Cooling Module Airflow Routing for Rankine Cycle Waste Heat Recovery
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Solution Overview
Problem
The challenge lies in packaging a cooling module that effectively rejects heat from both a coupled engine system and a Rankine cycle waste heat recovery system, particularly in vehicular applications where space is limited and both the Rankine cycle waste heat recovery condenser and charge air cooler require the coolest air, leading to packaging complexities.
Innovation Solution
A cooling module design that includes an air-cooled condenser for the Rankine cycle waste heat recovery system and an air-cooled charge air cooler for the engine system, with a radiator for engine coolant, where the condenser and charge air cooler are arranged to receive the coolest air, and a working fluid transfer tube routes the Rankine cycle working fluid efficiently, optimizing space usage and air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the condenser and charge air cooler are arranged to receive the coolest air, then waste heat recovery efficiency is improved, but packaging complexity increases due to limited space availability
Solution Approach 1:
The cooling module utilizes three-dimensional spatial arrangement to optimize air flow paths. The condenser and charge air cooler are positioned in different vertical and horizontal planes, allowing both components to access cool air from the front of the vehicle without conflicting for the same air stream. This dimensional separation resolves the packaging complexity while maintaining access to the coolest air for both heat rejection components.
Solution Approach 2:
The cooling module is segmented into distinct air flow paths for the condenser and charge air cooler. Separate air inlet regions and internal baffles create independent cooling channels, allowing each component to receive optimized cool air independently. This segmentation enables efficient waste heat recovery from both the Rankine cycle system and engine charge air without requiring a single contested air source, thus reducing packaging complexity.
2Area of stationary object
If multiple heat rejection components are packaged in limited space, then space utilization is improved, but air flow optimization becomes more difficult
Solution Approach 1:
The patent employs vertical stacking and layered arrangement of heat rejection components within the limited frontal area. The condenser, charge air cooler, and radiator are positioned at different heights and depths, creating multiple air flow layers. This three-dimensional packaging maximizes the use of available space while maintaining adequate air flow paths for each component, thereby preserving heat rejection efficiency despite high space utilization.
Solution Approach 2:
Different regions of the cooling module are designed with locally optimized air flow characteristics. The front region is optimized for high-velocity cool air intake, while rear and side regions are designed for heat dissipation. Each heat rejection component is positioned in the region most suitable for its thermal load and cooling requirements, allowing efficient heat rejection from multiple components packed in limited space.
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 design enhances waste heat recovery efficiency by ensuring both the Rankine cycle working fluid and engine system components receive the lowest temperature cooling air, improving overall power conversion efficiency and meeting emission control requirements while addressing space constraints.
Implementation Method 1
heat is transferred from the flow of Rankine cycle working fluid to the first flow of air passing through the condenser to cool and condense the flow of Rankine cycle working fluid to a liquid
Implementation Method 2
cool and condense the flow of Rankine cycle working fluid to a liquid
Implementation Method 3
heat is transferred from the flow of compressed charged air to the second flow of air passing through the charge air cooler in order to cool the flow of compressed charge air
Implementation Method 4
heat is transferred to that first flow of air from the engine coolant
Data Source
AI summary
A cooling module is coupled to an engine system and a Rankine cycle waste heat recovery system. The cooling module includes a heat exchanger for cooling a fluid of the engine system and a condenser for cooling a working fluid of the Rankine cycle waste heat recovery system, both of which extend in a width direction of the cooling module and are porous to a flow of cooling air in a depth direction of the cooling module. The condenser includes a first tubular header that extends in a height direction of the cooling module. A working fluid transfer tube fluidly couples the first tubular header to the Rankine waste heat recovery cycle system. The working fluid transfer tube has a first portion extending in the depth direction and a second portion extending in the height direction, the second portion being adjacent to the first tubular header in the width direction.