Compact Two-Stage Turbocharger Charge Air Cooling Unit With Stacked Coolers
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Solution Overview
Problem
Large turbocharged piston engines face challenges in accommodating turbochargers and charge air coolers due to their bulkiness, making it difficult to achieve a compact and easily installable and maintainable engine design, particularly in V-engines with multiple turbocharger units.
Innovation Solution
A charge air cooling unit for a two-staged turbocharger is designed with a stacked arrangement of charge air coolers and a manifold unit that guides cooling fluid efficiently through both coolers, allowing for a compact and modular design by orienting end faces in the same direction and using a single-side connection for the manifold unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If turbochargers and charge air coolers are designed with sufficient size for proper function, then cooling performance is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple charge air coolers into a single integrated unit with a common housing that contains all coolers and their respective channels. This merging approach maintains the cooling performance of multiple stages while reducing the overall number of separate components and connections needed in the system.
Solution Approach 2:
The common housing serves multiple functions simultaneously: it houses the charge air coolers, provides structural support, acts as a manifold for cooling fluid distribution, and serves as the interface with the turbocharger. This multi-functionality reduces the need for separate components and simplifies the overall system architecture.
2Reliability
If turbochargers and charge air coolers are designed with sufficient size for proper function, then cooling performance is improved, but the engine design becomes less compact
Solution Approach 1:
The patent nests multiple charge air coolers within a single common housing structure, where the coolers are arranged in a compact configuration. This nesting approach allows the coolers to occupy space efficiently while maintaining their individual cooling functions, thereby reducing the overall volume required compared to separate cooler assemblies.
Solution Approach 2:
The patent transitions from a linear or distributed arrangement of coolers to a compact three-dimensional configuration within the common housing. By utilizing vertical stacking and multi-dimensional channel routing, the design achieves compactness without sacrificing cooling performance.
3Reliability
If separate connecting channels are used for each turbocharger and cooler, then proper fluid flow is achieved, but ease of installation and maintenance deteriorates
Solution Approach 1:
The patent merges the connecting channels into a single integrated manifold structure within the common housing. This manifold distributes cooling fluid to all coolers through internal channels, eliminating the need for separate external connecting channels for each cooler. The unified structure simplifies installation and maintenance by reducing the number of connection points and assemblies required.
4Reliability
If multiple separate coolers are used for each turbocharger stage, then cooling coverage is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple charge air coolers into a single integrated unit with a common housing that contains all coolers and their respective channels. This merging approach maintains the cooling performance of multiple stages while reducing the overall number of separate components and connections needed in the system.
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
The design enables a compact, less complex, and easier-to-install and maintain charge air cooling system, reducing space requirements and maintenance effort while effectively cooling charge air in multiple stages.
Implementation Method 1
a first charge air cooler (22) having a first end face (62) provided with a first cooling fluid inlet (HI1) and a first cooling fluid outlet (HO1) and a second charge air cooler (24) having a second end face (64) provided with a second cooling fluid inlet (HI2) and a second cooling fluid outlet (HO2)
Data Source
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AI summary
The present invention relates to a charge air cooling unit (20) comprising a first charge air cooler (22) having a first end face provided with a first cooling fluid inlet and a first cooling fluid outlet and a second charge air cooler (24) having a second end face provided with a second cooling fluid inlet and a second cooling fluid outlet. Specifically, the second charge air cooler (22) is arranged adjacent to the first charge air cooler (24) such that the first end face and the second end face are oriented in the same direction. Further, the charge air cooling unit (20) comprises a manifold unit (52) connected to the first end face and the second end face for guiding a cooling fluid through the first charge air cooler (22) and the second charge air cooler (24).