Coolant Collector Bracket Sliding Mount for EGR Cooler Assembly
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Solution Overview
Problem
Conventional engine cooling systems, particularly those with exhaust gas recirculation (EGR) coolers, face challenges in manufacturing, assembly, cooling efficiency, and serviceability.
Innovation Solution
The engine system incorporates a coolant collector bracket that vertically supports the EGR cooler, featuring a horizontal coupling to the cylinder head and perpendicularly to the EGR cooler, with mounting legs that include slots for slidably inserting onto fasteners of the cylinder head, facilitating efficient coolant flow and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional coolant system with EGR cooler is used, then cooling function is provided, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The coolant collector bracket integrates multiple functions into a single component: it collects coolant from multiple cylinder heads, directs it to the EGR cooler, and provides mounting structure. This merging reduces the number of separate parts and simplifies manufacturing while maintaining the cooling function.
Solution Approach 2:
The coolant collector bracket serves multiple purposes simultaneously: it acts as a coolant collection point, a flow distribution channel, and a mounting structure for the EGR cooler. This multi-functionality reduces overall system complexity while ensuring reliable cooling operation.
2Reliability
If conventional coolant system components are used, then cooling is achieved, but assembly time and serviceability are reduced
Solution Approach 1:
The coolant collector bracket is designed as a modular component that can be assembled separately from the EGR cooler and other engine components. This segmentation allows for more efficient assembly and easier serviceability, as the bracket can be installed independently and replaced if needed.
Solution Approach 2:
The coolant collector bracket is pre-configured with integrated coolant passages and mounting features during manufacturing. This preliminary preparation of the bracket structure eliminates the need for complex field assembly operations and improves both assembly efficiency and serviceability.
3Reliability
If coolant passages are routed through multiple components, then cooling coverage is improved, but manufacturing precision requirements increase
Solution Approach 1:
The coolant passages are integrated directly into the coolant collector bracket as a unified structure, eliminating the need for separate passage routing through multiple components. This integration maintains comprehensive cooling coverage while significantly reducing the cumulative precision requirements that would arise from aligning multiple separate passages.
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 coolant flow management, improves assembly efficiency, and potentially addresses cooling system drawbacks in manufacturing and serviceability, while maintaining effective cooling performance.
Implementation Method 1
The coolant then flows longitudinally through a portion of the coolant jacket surrounding the cylinders of the engine. The coolant may then flow into a water jacket of one or more cylinder heads to cool the components of the cylinder heads
Implementation Method 2
an exhaust gas recirculation (EGR) cooler... The EGR system includes an EGR heat exchanger or cooler with a coolant inlet opening connected to a coolant outlet opening of the engine
Data Source
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AI summary
An internal combustion engine system including a cylinder block, a cylinder head attached to the cylinder block, an EGR cooler, and a coolant collector bracket configured to vertically support the EGR cooler is provided. The cylinder head includes a lateral surface including a plurality of fasteners positioned along a bottom edge of the lateral surface. The cylinder head also includes a plurality of coolant passages. The coolant collector bracket is horizontally coupled to the cylinder head and perpendicularly coupled to the EGR cooler. The coolant collector bracket includes a plurality of mounting legs directly coupled to the lateral surface of the cylinder head. The plurality of mounting legs include a plurality of slots. The plurality of mounting legs are slidably inserted onto the plurality of fasteners of the cylinder head via the plurality of slots.