Multi-Core Heat Recovery Charge Cooler for Intake Cooling
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Solution Overview
Problem
Existing charge air coolers with a single core are insufficient in reducing the temperature of charge gases to a desirable level for efficient engine operation, leading to inefficiencies in internal combustion engines.
Innovation Solution
Implementing a waste heat recovery system with multiple charge air coolers (CACs) that include a waste heat recovery core and a cooling fluid core, allowing for charge air to be cooled through interactions with both working and cooling fluids, optimizing temperature reduction and increasing the efficiency of the engine by repurposing waste heat energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single-core charge air cooler is used, then the device complexity is low, but the cooling effectiveness is insufficient to reduce charge gas temperature to desirable levels
Solution Approach 1:
The charge air cooler is divided into multiple independent cores (first core, second core, third core) that can process charge gas in series or parallel. Each core contains its own heat exchanger channels and cooling fluid passages, allowing the system to achieve greater total cooling capacity while maintaining modular architecture that simplifies manufacturing and maintenance.
Solution Approach 2:
The patent implements nested cooling by arranging cooling fluid passages within and around the heat exchanger channels of each core. The cooling fluid cores are positioned to provide both direct cooling of charge gas and indirect cooling of the heat exchanger structures themselves, creating a multi-layered thermal management system that maximizes cooling efficiency.
2Temperature
If multiple charge air coolers are implemented, then the cooling effectiveness increases, but the device complexity increases
Solution Approach 1:
Multiple cooling functions are merged into a single integrated charge air cooler assembly. The first, second, and third cores are combined with shared external housings, common mounting structures, and coordinated cooling fluid distribution systems. This merging approach achieves the cooling performance of multiple separate coolers while reducing overall system complexity through consolidation.
Solution Approach 2:
The cooling fluid circulation system serves multiple functions simultaneously: it cools charge gas in different cores, cools the heat exchanger structures, and can operate in different configurations (series or parallel) depending on operating conditions. The same basic core design is replicated across multiple units, providing universality that simplifies manufacturing and maintenance.
3Use of energy by moving object
If waste heat recovery is implemented through multiple cores, then the energy utilization efficiency improves, but the manufacturing complexity increases
Solution Approach 1:
The waste heat recovery system is segmented into identical modular cores that can be manufactured independently and then assembled. Each core contains a complete set of heat exchanger channels and cooling fluid passages, allowing for standardized production processes, quality control, and easy replacement or upgrade of individual modules without affecting the entire system.
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 multi-core CAC system effectively cools charge air to a target intake temperature, enhancing engine efficiency and power output by better utilizing thermal energy, and includes fail-safe mechanisms to maintain operation even in case of core failures.
Implementation Method 1
heat is exchanged between the charge gases and a working fluid (e.g., a coolant, a refrigerant, etc.) such that heat is transferred from the charge gases to the working fluid
Implementation Method 2
A first cooling fluid core includes a first cooling fluid inlet in fluid communication with a cooling fluid source and a first cooling fluid conduit fluidly coupled to the first cooling fluid inlet and a first cooling fluid outlet
Implementation Method 3
The working fluid is pumped to a heat exchanger where it is vaporized
Implementation Method 4
The vapor is passed through an expander and then through a condenser, where the vapor is condensed back to a fluid
Data Source
AI summary
A waste heat recovery system for an engine system includes a first charge air cooler in communication with a working fluid path of the waste heat recovery system. The first charge air cooler includes a first waste heat recovery core and a first cooling fluid core. The first waste heat recovery core includes a first working fluid inlet configured to receive a working fluid from the working fluid path. The first working fluid conduit is coupled to the first working fluid inlet and a first working fluid outlet. The first cooling fluid core includes a first cooling fluid inlet in fluid communication with a cooling fluid source and a first cooling fluid conduit fluidly coupled to the first cooling fluid inlet and a first cooling fluid outlet. The first cooling fluid conduit is configured to direct cooling fluid from the first cooling fluid inlet to the first cooling fluid outlet.