Charge Air Cooler Movable End Piece Thermal Deformation
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Solution Overview
Problem
Charge air cooler arrangements face deformation due to thermodynamic expansions and contractions caused by temperature differences, leading to potential leaks and reduced service life.
Innovation Solution
A flexible connection between the cooler and the housing allows for movement compensating thermodynamic changes, using movable end pieces that can pivot or be prestressed to counteract deformations, thereby enhancing stability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the cooler is rigidly connected to the housing, then structural stability is improved, but deformation damage occurs due to thermodynamic expansions and contractions
Solution Approach 1:
The end piece is designed to be movably attached to the housing, allowing it to pivot or move within a limited range of motion. This dynamic connection enables the cooler to accommodate thermodynamic expansions and contractions without causing deformation damage, while still maintaining structural stability during operation.
Solution Approach 2:
The connection between the end piece and housing is designed to change its mechanical parameters (rigidity, movement range) based on operational conditions. During normal operation, the connection provides stability, while during thermal cycles, it allows controlled movement to prevent damage.
2Productivity
If the cooler is designed for higher cooling capacity, then cooling efficiency is improved, but thermodynamic deformations increase causing damage
Solution Approach 1:
The movable end piece connection allows the cooler to handle higher thermal loads and thermodynamic deformations that result from increased cooling capacity, preventing structural damage while maintaining enhanced cooling performance.
3Ease of manufacture
If the end piece is fixed to the housing, then manufacturing simplicity is improved, but deformation damage occurs reducing service life
Solution Approach 1:
The movable attachment of the end piece to the housing provides a relatively simple connection structure that incorporates pivoting or movement capability. This design extends service life by accommodating thermal deformations without requiring complex compensation mechanisms.
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 solution extends the service life of the charge air cooler arrangement by preventing damage from thermal deformations and allows for higher loads, improving cooling efficiency by maintaining structural integrity.
Implementation Method 1
the charge air is cooled indirectly or directly by the tube structure as it flows through the cooler
Implementation Method 2
a coolant, in particular water, flows through a pipe structure within the cooler
Implementation Method 3
thermodynamic expansions and contractions of the cooler and/or the housing can be compensated for
Implementation Method 4
deformations of the cooler that occur as a result of temperature differences within the cooler
Data Source
Figure 1~2
Figure 3~7
Figure 8~10
AI summary
The invention relates to an intercooler assembly (1), comprising a housing (2) through which flow can pass and to a cooler (3) arranged therein. An extended service life and/or improved efficiency of the assembly (1) is achieved in that the cooler (3) has at least two opposite end parts (13, 14, 15, 16), wherein the cooler (3) is connected to the housing (2) by means of at least one such end part (13, 14, 15, 16) and at least one such end part (13, 14, 15, 16) is movably attached to the housing (2).