Oil Module Integrated Cooling Water Channel Design
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Solution Overview
Problem
Existing oil modules for combustion engines lack a space-saving and cost-effective design that maximizes the reliability of oil and water conduits while minimizing installation space and manufacturing complexity.
Innovation Solution
Incorporating a small cooling circuit within the oil module, with an open water channel on the housing that integrates both the small and large cooling circuits, eliminating external conduits and using functional modules as covers to reduce space and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closed water channel is used in the oil module housing, then the structural integrity and sealing are improved, but the installation space increases and manufacturing complexity increases due to required cores in casting
Solution Approach 1:
The water channel is segmented into closed sections (where sealing is critical) and open sections (where space reduction is beneficial). The channel is not uniformly closed or open but is divided into functional segments, allowing the housing to have both sealed and unsealed portions along the channel length.
Solution Approach 2:
Different sections of the water channel have different structural qualities - some sections are closed with housing walls for sealing, while other sections are open to the surface for space saving. This local differentiation allows each section to serve its specific function optimally.
2Reliability
If a closed water channel is used in the oil module housing, then the sealing is improved, but the manufacturing cost increases due to required cores in casting die
Solution Approach 1:
The manufacturing process is segmented to cast only the necessary closed sections of the housing that require sealing, while open sections are formed without requiring complex core structures. This reduces the overall manufacturing complexity and cost.
Solution Approach 2:
The unnecessary closed sections (and their associated manufacturing cores) are extracted from the design, leaving only the essential sealed portions. This simplifies the casting process by eliminating the need for complex core removal operations.
3Adaptability or versatility
If external water conduits and connecting elements are used, then the installation flexibility is improved, but the number of components increases and potential leak points increase
Solution Approach 1:
The water channel is merged directly into the housing structure, eliminating the need for separate external conduits and connecting elements. This integration reduces the total number of components while maintaining the necessary water flow paths.
Solution Approach 2:
The housing serves multiple functions: it contains the oil module components, provides structural support, and incorporates the water channel as an integral feature. This multi-functionality eliminates the need for dedicated external water conduits.
4Ease of manufacture
If a simple cover is used to close the open channel section, then the manufacturing simplicity is maintained, but the integration degree and space-saving are reduced
Solution Approach 1:
The functional module housing serves dual purposes: it performs its primary function (housing water pump, thermostat, etc.) and simultaneously acts as the cover for the open water channel section. This eliminates the need for a separate simple cover while maintaining manufacturing efficiency.
Solution Approach 2:
The cover function is merged with the functional module housing, creating a unified structure that performs both functions. This integration increases the overall system compactness and reduces the number of separate components.
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 design enhances the reliability of the water circuit and internal combustion engine by reducing leaks and installation space, while simplifying manufacturing and achieving a high degree of integration and cost-effectiveness.
Implementation Method 1
A water channel of the oil module has an open cross-section, that is, the channel is open along at least one section of its length onto the surface of the oil module housing
Implementation Method 2
When the cooling water temperature is sufficiently high, on the other hand, the thermostatic valve switches over and allows the water to flow through the so-called large cooling circuit which includes use of a water cooler
Implementation Method 3
Additional external water conduits are not needed, because the small cooling circuit is integrated into the oil module, so that, on the one hand, components are eliminated, for example, tubing or hose lines and their respective connecting elements, such as hose clips or similar parts
Data Source
AI summary
The invention relates to an oil module of a water-cooled internal combustion engine, comprising an oil filter, oil and water channels, a water pump and a thermostatic valve which opens various temperature-dependent water circuits. One water channel starts behind the thermostatic valve in the direction of flow and leads to the suction side of the water pump inside the oil module. The oil module has a housing to which at least one additional functional component is connected. The water channel extends along two sides of the housing which are oriented at an angle in relation to each other, both sides of said channel respectively opening on both sides on at least one sub-section of their length onto the surface of the housing and being closed, respectively by means of a cover to form a channel cross-section that is closed on all sides.