Piston Engine Base with Integrated Charge Air Casing
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Solution Overview
Problem
In large turbocharged piston engines, the large size and weight of turbochargers and charge air coolers cause vibration, isolation, sound, and sealing issues due to their placement on a bracket mounted onto the engine block, with the center of mass far from the engine block, leading to structural stress and limited mounting surface area.
Innovation Solution
A base with an integrated air casing for charge air cooling, which includes both low-pressure and high-pressure charge air coolers, is attached to a concrete base in stationary applications and a ship hull, reducing the weight on the engine block and bringing the center of mass closer, thereby alleviating vibration issues and enhancing the operation of turbochargers and connected components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If turbochargers and charge air coolers are placed on a bracket mounted onto the engine block, then the charging system is compact and integrated, but the weight on the bracket increases massively and the center of mass moves far from the engine block
Solution Approach 1:
The charge air coolers are extracted from the bracket assembly and relocated to the base structure. This separation removes the heavy cooling components from the engine block mounting, reducing the weight burden on the bracket while maintaining system integration through the base connection.
Solution Approach 2:
The charging system is redistributed across different spatial dimensions: turbochargers remain on the bracket for compact engine integration, while charge air coolers are positioned in the base structure below the engine. This dimensional separation optimizes both compactness and weight distribution.
2Device complexity
If turbochargers and charge air coolers are placed on a bracket mounted onto the engine block, then the charging system is integrated, but vibration and isolation problems increase due to the center of mass being far from the engine block
Solution Approach 1:
By extracting the heavy charge air coolers from the bracket assembly and relocating them to the base, the center of mass of the bracket assembly moves closer to the engine block. This reduces the lever arm and minimizes vibration and isolation problems while preserving system integration.
Solution Approach 2:
The base structure acts as a counterweight platform, positioning heavy components (charge air coolers) in the base below the engine block to balance the mass distribution. This counterbalancing reduces the harmful effects of having mass far from the engine center.
3Device complexity
If turbochargers and charge air coolers are placed on a bracket mounted onto the engine block, then the charging system is compact, but the mounting surface area on the engine block is insufficient for large masses
Solution Approach 1:
The mounting strategy utilizes the vertical dimension by placing heavy charge air coolers in the base structure below the engine block, where sufficient space and mounting area are available. This preserves the compact horizontal footprint on the engine block while accommodating large masses in the vertical dimension.
Solution Approach 2:
The charging system is segmented into two mounting zones: turbochargers mounted on the bracket for compact engine integration, and charge air coolers mounted in the base for adequate support area. This segmentation allows each component to be positioned optimally according to its mass and spatial requirements.
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 reduces vibration problems and improves the operation of turbochargers and connected systems by distributing the weight more evenly and reducing the distance of the center of mass from the engine block, leading to enhanced performance and reduced structural stress.
Implementation Method 1
an air casing (15) for pressurised charge air, in which air casing a charge air cooler (9, 11) is arranged
Data Source
Figure 1
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Figure 4
AI summary
A base (12) for a large turbocharged piston engine (2), on which base the piston engine (2) can be mounted, characterised in that the base (12) comprises an air casing (15) for pressurised charge air, in which air casing (15) a charge air cooler (9, 11 ) is arranged.