Orthogonal Double Heat Exchanger for Engine Cooling
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Solution Overview
Problem
Existing cooling systems for internal combustion engines face challenges in efficiently cooling compressed air and recirculated gases at high temperatures, leading to differential expansion issues and thermomechanical constraints that can compromise the integrity of the cooling system.
Innovation Solution
A double-flow heat exchanger with orthogonal axes for compressed air and recirculated gas flows, combined with a cooling liquid circuit that consecutively cools both gases and air, allowing for graduated cooling and minimizing heat accumulation and dilation issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single heat exchanger is used to cool both compressed air and recirculated gases, then the device complexity is reduced, but the thermomechanical stresses increase due to differential expansion from large temperature differences
Solution Approach 1:
The heat exchanger is divided into two separate cooling circuits: a first cooling circuit for recirculated gases and a second cooling circuit for compressed air. This segmentation allows each circuit to be optimized independently for its specific temperature range, preventing differential expansion issues while maintaining overall system compactness.
Solution Approach 2:
The two cooling circuits are arranged orthogonally to each other, with the first cooling circuit extending in a first direction and the second cooling circuit extending in a second direction perpendicular to the first. This spatial arrangement in different dimensions allows both circuits to coexist in a compact volume while minimizing thermal interference and differential expansion stresses.
2Productivity
If the gas temperatures are very high, then the cooling efficiency improves, but the crankcase temperature increases significantly, generating expansions
Solution Approach 1:
The heat exchanger incorporates localized cooling zones with different temperature characteristics: a first zone for high-temperature recirculated gases and a second zone for lower-temperature compressed air. This local quality variation allows efficient cooling of hot gases while protecting the crankcase from excessive temperature increases.
Solution Approach 2:
The heat exchanger acts as an intermediary device that decouples the thermal fields of the recirculated gases and compressed air. By processing these gases through separate cooling circuits, the system mediates the temperature differences and prevents direct thermal coupling that would cause crankcase expansion.
3Use of energy by moving object
If the cooling water circuit is arranged to cool both gases and air, then the use of energy is optimized, but the heat transfer efficiency decreases due to temperature differences
Solution Approach 1:
The system changes the operational parameters of the cooling water circuit by implementing two separate circuits with different flow rates, temperatures, and residence times optimized for their respective gases. The first cooling circuit is optimized for high-temperature recirculated gases while the second is optimized for compressed air, maintaining high heat transfer efficiency for each.
Solution Approach 2:
The cooling system dynamically adapts to the different thermal requirements of recirculated gases and compressed air by providing independent cooling circuits that can be optimized for their specific temperature ranges and flow characteristics, rather than using a single static cooling arrangement.
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 solution effectively manages temperature differences between compressed air and recirculated gases, reducing thermomechanical stresses and allowing for a compact, efficient cooling system that maintains structural integrity and enhances engine performance.
Implementation Method 1
a heat exchanger connected to two high-temperature gas circulation circuits, in particular compressed air and burnt gases, and in which a heat transfer fluid circulates
Implementation Method 2
the axis of the gas flow is substantially orthogonal to the axis of the compressed air flow
Data Source
Figure 1
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AI summary
Cooling system (100) for gas and compressed air, comprising a double-flow heat exchanger (10) through which the gases pass along a first axis and the compressed air along a second axis, characterized in that the exchanger (10) comprises a cooling chamber for the gases (42) adjoining and communicating with a cooling chamber for the compressed air (41) in which the axis of the gas flow (Xg) is substantially orthogonal to the axis of the compressed air flow (Xa).