Charge Air Cooler Condensate Removal via Tube Overhangs
Solution Overview
Problem
Existing charge air and exhaust gas coolers for internal combustion engines face challenges in efficiently removing large amounts of condensate that accumulate and can lead to disruptive buildup, particularly in low-pressure exhaust gas recirculation systems where the gas flow includes an exhaust gas/air mixture.
Innovation Solution
The design incorporates features such as tube overhangs, edge modulations, collector cross-section enlargements, guide elements, tear-off edges, and turbulence elements to atomize and transport condensate in a vaporized or aerosol-like form, ensuring it is removed effectively from the heat exchanger without accumulating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If condensate is allowed to accumulate in the heat exchanger, then the cooling function is maintained, but disruptive buildup occurs and reliability deteriorates
Solution Approach 1:
The patent extracts the condensate from the heat exchanger by utilizing the gas flow to remove condensate through the tube walls into the gas stream, where it is carried away to a collection point. This extraction mechanism prevents disruptive accumulation while maintaining the cooling function.
Solution Approach 2:
The gas flow acts as an intermediary medium that facilitates condensate removal. The condensate is transferred from the liquid phase in the heat exchanger to the gas phase stream, which then transports it away from the heat exchanger to a collection point, preventing accumulation.
2Ease of manufacture
If tube ends are flush with collector floor, then manufacturing is simplified, but condensate atomization is insufficient
Solution Approach 1:
The tube ends are extended beyond the collector floor before the gas flow arrives, creating a preliminary structure that promotes condensate atomization. This extension is designed in advance to interact with the gas flow and enhance condensate removal without complicating the manufacturing process significantly.
Solution Approach 2:
The tube ends are extended in the direction perpendicular to the collector floor, adding a dimensional aspect that enhances condensate atomization. This extension creates a three-dimensional interaction between the condensate, tube edges, and gas flow, improving removal efficiency while maintaining manufacturing simplicity.
3Productivity
If gas flow rate is increased to remove condensate, then condensate removal is improved, but energy consumption increases
Solution Approach 1:
The system uses the existing gas flow that is already present in the heat exchanger to remove condensate. The gas flow serves dual purposes: cooling the charge air and simultaneously transporting condensate away from the heat exchanger. This self-service mechanism eliminates the need for additional energy-consuming condensate removal systems.
Solution Approach 2:
The gas flow performs multiple functions: it cools the charge air through the heat exchanger tubes and simultaneously acts as a transport medium to remove condensate from the heat exchanger to a collection point. This multi-functionality improves condensate removal efficiency without requiring separate energy-intensive systems.
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 solution enhances the atomization and transport of condensate, preventing disruptive accumulation and ensuring efficient removal, even under conditions of varying gas flow rates and condensate volumes, particularly in intercoolers and exhaust gas coolers.
Implementation Method 1
the edge of the tube is exposed to a gas flow and distribution of condensate that has accumulated in the tube in fine droplets at the edge of the tube is promoted
Implementation Method 2
allows condensate that has accumulated to be introduced into the gas stream in vaporized or aerosol-like atomized form
Implementation Method 3
the condensate is transported away through the outlet and does not accumulate in a disruptive amount in the Heat exchanger
Implementation Method 4
the edge of the tube is exposed to a gas flow and distribution of condensate that has accumulated in the tube in fine droplets at the edge of the tube is promoted
Implementation Method 5
the enlargement of the cross section achieves an equalization of the flow rate of the gas over the length of the collector
Implementation Method 6
a wall of the collector opposite the tubes is inclined in relation to a direction perpendicular to the tubes, which allows the gas flow to graze the wall and optimally propel the condensate film
Implementation Method 7
a turbulence element is provided in some of the tubes in the form of an inserted and soldered inner rib, with the turbulence element projecting beyond the end of the tube and into the collector
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The exchanger has a collector box (2) provided with a set of substantially parallel tubes on an output side, where the tubes open into the collector box on the output side. A gas flow flows from the tubes into the collector box and from the collector box into an outlet (2a) of the collector box. Structures (15, 16) cooperate with the gas flow and are provided at one of the tubes or the collector box such that a condensation is transported to the outlet by the structure.