Transitional Turbulator for Charge Air Cooler Icing Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Air-to-air charge air coolers (CACs) face issues with icing and condensation, which can lead to engine performance reduction and fault codes, and increasing their size or using coolant-to-air heat exchangers is not feasible due to space and cost constraints.
Innovation Solution
The CAC employs turbulators with varying densities in both longitudinal and transverse directions, allowing for optimized airflow and pressure distribution to prevent icing and condensation, with higher density turbulators at the inlet and lower density at the outlet, or split densities in a transverse direction to manage ice and water accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the CAC size is increased to prevent icing and condensation, then the cooling effectiveness is improved, but the space constraints in the vehicle are violated
Solution Approach 1:
The patent applies local quality by varying the turbulator pitch along the longitudinal direction of the tubes. The pitch is smaller at the inlet end and larger at the outlet end, creating different flow characteristics in different sections. This allows the inlet section to effectively prevent icing and condensation through tighter turbulator spacing, while the outlet section uses larger spacing to reduce pressure drop, all within the same compact heat exchanger volume.
Solution Approach 2:
The patent changes the geometric parameter of the turbulators by varying the pitch along the tube length. This parameter change allows optimization of the balance between preventing icing/condensation (requiring smaller pitch) and maintaining acceptable pressure drop (requiring larger pitch), enabling the system to achieve reliable operation without increasing overall size.
2Reliability
If coolant-to-air heat exchangers are used to prevent icing and condensation, then the cooling reliability is improved, but the cost and system complexity increase
Solution Approach 1:
The patent applies self-service by using the compressed air itself to prevent icing and condensation. The varying pitch turbulators create controlled turbulence and pressure gradients that prevent moisture accumulation without requiring external coolant systems. The system uses its own operating conditions (compressed air flow) to solve the icing problem, eliminating the need for additional coolant-to-air heat exchangers and reducing overall system complexity.
3Ease of manufacture
If uniform pitch turbulators are used throughout the tube, then the manufacturing simplicity is improved, but the airflow optimization and icing prevention effectiveness are reduced
Solution Approach 1:
The patent implements local quality by differentiating the turbulator pitch in different sections of the tube. The inlet section has smaller pitch for effective icing prevention, while the outlet section has larger pitch. This localized differentiation improves reliability without significantly complicating manufacturing, as the varying pitch can be achieved through standard fabrication techniques for spiral or imbricated turbulator designs.
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 configuration effectively reduces icing and condensation, maintaining engine performance by ensuring ice and water are slowly directed out of the turbulator area, preventing blockages and ensuring efficient cooling without compromising power output.
Implementation Method 1
A turbulator is arranged in at least one of the plurality of tubes. The turbulator has a pitch defined in a direction transverse to airflow through the tube.
Data Source
AI summary
An air-to-air charge air cooler for cooling air supplied to an internal combustion engine includes a tube assembly including a plurality of tubes extending in a longitudinal direction. The plurality of tubes is arranged adjacent to one another. Each of the plurality of tubes includes an inlet to receive airflow and an outlet to output airflow. A turbulator is arranged in at least one of the plurality of tubes, the turbulator having a pitch defined in a direction transverse to airflow through the tube. The pitch varies in at least one of a longitudinal direction and a transverse direction of the tube.