Intercooler Inversion for Corrosion Prevention in Small Planing Boats
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Solution Overview
Problem
The existing design of intercoolers in small planing boats, such as personal watercraft, is prone to corrosion and damage due to the retention of cooling water, especially saltwater, which can cause corrosion and is exacerbated by the longitudinal arrangement that is influenced by the up and down movement of the boats during operation.
Innovation Solution
The intercooler configuration is modified with a cooling water passage that includes a lower inlet and upper outlet, or vice versa, to facilitate faster drainage of cooling water and reduce stress from movement, along with a compact arrangement that minimizes exposure to heat radiation and allows for a two-pass cooling system, enhancing efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the intercooler extends longitudinally along the side of the engine, then the cooling water passage can be arranged to cool the compressed air, but cooling water remains in the intercooler after the engine stops causing corrosion
Solution Approach 1:
The cooling water passage is inverted so that the inlet is at the lower end and the outlet is at the upper end, opposite to the conventional arrangement. This inversion enables cooling water to drain completely from the intercooler by gravity when the engine stops, preventing corrosion while maintaining effective cooling during operation.
2Adaptability or versatility
If the intercooler extends longitudinally, then it can be connected to the compressor and intake manifold, but the up and down movement of the boat causes larger stress on the intercooler
Solution Approach 1:
The intercooler is reoriented from a longitudinal horizontal arrangement to a vertical arrangement. This dimensional change allows the intercooler to be connected to both the compressor and intake manifold while its vertical orientation makes it less susceptible to stress from the boat's up and down movements, as the movement is perpendicular to the intercooler's main axis.
3Temperature
If the cooling water inlet is at the upper end and outlet at the lower end, then cooling water flows downward, but water remains in the intercooler after operation
Solution Approach 1:
The cooling water passage is inverted so that the inlet is at the lower end and the outlet is at the upper end. During operation, the pump forces water upward against gravity to achieve effective cooling. After operation, gravity naturally drains all water from the passage, preventing corrosion. This inversion resolves the contradiction between cooling efficiency and corrosion prevention.
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 configuration prevents corrosion by ensuring complete drainage of cooling water and reduces the risk of damage from mechanical stress, while maintaining efficient cooling and engine output through effective air temperature management.
Implementation Method 1
cooling water enters the cooling unit from the center of the intercooler at the forward end and exits from the center of the intercooler at the rear end after cooling air in the intercooler by heat exchange while passing through the cooling unit
Data Source
AI summary
An air passage and a cooling water passage can be formed in an intercooler provided on a small planing boat. A cooling water inlet of a cooling water passage in the intercooler can be provided at the lower end of the intercooler. A cooling water outlet can be at the upper end of the intercooler. The intercooler can be vertically elongated and disposed at the front side of the engine. Further, a discharge port of a supercharger can be directed upwardly and an air inlet of the intercooler can be provided on the intercooler at the upper part. Furthermore, the intercooler, the supercharger and an intake manifold can be arranged such that when viewed in the lateral direction, the intercooler and supercharger overlap each other and when viewed in the longitudinal direction, the intercooler and intake manifold can also overlap each other. Moreover, the intercooler can be of a two-pass type.