Oil Cooler Bypass Valve Asymmetric Bolting Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing oil coolers suffer from reduced bolting force and fatigue damage in fixing bolts due to vibrations from oil movement and vehicle vibrations, as the direction of fixing bolts and bypass valve connection differ, leading to potential leakage.
Innovation Solution
The oil cooler design aligns the direction of fixing bolts with the bypass valve connection in the length direction, using flanges and valve protrusions for secure bolting, and incorporates connectors with extension rings and o-rings for enhanced air tightness and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fixing bolts are installed perpendicular to the length direction of the header tank, then the bypass valve can be connected, but the bolting force decreases due to vibrations from oil movement and vehicle vibrations
Solution Approach 1:
The bypass valve body is designed with an asymmetric structure where the connection surface for the fixing bolts is inclined relative to the length direction of the header tank. Specifically, the connection surface is formed at an angle of 45 degrees to the length direction, allowing the fixing bolts to be installed in a direction that is not perpendicular to the header tank's length direction. This asymmetric design enables the bolts to resist vibrations from oil movement and vehicle vibrations more effectively, maintaining bolting force while preserving the bypass function.
2Reliability
If the fixing bolts are installed in a direction different from the bypass valve connection direction, then the bypass valve can be mounted, but fatigue accumulates in the fixing bolts causing damage and leakage
Solution Approach 1:
The bypass valve body incorporates an asymmetric connection surface that is inclined at 45 degrees to the length direction of the header tank. This asymmetric design allows the fixing bolts to be installed in an optimized direction that aligns with the primary vibration forces, enabling the bolts to better resist fatigue from vibrations caused by oil movement and vehicle operation. The asymmetric structure maintains reliable bolting while preserving the bypass functionality.
Solution Approach 2:
The connection surface of the bypass valve body is designed in a different dimensional orientation relative to the header tank's length direction. Instead of being perpendicular (one-dimensional alignment), the connection surface is inclined at 45 degrees, introducing a dimensional change that allows the fixing bolts to engage in an optimized direction for vibration resistance. This dimensional reorientation enables the bolts to better withstand multi-directional vibrations without compromising the bypass valve's mounting or functionality.
3Reliability
If the fixing bolts are installed perpendicular to the length direction, then the bypass valve connects to the header tank, but vibrations from oil movement and vehicle body cause bolting force loss
Solution Approach 1:
The bypass valve body features an asymmetric connection surface inclined at 45 degrees to the header tank's length direction. This asymmetric configuration allows the fixing bolts to be installed in a direction that optimizes their ability to resist vibrations from oil movement and vehicle body movements. The inclined connection surface enables the bolts to maintain more stable bolting force by aligning better with the vibration forces, preventing the bolting force loss that occurs with perpendicular installation.
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 maintains the bolting force and prevents fatigue damage in fixing bolts, ensuring reliable operation by synchronizing the bolt direction with the bypass valve connection and enhancing structural integrity through improved air tightness.
Implementation Method 1
vibrations generated by movement of oil in a bypass valve and vibrations generated in a vehicle body
Implementation Method 2
The external type oil cooler serves to lower a temperature of the oil through heat exchange with atmosphere
Implementation Method 3
connectors with extension rings and o-rings for enhanced air tightness
Data Source
AI summary
An oil cooler includes a plurality of tubes having both ends each fixed to a pair of header tanks in the length direction to form channels. The oil cooler further includes heat radiation fins, a first flange having an inlet pipe and an outlet pipe each coupled thereto in the length direction, a second flange coupled to any one of the header tanks in the length direction, and a bypass valve installed between the first flange and the second flange. The fixing bolts bolt the first flange, the bypass valve, and the second flange together while penetrating through the first flange, the bypass valve, and the second flange in the length direction.