Common-Rail Cooling System for Internal Combustion Engine
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Solution Overview
Problem
Existing internal combustion engine cooling systems suffer from uneven coolant distribution and high pressure losses due to limited coolant entry points, leading to increased fuel consumption and reduced cooling efficiency.
Innovation Solution
The implementation of a 'common-rail' cooling system with conical inlet and outlet rails and flow guide vanes, allowing for even coolant distribution and low-pressure-loss cross-flow cooling, enabling efficient coolant delivery to all cylinders and coolers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If coolant is supplied through limited entry points (one or two) into the water jacket, then the cooling system structure is simple, but the coolant distribution becomes uneven and pressure losses increase
Solution Approach 1:
The patent segments the cooling system by introducing multiple coolant entry points (at least three) into the water jacket, with each entry point serving specific cylinder groups. This segmentation enables balanced coolant distribution to different cylinders while maintaining structural simplicity through the modular entry point configuration.
Solution Approach 2:
The patent applies local quality by assigning different entry points to different spatial zones of the engine - front cylinders receive coolant from front entry points while rear cylinders receive coolant from rear entry points. This localized coolant supply optimizes pressure distribution and reduces energy losses in specific regions.
2Ease of manufacture
If coolant is supplied through limited entry points, then the system is simple to manufacture, but coolant distribution to individual cylinders becomes uneven
Solution Approach 1:
The water jacket is divided into multiple cooling circuits, with each circuit having its own dedicated entry point. This segmentation allows each cylinder group to receive optimized coolant flow independently, achieving uniform distribution without complex manufacturing requirements.
Solution Approach 2:
The patent transitions from a single-entry-point linear distribution system to a multi-entry-point three-dimensional distribution network. By adding the spatial dimension of multiple entry points throughout the water jacket volume, the system achieves uniform coolant distribution while maintaining manufacturing simplicity.
3Device complexity
If the thermostat is attached to one end of the cylinder head with single-sided water supply, then the cooling system structure is simplified, but the water supply to individual areas in the head varies greatly
Solution Approach 1:
The cooling system is segmented into multiple independent cooling circuits, each with its own thermostat and entry point configuration. This allows balanced water supply to different cylinder groups while maintaining overall system structural simplicity through modular circuit design.
Solution Approach 2:
Instead of having a single thermostat controlling one-sided water supply, the patent inverts the approach by distributing multiple entry points throughout the water jacket, each with its own thermostat control. This reversal of the conventional single-point control architecture achieves uniform water distribution while keeping the system structure manageable.
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 design ensures even coolant distribution, reduces pressure losses, saves pump power, minimizes cylinder distortion, and enhances cooling efficiency, resulting in improved engine performance and reduced fuel consumption.
Implementation Method 1
A water flow in the crankcase and in the cylinder head that flows essentially in the transverse direction is advantageous from a cooling point of view. In front of the entry into the crankcase, there is an entry volume ('common rail') into which the water from the pump can flow with little loss.
Implementation Method 2
The cooling circuit of the internal combustion engine has a coolant pump, after which an inlet rail is arranged in the flow direction of the coolant. In the coolant flow direction in an engine oil cooler and an exhaust gas recirculation cooler, the are arranged before or after the inlet rail and branched into the crankcase.
Data Source
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AI summary
Described is an internal combustion engine, in particular with a dual-circuit water cooling system, comprising a crankcase, at least one inlet and/or outlet rail that is arranged upstream of the crankcase, communicates with the crankcase and holds coolant, at least one coolant-conducting cylinder head, and at least one outlet and/or inlet rail that is arranged downstream of the cylinder head, communicates with the cylinder head and holds coolant.