Multi-Stage Cooling System with Downstream Heat Exchangers
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Solution Overview
Problem
Existing cooling systems for machines, such as those used in construction and mining equipment, face inefficiencies due to the limited capacity to adapt to changing engine operating conditions, where radiator and charge air heat loads may increase or decrease together or independently, leading to suboptimal performance.
Innovation Solution
A multi-stage cooling system with a first heat exchanger and a second heat exchanger located downstream, where air passes through both, and a valve regulated by a controller to manage fluid flow based on operating conditions, ensuring optimal heat transfer and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple heat exchangers are co-located to conserve space, then the space utilization is improved, but the heat transfer efficiency deteriorates due to interference between heat exchangers
Solution Approach 1:
The cooling system is divided into multiple independent stages with separate heat exchangers (first heat exchanger for radiator, second heat exchanger for charge air cooler). Each stage handles specific heat loads independently, preventing thermal interference while maintaining compact packaging through sequential arrangement in the airflow path.
2Device complexity
If a fixed heat exchanger configuration is used, then the device complexity is reduced, but the adaptability to different engine operating conditions deteriorates
Solution Approach 1:
The system incorporates controllable flow regulation mechanisms (valves, actuators) that dynamically adjust the flow distribution between the first and second heat exchangers based on real-time engine operating conditions. This allows the system to adapt to varying heat loads from the radiator and charge air cooler independently, optimizing cooling efficiency across different operating modes.
Solution Approach 2:
The system changes operational parameters (fluid flow rates, heat exchanger activation) based on detected engine conditions. The controller monitors engine parameters and adjusts the cooling system configuration accordingly, enabling the same physical system to serve multiple operating conditions effectively.
3Power
If the heat exchanger size is increased to handle maximum heat load, then the cooling capacity is improved, but the space constraint is violated
Solution Approach 1:
Instead of using one large heat exchanger, the system segments the cooling function into multiple smaller heat exchangers arranged in stages. Each heat exchanger handles a portion of the total heat load, allowing the system to achieve maximum cooling capacity while keeping individual component sizes and overall package footprint within spatial constraints.
Solution Approach 2:
The heat exchangers are arranged sequentially in the airflow dimension rather than parallel, utilizing the length of the airflow path to accommodate multiple heat transfer surfaces. This dimensional arrangement maximizes heat exchange area within the available space envelope.
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 enhances cooling efficiency by accounting for varying engine operating conditions, optimizing heat rejection and reducing the size of the heat exchanger package while maintaining performance across different load scenarios.
Implementation Method 1
a first heat exchanger configured to remove heat from at least a portion of a first fluid
Implementation Method 2
a second heat exchanger configured to remove heat from a portion of a second fluid
Data Source
AI summary
A cooling system is provided having a first heat exchanger configured to remove heat from at least a portion of a first fluid and a second heat exchanger configured to remove heat from a portion of a second fluid. The second heat exchanger is located downstream of the first heat exchanger relative to the flow of air passing through the first heat exchanger so that a substantial portion of the air passing through the first heat exchanger also passes through the second heat exchanger. The cooling system also has a valve located to regulate the flow of the second fluid through the second heat exchanger. The cooling system further has a controller configured to actuate the valve to restrict the flow of the second fluid through the second heat exchanger when the first heat exchanger is removing heat from the first fluid.