Remote Charge-Air Cooling System for Enclosed Engines
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Solution Overview
Problem
Traditional charge-air cooling systems integrated with engines are not suitable for enclosed environments, as they either reduce engine performance or require inefficient heat transfer outside the structure, limiting the use of high-performance engines like Tier II engines in such settings.
Innovation Solution
A remote cooling system using a high-efficiency local air-to-water charge-air cooling device with a secondary water loop to transfer heat externally, avoiding integral integration with the engine and minimizing internal environment heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional integral charge-air cooling system is used, then the engine can be cooled effectively, but the system cannot be deconstructed and reused in other applications
Solution Approach 1:
The cooling system is divided into separate modular components: a charge-air cooler assembly and a radiator assembly that can be independently removed and reused. This segmentation allows the system to be deconstructed for different applications while maintaining cooling functionality.
Solution Approach 2:
The charge-air cooler is extracted as a separate removable component from the engine assembly, allowing it to be taken out and reused in other applications. This extraction enables versatility without requiring the entire engine assembly to be replaced.
2Temperature
If a single-stage air-to-air cooling system is used in an enclosed structure, then heat is transferred to the exterior, but the internal air pressure drop increases and engine performance reduces
Solution Approach 1:
A water intermediary is introduced between the charge-air cooler and the radiator. The charge-air cooler transfers heat to water, which then carries the heat to the radiator for external dissipation. This intermediary pathway allows effective heat removal without significant pressure drops in the air intake system.
Solution Approach 2:
The system uses hydraulic principles by transferring heat through a water loop rather than direct air-to-air cooling. The water circulation system efficiently carries heat from the charge-air cooler to the radiator, enabling effective cooling with minimal impact on air flow and engine performance.
3Adaptability or versatility
If a two-stage integral cooling system is used, then the engine can be cooled in enclosed environments, but the system is constructed as an integral packaged component and cannot be deconstructed
Solution Approach 1:
The cooling system is segmented into separate assemblies (charge-air cooler and radiator) that can be manufactured independently and then assembled. This segmentation provides application flexibility while maintaining the benefits of a two-stage cooling system for enclosed environments.
Solution Approach 2:
The removable charge-air cooler assembly can be used with different engine configurations and in different applications (enclosed or open environments). This universal design allows the same component to serve multiple functions and applications, enhancing adaptability.
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
Enables high-performance engine operation in enclosed environments without significant efficiency reduction or internal heating, by effectively cooling engines using a separate air-to-water system and external heat transfer.
Implementation Method 1
a high-efficiency local air-to-water charge-air cooling device
Implementation Method 2
uses a secondary water loop to remove heat via a remote cooling device to an external environment
Data Source
AI summary
A remote cooling system (10) for cooling turbocharged compressed air from a charge-air cooled engine (12) which is placed within an enclosed environment. The cooling system (10) comprises a charge-air cooler (14) located a predetermined distance from the engine (12). The charge-air cooler (14) comprises a fluid receiver (16) which receives turbocharged air from the engine 12, an air-to-water heat exchanger (24) which cools the turbocharged air received from the fluid receiver (16), and a fluid return member (26) for returning cooled air to the engine (12). A secondary cooling device (34), located outside of the enclosed environment, provides heat transfer from the heat exchanger (24) within the charge-air cooler (14) to an external environment.