Segmented End Cover for Charge Air Cooler Maintenance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing end covers for charge air coolers in large internal combustion engines are heavy and require complete removal for O-ring replacement, leading to lengthy maintenance times and engine downtime, as well as the need for hoisting equipment due to their weight.
Innovation Solution
A redesigned end cover with a cover plate, outer and inner walls forming multiple chambers, a connecting surface with accessible maintenance holes, and a flow channel, allowing for easy access and replacement of O-rings without removing the entire end cover or associated piping, significantly reducing maintenance time and eliminating the need for hoisting equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the end cover is designed as a heavy cast iron piece for structural integrity, then the structural strength is improved, but the weight increases and maintenance becomes difficult
Solution Approach 1:
The end cover is segmented into a main body and removable maintenance holes. The maintenance holes can be opened to provide access to O-rings and sealing surfaces without removing the entire end cover, enabling localized maintenance while preserving the overall structural integrity of the heavy cast iron construction.
2Ease of repair
If the entire end cover is removed for O-ring replacement, then complete access to sealing surfaces is achieved, but maintenance time increases to 36 man-hours
Solution Approach 1:
The end cover incorporates removable maintenance holes that segment the access path to sealing surfaces. These holes can be opened independently to allow technicians to reach and replace O-rings at connecting pipes without dismantling the entire end cover assembly, reducing maintenance time from 36 man-hours to approximately 1 man-hour.
Solution Approach 2:
The maintenance holes are extracted as separate accessible openings in the end cover structure. This allows the extraction of the maintenance function from the overall end cover removal process, enabling O-ring replacement through the holes while the end cover remains installed on the charge air cooler.
3Ease of repair
If the end cover is removed for maintenance, then access to connecting pipes is achieved, but engine downtime increases significantly
Solution Approach 1:
The end cover is segmented with removable maintenance holes that provide access to connecting pipes without requiring removal of the entire end cover. This segmentation enables rapid maintenance of O-rings and sealing surfaces, reducing engine downtime from 36 man-hours to approximately 1 man-hour and improving overall engine availability.
4Weight of moving object
If hoisting equipment is used to lift the heavy end cover, then safe handling is achieved, but equipment requirements and complexity increase
Solution Approach 1:
The end cover design incorporates removable maintenance holes that eliminate the need to lift and remove the entire heavy cast iron end cover for routine O-ring replacement. By segmenting the access function into removable holes, the invention eliminates the requirement for hoisting equipment and heavy lifting gear, reducing equipment complexity and requirements.
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
The end cover (1) for a charge air cooler of turbocharged internal combustion engine comprises a plurality of chambers (9, 11, 13, 14) that are provided with openings for accommodating connecting pipes (39, 40, 41). Each of the chambers (9, 11, 13, 14) comprises a maintenance hole (20, 21, 22, 23) for accessing the chamber (9, 11, 13, 14).