Split Cooling System for Diesel Engine Intercooler Temperature Control
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Solution Overview
Problem
Traditional cooling systems for diesel locomotive engines lack flexibility in providing lower coolant temperatures to intercoolers, limiting combustion efficiency and increasing emissions.
Innovation Solution
A split cooling system with an independent cooling loop for the intercooler radiator, controlled by a temperature switch or microprocessor, allows for additional cooling of the coolant before it reaches the intercooler, using a dedicated fan and separate coolant paths to achieve lower coolant temperatures and reduce emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional cooling system with a single coolant loop is used, then the system structure is simple, but the coolant temperature cannot be independently controlled for different components
Solution Approach 1:
The cooling system is divided into separate coolant loops: a first coolant loop for the engine and a second coolant loop for the intercooler. This segmentation allows independent temperature control for each component, enabling the intercooler to receive cooler coolant without affecting engine cooling requirements.
Solution Approach 2:
A temperature-controlled valve is introduced as an intermediary device to regulate coolant flow between loops. The valve selectively opens or closes to control coolant distribution, enabling flexible temperature management while maintaining system integration.
2Temperature
If the coolant temperature is increased to maintain engine operating parameters, then the engine can operate efficiently, but the intercooler cannot provide sufficient cooling to the charge air
Solution Approach 1:
By separating the coolant circulation into two independent loops, the system can maintain lower temperatures in the intercooler loop while keeping the engine loop at optimal operating temperatures. This eliminates the temperature compromise required in single-loop systems.
3Power
If a single radiator is used for both engine cooling and intercooler cooling, then the system is simpler, but the cooling capacity for the intercooler is limited
Solution Approach 1:
The cooling system uses separate radiators for the first coolant loop (engine) and second coolant loop (intercooler). This allows each radiator to be optimized for its specific cooling requirements, with the intercooler radiator dedicated to providing maximum cooling capacity for charge air.
4Temperature
If the coolant flow path is lengthened to provide more cooling opportunities, then the coolant temperature decreases, but the system response time increases
Solution Approach 1:
The system uses dynamic control of the temperature-controlled valve to rapidly adjust coolant flow distribution. This enables quick response to temperature changes by selectively directing coolant flow, avoiding the delayed response associated with lengthening the entire coolant circulation path.
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 approach enhances combustion efficiency by providing cooler charge air, reduces emissions, and lowers fuel consumption by allowing for more flexible coolant temperature management.
Implementation Method 1
the intercooler comprising an air-to-liquid heat exchanger for exchanging heat between the combustion air and a liquid coolant
Implementation Method 2
at least one engine coolant radiator
Implementation Method 3
it then enters a pair of pumps that are mounted on the engine block. The pumps then circulate the coolant through fluid passages within the engine
Implementation Method 4
The coolant exits both the radiators and enters an oil cooler, which is in parallel to an expansion tank
Data Source
AI summary
A system and method for cooling an internal combustion engine. In one embodiment of the invention a cooling system for an internal combustion engine is disclosed, comprising an engine; an intercooler for receiving combustion air from a turbocharger, the intercooler comprising an air-to-liquid heat exchanger for exchanging heat between the combustion air and a liquid coolant; an intercooler radiator; at least one engine coolant radiator; an expansion tank; an oil cooler; and at least one pump, wherein the dedicated fan is controlled by a temperature switch or controller and wherein the at least one engine coolant radiator and the intercooler radiator are located on opposite sides of the engine.