Multi-Stage Charge Air Cooler for High-Power Work Vehicle Cooling
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Solution Overview
Problem
High-power work vehicles face cooling challenges due to limited space under the hood, as typical cooling systems are not sufficient to accommodate the increased cooling needs of high-power engines, leading to inadequate heat dissipation.
Innovation Solution
A multi-stage cooling system comprising a charge air cooler system and a high/low temperature radiator system, which includes multiple heat exchangers and fluid flow paths to efficiently dissipate heat, allowing for effective cooling of high-power engines within the constrained space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a typical cooling system is used, then the structure is simple and occupies less space, but the cooling capacity is insufficient for high-power engines
Solution Approach 1:
The cooling system is divided into multiple independent stages: a first stage cooler and a second stage cooler, each with separate coolant flow paths. This segmentation allows each stage to be optimized for specific cooling requirements while fitting within the limited space under the hood of high-power work vehicles.
Solution Approach 2:
The patent utilizes vertical stacking of cooling components, arranging the first stage cooler and second stage cooler at different heights and positions. This three-dimensional arrangement maximizes the use of available space under the hood, accommodating the increased cooling capacity needed for high-power engines without increasing the horizontal footprint.
2Temperature
If cooling capacity is increased to handle high-power engines, then heat dissipation improves, but the system becomes more complex and harder to accommodate in limited space
Solution Approach 1:
The cooling system uses a single coolant pump that serves multiple functions: it circulates coolant through both the first stage cooler and the second stage cooler, as well as through the radiator. This multi-functionality reduces the number of separate components needed, simplifying the overall system while maintaining the enhanced cooling capacity required for high-power engines.
Solution Approach 2:
The system incorporates variable speed control for the coolant pump, allowing it to adjust its operation dynamically based on the cooling demands of the engine. This dynamic adjustment optimizes heat dissipation efficiency across different operating conditions without requiring multiple fixed-speed pumps or complex control systems.
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 system provides more efficient cooling, enabling higher power engines to operate effectively while fitting within the space constraints of work vehicles, ensuring adequate heat dissipation and maintaining optimal component temperatures.
Implementation Method 1
a first stage that receive charge air at a first temperature via a charge air flow path and receives coolant fluid via a first coolant fluid flow path
Implementation Method 2
receives the charge air at a second temperature from the first stage of the charge air cooler system via the charge air flow path
Implementation Method 3
a low temperature radiator system that includes a low temperature radiator that directs the coolant fluid toward the third stage of the charge air cooler system
Implementation Method 4
high temperature radiator system that directs the coolant fluid toward the first stage of the charge air cooler system
Implementation Method 5
a water hydraulic oil cooler system that receives hydraulic oil via a hydraulic oil flow path. The water hydraulic oil cooler includes a first stage that receives the coolant fluid via the second coolant fluid flow path and receives the hydraulic oil via the hydraulic oil flow path
Data Source
AI summary
A cooling system includes a charge air cooler system that includes a first stage that receives charge air via a charge air flow path and receives coolant fluid via a first coolant fluid flow path. A second stage receives charge air from the first stage via the charge air flow path, outputs the charge air, and receives the coolant fluid via a second coolant fluid flow path. A third stage receives and outputs the charge air from the second stage via the charge air flow path and receives the coolant fluid via a third coolant fluid flow path. The cooling system includes a low temperature radiator system that includes a low temperature radiator that directs the coolant fluid toward the third stage via the third coolant fluid flow path and includes a high temperature radiator system that directs the coolant fluid toward the first stage and second stage.