Integrated Charge Air Cooler Cover with Thermostatic Valve
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Solution Overview
Problem
The complex tangle of piping in diesel engine cooling systems leads to accessibility issues for thermostat valves and causes adverse vibrations due to low natural frequencies, making maintenance and inspection challenging.
Innovation Solution
A cover for the charge air cooler with integrated valve housings and thermostrictive elements that enhance stiffness and accessibility, allowing for modular substitution of valve components and improved vibration response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate piping systems are used for each cooling system, then each system can be independently designed and maintained, but the overall system complexity increases and accessibility for maintenance deteriorates
Solution Approach 1:
The patent combines multiple separate cooling system piping into a single integrated charge air cooler assembly that houses all coolant passages and thermostat valves within one unified structure, eliminating the need for separate piping systems while maintaining independent temperature control for each cooling circuit
Solution Approach 2:
The integrated charge air cooler serves multiple functions simultaneously: it cools charge air, houses multiple thermostat valves for different cooling circuits, and provides a unified mounting structure for all cooling system components, replacing what were previously separate independent systems
2Ease of repair
If thermostat valves are integrated into the charge air cooler cover, then accessibility for inspection and maintenance is improved, but the manufacturing complexity increases
Solution Approach 1:
The charge air cooler cover is segmented into multiple separate valve housing components, each containing an individual thermostat valve, allowing each valve to be independently accessed, inspected, and replaced without disassembling the entire cooler assembly
Solution Approach 2:
The thermostat valves are nested within the charge air cooler cover structure, with each valve housed in its own integrated valve housing that is part of the overall cooler assembly, providing compact integration while maintaining accessibility
3Ease of manufacture
If flexible piping components are used, then assembly ease is improved, but vibration resistance deteriorates due to low natural frequencies
Solution Approach 1:
Instead of using flexible piping components that require minimal assembly steps, the patent employs rigid integrated structures with precision-machined mating surfaces and sealed connections, inverting the conventional approach by prioritizing vibration resistance over assembly 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 solution provides easier access for maintenance, increased durability, and enhanced vibration resistance, reducing adverse vibrations and improving the overall efficiency of the cooling system.
Implementation Method 1
a thermostat valve, installed in a charge air cooler cover
Data Source
AI summary
A cover for a charge air cooler of a turbocharged engine. The cover body defines a cooling water plenum, which has an opening at a first side of the cover for attachment over a water outlet of the charge air cooler. A plurality of valve housings are formed integrally with the body of the cover at a second side of the cover opposite the cooling water plenum opening. Each valve housing has a peripheral wall that extends from the cover to define an inner chamber, which opens into an inner fluid passage formed in the cover.