Coupling Heat Exchanger for Engine Warm-Up and Waste Heat Recovery
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Solution Overview
Problem
Internal combustion engines waste a significant portion of energy as heat, which is not efficiently utilized, leading to reduced efficiency and increased fuel consumption.
Innovation Solution
A steam circuit is integrated into the exhaust system of an internal combustion engine, utilizing waste heat to accelerate the warm-up phase, reduce cooling needs, and provide auxiliary heating, without requiring additional cooling systems, by using a coupling heat exchanger that feeds waste heat into the engine's cooling system and can redirect it for interior heating when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If waste heat from the steam circuit is fed into the engine cooling system during warm-up phase, then the warm-up phase is shortened and fuel consumption is reduced, but the engine temperature control may be affected
Solution Approach 1:
A coupling heat exchanger is introduced as an intermediary device between the steam circuit and the engine cooling system. This heat exchanger transfers waste heat from the steam circuit to the engine cooling system during warm-up phase without directly mixing the two circuits, thereby accelerating warm-up while maintaining independent control over engine temperature through the existing thermostat regulation
Solution Approach 2:
The system dynamically switches between different operating modes: during warm-up phase, the coupling heat exchanger is activated to transfer waste heat to accelerate warming; during normal operation, the thermostat maintains standard temperature control. This dynamic switching allows the system to adapt to different thermal conditions and maintain optimal engine temperature control
2Loss of energy
If a separate cooling circuit for the coupling heat exchanger is implemented, then waste heat can be effectively utilized, but the device complexity and installation space increase
Solution Approach 1:
The coupling heat exchanger is integrated into the existing engine cooling system rather than implementing a completely separate cooling circuit. The heat exchanger utilizes the engine's existing coolant flow path, merging the waste heat recovery function with the existing cooling infrastructure, thereby reducing overall system complexity and installation space requirements
Solution Approach 2:
The coupling heat exchanger serves multiple functions: during warm-up phase, it transfers waste heat to accelerate engine warming; during normal operation, it can redirect waste heat for interior heating or prevent engine cooling. This multi-functionality eliminates the need for separate dedicated circuits for different thermal management functions
3Adaptability or versatility
If the coupling heat exchanger is used to heat the interior when engine load is low, then interior heating is provided, but the engine cooling efficiency may be reduced
Solution Approach 1:
The system dynamically switches between different operating modes based on engine conditions: during low engine load, the coupling heat exchanger redirects waste heat to heat the interior; during high load or warm-up phase, it maintains engine cooling. This dynamic switching allows the system to adapt to different thermal demands while maintaining engine temperature control
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 shortens the warm-up phase of the engine, reduces fuel consumption, eliminates the need for a separate low-temperature cooling circuit, and allows for weight and space savings, while maintaining engine temperature control and improving thermal efficiency.
Implementation Method 1
the waste heat from the steam circuit is fed into a first circuit of the engine cooling system via a coupling heat exchanger
Implementation Method 2
thermal energy is extracted from the exhaust gas of an internal combustion engine via a steam circuit and partially converted into mechanical and electrical energy by a turbine
Implementation Method 3
the lowest available temperature level in the coupling heat exchanger (condenser) of the steam circuit
Data Source
Figure 1
AI summary
The invention relates to a device for utilizing waste heat of an internal combustion engine (10). A heat exchanger (26) of a circuit (24) of a working medium is provided in the exhaust section (20) of said internal combustion engine. Connected upstream of said heat exchanger (26) is a pump (30), wherein the circuit (24) contains an expansion machine (28). A coupling heat exchanger (40) is situated in the circuit (24) of the working medium, through which coupling heat exchanger flows the working medium of the circuit (24) and the cooling medium of the internal combustion engine (10).