Construction Machine Cooling System Heat Exchanger Arrangement
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Solution Overview
Problem
In hydraulic excavators, the compact size of the upper revolving structure limits the space for heat exchangers like radiators, oil coolers, intercoolers, and condensers, making it difficult to maintain effective cooling performance in narrow spaces.
Innovation Solution
The heat exchangers are arranged in a specific order based on their heat release amounts within the flow direction of the cooling air, with the radiator and oil cooler positioned downstream and the intercooler and condenser upstream, allowing for efficient heat release and compact placement, and a dust protective net is used to trap dust and insects, while flexible air hoses improve assembly and maintenance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the upper revolving structure is formed in a compact size to accommodate within vehicle width, then the excavator can revolve in narrow working sites, but the space for heat exchangers is narrowed making it difficult to maintain cooling performance
Solution Approach 1:
The heat exchangers are arranged in multiple layers along the cooling air flow direction, transitioning from a single-plane layout to a three-dimensional stacked configuration. This allows five heat exchangers to be accommodated in a compact space while maintaining adequate cooling surfaces for each unit.
Solution Approach 2:
The heat exchanger group is segmented into multiple functional units (radiator, oil cooler, intercooler, condenser, fuel cooler) arranged in sequence along the air flow path. Each unit is positioned at a specific location to optimize heat release efficiency while maintaining compact overall dimensions.
2Area of stationary object
If multiple heat exchangers are arranged in a narrow space, then the compact design is achieved, but the cooling performance of each heat exchanger becomes difficult to maintain
Solution Approach 1:
Each heat exchanger unit is positioned at a specific location along the cooling air flow path based on its heat release characteristics. The radiator and oil cooler with large heat release amounts are placed downstream where cooling air is most effective, while the intercooler and condenser with smaller heat release amounts are positioned upstream, optimizing local cooling efficiency for each unit.
3Area of stationary object
If heat exchangers are arranged in parallel and series combinations, then space efficiency is improved, but the complexity of arrangement increases
Solution Approach 1:
The heat exchangers are pre-positioned in a standardized arrangement pattern along the cooling air flow direction before assembly. The radiator and oil cooler are positioned downstream in parallel, while the intercooler and condenser are positioned upstream in parallel, with the fuel cooler arranged at the front. This predetermined layout simplifies the assembly process and reduces installation complexity.
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 arrangement maintains cooling performance while allowing all heat exchangers to be accommodated in a narrow space, reduces cleaning frequency, and enhances operational efficiency by facilitating easy assembly and maintenance.
Implementation Method 1
a cooling fan which is rotated by receiving a power from a power source to suck in outside air as the cooling air
Implementation Method 2
a heat exchanger unit for cooling a liquid by cooling air generated by the cooling fan
Data Source
AI summary
A radiator and an oil cooler are arranged at a front surface side of a cooling fan in parallel with each other in a flow direction of the cooling air, an intercooler and a condenser are arranged in parallel at a front surface side of the radiator and oil cooler, and a fuel cooler is arranged at a front surface side of the condenser. By arranging respective heat exchangers such that the heat release amount thereof sequentially increases from the upstream side toward the downstream side in the flow direction of the cooling air, each heat exchanger can efficiently release the heat of the fluid to be cooled. By arranging the fuel cooler at the front surface side of the condenser, two heat exchangers of the condenser and the fuel cooler can be accommodated within a range of the thickness dimension of the intercooler.