Charge Air Cooler Axial Fan Bracket Isolator Noise
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Solution Overview
Problem
Existing engine designs face challenges in efficiently cooling the charge air due to limited space in the engine compartment, leading to increased design complexity and reduced serviceability, with conventional fan systems often requiring additional components that occupy volume and increase noise.
Innovation Solution
A charge-air cooler system coupled to upper and lower brackets via isolators, with an axial dual fan system extending vertically to these brackets, reducing noise and simplifying assembly and maintenance, while allowing for increased airflow through the intercooler.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a dedicated fan system is placed in the engine compartment to increase airflow through the intercooler, then vehicle performance is enhanced, but the design complexity and assembly complexity increase due to limited space and the need for additional mounting components
Solution Approach 1:
The fan system is merged with the intercooler assembly by integrating the mounting brackets directly into the intercooler structure. The brackets protrude from the periphery of the intercooler and serve dual purposes: structural support for the intercooler and mounting points for the fan assembly, eliminating the need for separate mounting components
Solution Approach 2:
The mounting brackets are designed with multi-functionality, serving both as structural supports for the intercooler and as attachment points for the fan assembly. This universal component design reduces the total number of parts needed and simplifies the overall system architecture
2Reliability
If mounting brackets and additional supports are added to secure the fan to the heat exchanger, then the fan assembly is stabilized, but the noise from the fan system increases
Solution Approach 1:
Rubber isolators are introduced as intermediary elements between the fan assembly and the mounting brackets. These isolators serve as mediators that decouple the fan system from the rigid structural supports, allowing vibration isolation while maintaining the structural connection, thereby reducing noise transmission
Solution Approach 2:
Rubber isolators are pre-installed between the fan assembly and mounting brackets to provide beforehand cushioning against vibrations and noise. This preventive measure cushions the fan system from generating and transmitting noise during operation
3Reliability
If numerous layered components are used to secure the fan in place, then the fan assembly is firmly mounted, but serviceability is reduced due to the need to dismantle multiple components for maintenance
Solution Approach 1:
The fan assembly is designed as a segmented, modular unit that can be independently removed from the intercooler assembly. The mounting brackets and isolators allow the fan to be detached as a separate module, enabling maintenance personnel to service the fan without dismantling the entire intercooler or other layered components
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 enhances vehicle performance by increasing airflow, reduces noise, and simplifies manufacturing and servicing, while maintaining structural rigidity and durability, even in constrained engine compartments.
Implementation Method 1
Electric fans increase airflows in engines, particularly when used in combination with components like heat exchangers. Thus, increased airflows increase a cooling rate to enhance vehicle performance.
Implementation Method 2
the axial dual fan system connected to the upper and lower brackets via one or more isolators... the vibrational energy transferred to the axial dual fan system from the vehicle may be reduced during operation, which reduces the noise emanating therefrom
Implementation Method 3
a charge-air cooler coupled via upper and lower brackets to a vehicle body... increased airflows increase a cooling rate to enhance vehicle performance
Data Source
AI summary
A system for increasing air flow across a heat exchanger of a vehicle is described. In one particular example, the system comprises a charge-air cooler coupled via upper and lower brackets to a vehicle body, and an axial dual fan connected to the upper and lower brackets via one or more isolators. With this arrangement, the cooling system described allows for vehicle performance to be enhanced while also increasing the durability and robustness of the system and reducing the noise produced therefrom.