Charge Air Cooler Stator Adapter Accessibility
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Solution Overview
Problem
Existing engine systems with turbocharging or supercharging face challenges in efficiently cooling compressed air, which affects the density and power output, and there is a need for a configuration that allows access to internal components without disassembly.
Innovation Solution
A system comprising a turbocharger system with a charge-air cooler positioned below the compressor, a turbocharger bracket for mounting, and a stator adapter with an accessibility window, where the charge-air cooler is closer to the window than the turbocharger system, allowing for efficient cooling and maintenance access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the charge-air cooler is positioned below the compressor to improve cooling efficiency, then the cooling performance increases, but the accessibility to internal components for maintenance deteriorates
Solution Approach 1:
The patent positions the charge-air cooler in the vertical dimension below the compressor, optimizing cooling efficiency while using the horizontal dimension (accessibility window in the stator adapter) to maintain maintenance access. This spatial dimensionality change resolves the contradiction by separating the cooling function optimization from the maintenance access requirement.
2Ease of repair
If the charge-air cooler is positioned closer to the accessibility window, then maintenance access is improved, but the cooling efficiency may deteriorate
Solution Approach 1:
The stator adapter acts as an intermediary element that provides the accessibility window for maintenance while the charge-air cooler maintains its optimal position below the compressor for cooling efficiency. The intermediary structure allows both requirements to coexist without direct compromise.
3Use of energy by moving object
If the swept volume is decreased to increase current load, then fuel consumption decreases, but the power output may be affected
Solution Approach 1:
The patent changes the parameter of charge air temperature through active cooling, which increases charge air density. This parameter change allows the engine to maintain or increase power output even with decreased swept volume, resolving the contradiction between fuel efficiency and power output.
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 the cooling efficiency of charge air, increases power output, and facilitates quicker maintenance by maintaining access to internal components without disassembly, thereby improving manufacturing efficiency and reducing maintenance costs.
Implementation Method 1
The CAC may be arranged downstream of the compressor and may cool compressed air flowing therethrough
Data Source
AI summary
Various systems are provided for a charge-air cooler system. In one example, a system includes a turbocharger system having at least one compressor and one turbine and configured to provide charge air to an engine. The system also includes a charge-air cooler system having at least one charge-air cooler arranged below the at least one compressor, a turbocharger bracket arranged directly below the charge-air cooler system and shaped to mount the charge-air cooler and the turbocharger system to the engine, and a stator adapter physically coupling an alternator to the engine. The stator adapter includes an accessibility window arranged below the charge-air cooler system. The at least one charge-air cooler is closer to the accessibility window than the turbocharger system.