The patent segments the cleaning function from the EGR coolant supply cover by providing separate external cleanout ports on the valve assembly. The T-handle operates these ports independently without requiring removal of the cover. This segmentation maintains the cover's permanent installed position for reliability while providing accessible cleaning points for ease of operation
Solution Approach 2:
The patent introduces external cleanout ports and a T-handle as intermediary access points that provide a pathway to the oil cooler's internal passages without requiring removal of the EGR coolant supply cover. This intermediary mechanism maintains secure cover retention while enabling easy cleaning operations through the valve assembly's external interface
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
Enables repetitive backflushing of the oil cooler to dislodge debris, maintaining optimal coolant flow and reducing the need for frequent oil cooler replacements, while allowing for monitoring of coolant discharge temperature to diagnose blockages and aid in cleaning processes.
Implementation Method 1
The engine oil cooler transfers heat from the entering hot oil to the coolant via the heat exchanger contact so that the oil exiting the cooler is at an acceptable temperature
Implementation Method 2
The valve stem is movable from a first position to a second position, wherein in the first position the valve stem is not seated on the EGR coolant supply port, and wherein in the second position the valve stem is seated on the EGR coolant supply port
Data Source
AI summary
An engine oil cooler backflush valve assembly is provided as a replacement cap to an engine oil cooler EGR coolant supply cover. The backflush valve assembly includes a main body through which a valve stem is inserted. The valve stem has a bushing threadedly attached thereto which moves the valve stem between first and second positions. A removable cap is provided to cover the backflush valve assembly during normal operation and to be removed during backflush operation. A removable lock can also be used to secure the cap and/or bushing to the main body of the assembly.