Extruded Profile Expansion Tank for Modular Cooling Systems
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Solution Overview
Problem
The complexity and cost of designing and manufacturing expansion tanks for cooling systems of internal combustion engines are increased due to the need for different tanks for different engines, leading to higher design complexity and manufacturing costs.
Innovation Solution
A two-chamber expansion tank design with a base body formed from an extruded profile, where the coolant chamber and expansion chamber are separated by a partition wall, allowing for adjustable volumes by changing the length of the base body, and featuring a ventilation system with overflow lines and baffle structures for efficient coolant management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different expansion tanks are provided for different internal combustion engines, then the cooling system can be matched to the respective engine, but the design complexity and manufacturing costs increase
Solution Approach 1:
The expansion tank is designed with a modular base body that can be produced in standard sizes through extrusion. By combining different numbers and arrangements of insert panes with standardized base bodies and cover elements, a single universal expansion tank design can serve multiple different internal combustion engines, eliminating the need for completely different tank designs for each engine type.
Solution Approach 2:
The expansion tank is divided into modular components: a base body formed from extruded profile sections, insert panes that divide the interior into chambers, and cover elements. These segmented components can be selectively combined to create different chamber configurations and volumes, allowing adaptation to various engine requirements without redesigning the entire tank.
2Adaptability or versatility
If different expansion tanks are provided for different internal combustion engines, then the cooling system can be matched to the respective engine, but the manufacturing costs increase
Solution Approach 1:
The base bodies are produced using extrusion processes with standardized cross-sections that can be manufactured efficiently in large quantities. These universal base body designs reduce tooling costs and manufacturing complexity while still allowing adaptation to different engines through the modular pane and cover element system.
Solution Approach 2:
The internal volume and chamber configuration are adjusted by changing the number, position, and dimensions of insert panes rather than redesigning the entire base body. This parameter change approach allows cost-effective customization of tank capacity and chamber arrangement for different engine applications while maintaining the same base manufacturing process.
3Device complexity
If the expansion tank is designed with fixed chamber volumes, then the structure is simple, but the tank cannot be adapted to new cooling systems
Solution Approach 1:
The interior of the expansion tank is divided into multiple chambers by insert panes that can be selectively added or removed. This segmentation allows the total volume and individual chamber volumes to be adjusted by changing the pane configuration, enabling adaptation to new cooling system requirements while maintaining a simple overall structural design based on standardized base bodies.
Solution Approach 2:
The expansion tank design allows dynamic reconfiguration of chamber volumes and arrangements by selecting different combinations of base bodies, insert panes, and cover elements. This dynamic adaptability enables the same basic design platform to serve multiple applications without requiring complete redesigns when new cooling systems are introduced.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The compensation tank (10) has a coolant chamber (12) for receiving a coolant, where the coolant chamber is connected with the cooling system in a fluid-permeable manner through a connecting piece (14) and a vent connection (16). A base body (28) is provided, which is closed by two cover elements in a fluid-tight manner. The base body is designed in the form of a section of an extruded profile. The cover elements are made of aluminum or plastic. An independent claim is included for a method for manufacturing a compensation tank for an agricultural motor vehicle.