Integrating Intercooler into Crankcase Lower Part
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Solution Overview
Problem
Internal combustion engines with supercharging face challenges in efficiently cooling charge air due to limited space and high fluidic resistance, particularly between low-pressure and high-pressure compressors.
Innovation Solution
Integrating an intercooler or charge air intermediate cooler into the crankcase lower part, which is cooled by a coolant, and optionally combining it with the oil sump or bearing plate to minimize space usage and reduce flow resistance, while also incorporating an EGR cooler for exhaust gas recirculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an intercooler is installed separately in the engine, then charge air cooling is achieved, but space requirements increase and flow resistance increases
Solution Approach 1:
The intercooler is integrated into the crankcase lower part, merging two previously separate components (intercooler and crankcase lower part) into a single unified structure. This eliminates the need for separate intercooler installation space and reduces overall engine footprint while maintaining charge air cooling functionality.
Solution Approach 2:
The crankcase lower part is designed to serve multiple functions: it acts as both the crankcase lower part enclosing the space below the crankshaft and as the intercooler for charge air cooling. This multi-functionality eliminates the need for dedicated intercooler space and reduces the number of separate components required.
2Temperature
If an intercooler is installed separately in the engine, then charge air cooling is achieved, but flow resistance increases
Solution Approach 1:
By merging the intercooler with the crankcase lower part, the charge air flow path is streamlined through an integrated design that eliminates additional fittings and connections. The intercooler channels are directly formed within the crankcase lower part structure, reducing fluidic resistance compared to separate installations.
3Area of stationary object
If the intercooler is integrated into the crankcase lower part, then space requirements are reduced, but manufacturing complexity increases
Solution Approach 1:
The crankcase lower part is divided into functional zones: the oil sump area and the intercooler channels. This segmentation allows the intercooler functionality to be integrated into existing manufacturing processes while maintaining clear functional differentiation and simplifying assembly.
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 effectively cools charge air, reduces space requirements, and minimizes flow resistance, enhancing engine efficiency and reducing exhaust gas emissions by utilizing existing installation space within the engine.
Implementation Method 1
an intercooler (22), which is cooled by a coolant (37)
Implementation Method 2
the intercooler and/or the charge air intermediate cooler is cooled by a coolant
Implementation Method 3
a charge air intermediate cooler (21), which is cooled by a coolant (37)
Data Source
AI summary
A crankcase lower part for a supercharged internal combustion engine, wherein the crankcase lower part extends about a space below the crankshaft. The crankshaft lower part comprises an intercooler, which is cooled by coolant, and/or a charge air intermediate cooler, which is cooled by a coolant. The intercooler and/or the charge air intermediate cooler is integrated into the crankcase lower part.