Cooling Module Asymmetric Heat Exchanger Layout
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Solution Overview
Problem
Traditional cooling systems for large-scale turbo diesel engines face inefficiencies due to equal face area requirements for high-temperature and low-temperature circuits, leading to suboptimal fan performance and limited space utilization, with increased emission standards further complicating heat rejection and cooling efficiency.
Innovation Solution
A cooling module design featuring a box-shaped structure with oppositely disposed low-temperature heat exchanger circuits and a high-temperature heat exchanger circuit, utilizing a constant volumetric flow fan that operates as both a sucker fan for low-temperature and a blower fan for high-temperature circuits, optimizing face area and air mass flow while reducing noise and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the high-temperature and low-temperature circuits are positioned in a front to back configuration with equal face area, then the structural simplicity is improved, but the cooling performance of the low-temperature circuit deteriorates when it requires more face area
Solution Approach 1:
The patent applies asymmetry by positioning the low-temperature circuit and high-temperature circuit on opposite walls of the box structure, allowing each circuit to have different face areas optimized for its specific cooling requirements. The low-temperature circuit can have a larger face area to achieve better cooling performance without forcing the high-temperature circuit to have the same area, thus resolving the contradiction between structural simplicity and cooling performance.
2Productivity
If the circuits are positioned in a side to side configuration to adjust face area, then the cooling performance is improved, but the space utilization deteriorates due to increased depth requirement
Solution Approach 1:
The patent transitions from a traditional side-to-side or front-to-back single-dimension arrangement to a three-dimensional box structure where circuits are positioned on opposite walls. This dimensional change allows both circuits to have adequate face area for optimal cooling performance while maintaining compact overall dimensions and improving space utilization compared to increased depth configurations.
3Ease of manufacture
If a sucker fan is used in mobile applications with ram air, then the fan mounting simplicity is improved, but the fan efficiency deteriorates due to high operating temperature
Solution Approach 1:
The patent introduces a shroud or housing as an intermediary structure that encloses the fan and directs airflow through the heat exchanger circuits. This shroud acts as a mediator between the fan and the high-temperature environment, allowing the fan to operate in a cooler, controlled airflow path while still achieving effective cooling of both circuits, thus improving fan efficiency without sacrificing mounting simplicity.
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 enhances fan efficiency, increases heat transfer capacity, and optimizes functional heat exchanger face area per given space, improving cooling performance and reducing fan noise and power consumption.
Implementation Method 1
The fan is configured to draw air from outside the structure through the at least one low-temperature heat exchanger circuit and redirect the air out of the structure through the at least one high-temperature heat exchanger circuit
Implementation Method 2
at least one of the walls comprises at least one low-temperature heat exchanger circuit and at least one of the walls comprises a high-temperature heat exchanger circuit
Data Source
AI summary
A cooling module for use with an internal combustion engine having separate cooling circuits, the cooling module having a cuboid shaped structure having walls defining an internal open portion, at least one of the walls comprising a low-temperature heat exchanger circuit and one of the walls comprising a high-temperature heat exchanger circuit and a fan located within the open portion of the structure and enclosed by the walls. The fan is configured to act as a sucker fan to draw air from outside the structure through the at least one low-temperature heat exchanger circuit and to act as a blower fan by redirecting the air out of the structure through the at least one high-temperature heat exchanger circuit. The cooling module has increased fan efficiency, reduced noise, and optimal functional heat exchanger face area per given space.