Vehicle Air Compressor Discharge Cooling Jumper
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Solution Overview
Problem
Heavy vehicle air braking systems face inefficiencies in cooling compressed air, leading to increased temperatures and potential carbon buildup, which can affect the operation and longevity of downstream components.
Innovation Solution
A vehicle air compressor apparatus with a discharge air cooling jumper is introduced, which connects externally between intermediate ports to cool compressed air before it is delivered, reducing the temperature of the air exiting the compressor and preventing carbon buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressed air is delivered directly from the compressor without additional cooling, then the system structure remains simple, but the discharge air temperature remains high causing carbon buildup and reduced efficiency of downstream components
Solution Approach 1:
The discharge air cooling jumper is nested within the existing cylinder head assembly structure, utilizing the space between the discharge port and the cylinder head exterior. The jumper connects internally to the discharge air stream while extending externally to provide cooling surface area, effectively nesting the cooling function within the existing compressor structure without adding separate external cooling systems.
Solution Approach 2:
The cooling jumper extends in a third dimension from the discharge port area, projecting outward from the cylinder head to provide additional cooling surface area. This dimensional extension allows the compressed air to be cooled by ambient air or radiator airflow passing over the external portion of the jumper, adding cooling capacity without increasing the footprint of the main compressor body.
2Temperature
If the discharge line is made longer to cool compressed air, then cooling effectiveness improves, but the system size and installation space requirements increase
Solution Approach 1:
The cooling jumper provides preliminary cooling of the discharged compressed air immediately at the discharge port, before the air enters the discharge line. By cooling the air at the source rather than relying on extended line length, the system achieves effective cooling while keeping the discharge line short and minimizing installation space requirements.
3Temperature
If the discharge line diameter is increased to improve cooling, then cooling effectiveness improves, but the device size and cost increase
Solution Approach 1:
The cooling jumper acts as an intermediary cooling element between the compressed air stream and the ambient environment. Rather than increasing the discharge line diameter, the jumper provides an additional heat transfer pathway, serving as a mediator that facilitates cooling without requiring larger piping or increased system volume.
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 solution achieves a 15% to 50% reduction in discharge air temperature, improving the operational efficiency of downstream components and reducing the risk of carbon buildup, while maintaining the pneumatic function of the compressor without modifying the crankcase assembly.
Implementation Method 1
The discharge air cooling jumper is arranged to cool compressed air passing from the first intermediate port through a discharge air path of the jumper to the second intermediate port
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A vehicle air compressor apparatus is provided for a heavy vehicle air braking system. The apparatus comprises a crankcase, and a cylinder head disposed on the crankcase. The cylinder head includes (i) an air inlet port through which air can be received for compression within the crankcase and the cylinder head, (ii) a discharge port through which compressed air can be delivered from the cylinder head, (iii) a first port through which compressed air can pass, and (iv) a second port through which cooled compressed air can pass. The apparatus further comprises a discharge air cooling jumper connected externally of the cylinder head between the first and second ports. The jumper is arranged to cool compressed air passing from the first port through a discharge air path of the jumper to the second port to provide cooler compressed air to be delivered from the cylinder head through the discharge port.