Charge Air Guide Element Cooling Channel Design
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Solution Overview
Problem
Medium speed internal combustion engines face challenges with corrosive exhaust gases from EGR systems damaging charge air system components, leading to increased maintenance and reduced component lifespan due to chemical reactions with condensate.
Innovation Solution
The design incorporates modular, cast charge air guide elements with integrated cooling water channels and drainage systems, allowing for easy replacement and maintenance of components without dismounting the charge air or cooling systems, and includes a water ring element with conduit structures for efficient cooling and fluid connection, suitable for both in-line and V-configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If EGR system is implemented to reduce NOX emission, then NOX emission is reduced, but charge air system components are subjected to corrosive exhaust gas leading to reduced component lifespan
Solution Approach 1:
The patent extracts the charge air guide element as a separate, replaceable component from the engine assembly. This allows the corrosive part to be removed and replaced independently without dismantling the entire engine or cooling system, thereby addressing the reduced component lifespan issue while maintaining the EGR system's NOX reduction benefit
Solution Approach 2:
The charge air guide element is designed as a modular component with integrated cooling channels that can be serviced independently. This segmentation allows targeted replacement of only the corrosive charge air guide element rather than the entire cooling system or engine, extending effective component lifespan while maintaining EGR functionality
2Quantity of substance
If complex charge air systems with long pipes are used in medium speed engines, then charge air distribution is achieved, but serviceability of components is reduced
Solution Approach 1:
The charge air guide element is extracted as a removable module that can be accessed and replaced without dismantling the complex charge air system piping. This maintains the charge air distribution function while dramatically improving serviceability by allowing direct access to the corrosive component
Solution Approach 2:
The system transitions from a fixed, integrated charge air system to a dynamic configuration where the charge air guide element can be independently removed and replaced. This dynamic design maintains charge air distribution while enabling easy maintenance of specific components
3Temperature
If integrated cooling water channel system is incorporated into charge air guide element, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling water channel system is merged with the charge air guide element into a single integrated component. This combination improves cooling efficiency by ensuring optimal thermal management of the charge air while the modular design allows the integrated component to be manufactured as a complete unit, balancing manufacturing complexity with performance benefit
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 accessibility and replaceability of damaged components, extends the lifespan of affected parts by removing aggressive condensate, and simplifies maintenance by allowing the charge air guide elements to stay mounted during servicing, while providing effective cooling and fluid connections for various engine configurations.
Implementation Method 1
chemical reactions with condensate
Implementation Method 2
cooling water channel system
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A charge air guide element (23) and a water ring element (40) for an internal combustion engine are configured to supply cooling water to the water ring element (40) via the charge air guide element (23). Specifically, a cooling water channel system (50A, 50B) may be integrated into a wall structure of the charge air guide element (23) and comprise at least one opening at the cylinder unit side of the charge air guide element (23), which opens towards the top side of the charge air guide element (23), and at least one opening at an access side of the charge air guide element (23), the access side being opposite to the cylinder unit side. Moreover, a specific arrangement of screw guiding holes (64A, 64B) at the charge air guide element (23) may allow using the charge air guide element (23) for internal combustion engines in in-line configuration and in V-configuration.