Integrated Coolant Collector Bracket for EGR Cooler Assembly
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Solution Overview
Problem
Conventional coolant systems for internal combustion engines, particularly those involving an exhaust gas recirculation (EGR) cooler, face challenges in manufacturing, assembly, and serviceability.
Innovation Solution
A coolant collector bracket is designed to connect a cylinder head of an engine system to an EGR cooler, featuring a first planar surface for vertical support, orthogonal second surfaces with coolant inlets, internal channels, and recessed/exposed coolant outlets/inlets for efficient coolant flow, with mounting legs and gaskets for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional coolant system with separate coolant collecting rail and EGR cooler mounting is used, then the system can be manufactured and assembled, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent combines the coolant collecting rail and EGR cooler mounting bracket into a single integrated component. The coolant collector bracket simultaneously serves as the coolant collection structure and the mounting structure for the EGR cooler, eliminating the need for separate components and reducing assembly steps.
Solution Approach 2:
The coolant collector bracket performs multiple functions: it collects coolant from the cylinder head, serves as a mounting structure for the EGR cooler, provides coolant flow paths to the EGR cooler, and structurally supports the EGR cooler assembly. This multi-functional design reduces the overall number of components required.
2Ease of operation
If multiple separate components are used for coolant collection and EGR cooler mounting, then functional requirements are met, but assembly time and serviceability are reduced
Solution Approach 1:
By integrating the coolant collecting rail and EGR cooler mounting bracket into one component, the assembly process is simplified. The EGR cooler is mounted directly to the integrated bracket, reducing the number of assembly steps and time required for installation and maintenance.
3Manufacturing precision
If coolant inlets and channels are not pre-aligned in the mounting bracket, then manufacturing is simpler, but alignment precision and cooling efficiency are reduced
Solution Approach 1:
The integration of coolant channels directly into the mounting bracket allows for precise alignment of coolant inlets with the EGR cooler ports. The coolant channels are formed as integral parts of the bracket structure, ensuring accurate positioning and alignment during manufacturing.
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
Facilitates efficient coolant flow and easy assembly by providing a robust, aligned connection between the cylinder head and EGR cooler, enhancing manufacturing and serviceability.
Implementation Method 1
A plurality of internal coolant channels are provided for moving coolant from the cylinder head to a cylinder block
Implementation Method 2
an exhaust gas recirculation (EGR) cooler with a coolant inlet opening and a coolant outlet opening
Data Source
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AI summary
A coolant collector bracket (18) including a front side, a back side, and a top side is provided. The back side is opposite the front side and includes a plurality of coolant inlets (43) for receiving coolant from a cylinder head (14). The top side includes an exhaust gas recirculation (EGR) cooler inlet (38) and an EGR coolant outlet (36). The EGR coolant inlet (38) and the EGR coolant outlet (36) are substantially orthogonal to the plurality of coolant inlets (43).