Charge Air Line Integration in Engine Mounts
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Solution Overview
Problem
Existing arrangements of charge air lines in internal combustion engines are not economical in terms of assembly and weight, and do not efficiently integrate the charge air cooler, leading to complex and space-consuming designs.
Innovation Solution
Integrating sections of the charge air line into engine mounts on both longitudinal sides of the engine, with the charge air cooler connected to mounting flanges, allowing the engine supports to also function as stiffening sections for the charge air line and carrying the cooler as an intermediate section, while maintaining a freely accessible oil pan flange for easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the charge air line is arranged separately from the engine mounts, then the assembly and installation are simpler, but the overall structure becomes more complex and space-consuming
Solution Approach 1:
The patent combines the charge air line with the engine mounts by integrating mounting flanges directly into the engine mount structure. This merging eliminates the need for separate charge air line supports and reduces the number of individual components, thereby simplifying the overall structure while maintaining assembly simplicity through the unified design.
Solution Approach 2:
The engine mounts are designed to serve multiple functions: providing mechanical support for the engine and simultaneously serving as structural supports for the charge air line through integrated mounting flanges. This multi-functionality reduces the need for separate support structures and simplifies the overall assembly without compromising manufacturing ease.
2Weight of stationary object
If the charge air cooler is separately mounted, then the assembly and installation are simpler, but the overall weight increases and space efficiency decreases
Solution Approach 1:
The charge air cooler is integrated with the engine mounts through shared mounting flanges, combining what would traditionally be separate components into a unified assembly. This integration eliminates redundant mounting hardware and reduces the overall weight while maintaining assembly simplicity through the standardized flange connection system.
Solution Approach 2:
The charge air cooler is positioned and supported within the spatial envelope defined by the engine mounts, with the cooler effectively nested within the structural framework provided by the mounts. This nesting arrangement optimizes space utilization and reduces overall weight by eliminating separate support structures.
3Stability of the object's composition
If the charge air line sections are integrated into engine mounts, then the structure becomes more stable and space-saving, but the manufacturing complexity of engine mounts increases
Solution Approach 1:
The mounting flanges for the charge air line are integrated directly into the engine mount casting, creating a unified structural component. This merging enhances structural stability by eliminating separate mounting brackets and improving rigidity, while the casting process absorbs the additional manufacturing complexity without significantly impacting production feasibility.
Solution Approach 2:
The engine mounts are designed as multi-functional components that simultaneously provide mechanical support and structural attachment points for the charge air line. This multi-functionality is achieved through integrated flanges in the casting, which enhances structural stability while the standardized casting process keeps manufacturing complexity manageable.
4Reliability
If fastening flanges project beyond the end face of the engine, then the charge air cooler can be reliably held, but the design complexity and assembly constraints increase
Solution Approach 1:
The projecting fastening flanges are integrated into the engine mount structure, combining the mounting function with the structural support function. This integration ensures reliable holding of the charge air cooler while the unified design reduces overall complexity compared to separate mounting brackets with projecting flanges.
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 results in a more stable, space-saving, and cost-effective arrangement that simplifies assembly and reduces weight, with the engine mounts providing additional structural support and easy access for the charge air cooler connection to the cooling system.
Implementation Method 1
the charge air cooler (13) connected to mounting flanges (6h, 7h) of the two engine mounts (6, 7) and communicating with the integrated sections (6e, 7e) of the charge air line (10)
Data Source
Figure 1
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AI summary
The engine has a charge air line including sections (6e, 7e) that are guided through respective laterally mounted engine carriers (6, 7), which are provided at two respective long sides (4, 5) of the engine. An intercooler (13) is switched between the engine carriers. The charge air line sections are integrated into the respective engine carriers. The intercooler is attached at mounting flanges (6h, 7h) of the engine carriers, so that the intercooler is carried by the engine carriers. The intercooler is in contact with the integrated charge air line sections.