Two-Stage Air-to-Air Cooler Layout for Compact Engine Intakes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing turbocharged engine systems require additional plumbing hardware and liquid cooling systems, which increase complexity and transient effects, affecting fuel consumption and emissions.
Innovation Solution
A two-stage air-to-air cooling system with parallel flow arrangement, utilizing first and second stage air-to-air coolers oriented in different directions to redirect charge air efficiently within the engine system, eliminating the need for additional plumbing and liquid cooling hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooled charge air cooler is used, then cooling efficiency is improved, but system complexity increases due to additional plumbing hardware and liquid cooling systems
Solution Approach 1:
The patent replaces the liquid cooling system with an air-to-air cooling system. The charge air cooler assembly uses ambient air flowing through external passages to cool the charge air in internal passages, eliminating the need for liquid coolant circulation systems, pumps, and complex plumbing hardware while maintaining effective charge air cooling
Solution Approach 2:
The patent extracts the liquid cooling system components (coolant pumps, radiators, complex piping) from the engine system and replaces them with a simpler air-to-air heat exchange system. The charge air cooler assembly stands as a self-contained unit that uses atmospheric air for cooling without requiring integration into the engine's liquid cooling circuit
2Temperature
If traditional charge air cooling system is used, then cooling function is achieved, but transient effects increase affecting fuel consumption and emissions
Solution Approach 1:
The patent employs variable geometry turbochargers with adjustable vanes that can dynamically respond to changing engine load and speed conditions. This dynamic adjustment optimizes the compression ratio and charge air flow characteristics, reducing transient effects during acceleration and load changes, thereby improving fuel consumption and emissions performance
Solution Approach 2:
The charge air cooler assembly is designed with a compact layout and optimized airflow paths that enable rapid cooling response. The separate air-to-air coolers for first and second stage charge air are positioned and dimensioned to provide immediate cooling effect when charge air temperature rises, reducing the thermal inertia and transient temperature fluctuations that affect engine efficiency
3Temperature
If first stage and second stage charge air are cooled in same direction, then system layout is simplified, but cooling efficiency decreases
Solution Approach 1:
The patent divides the charge air cooling function into separate first stage and second stage air-to-air coolers. The first stage cooler handles charge air from the low-pressure turbocharger while the second stage cooler handles charge air from the high-pressure turbocharger. This segmentation allows each cooler to be optimized for its specific function and arranged in different orientations to maximize cooling efficiency
Solution Approach 2:
The patent arranges the first stage air-to-air cooler with its flow direction substantially perpendicular to the second stage air-to-air cooler's flow direction. This orthogonal arrangement in different spatial dimensions allows both coolers to operate independently at optimal angles, maximizing heat exchange efficiency while managing the complexity of the cooler assembly layout
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
Reduces the length of air transfer hardware, improves engine performance by minimizing transient effects, and enhances fuel efficiency and emission control.
Implementation Method 1
a first stage air-to-air cooler, a second stage air-to-air cooler
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
An engine system includes a charge air cooler assembly that is configured to direct air to different parts of the engine system and to reduce overall void volume within the air intake system. The charge air cooler assembly includes a first stage air-to-air cooler arranged to direct a first charge air along a first direction from an inlet to an outlet of the first stage air-to-air cooler. The charge air cooler assembly also includes a second stage air-to-air cooler arranged to direct a second charge air along a second direction from an inlet to an outlet of the second stage air-to-air cooler that is different from the first direction. In some embodiments, the first stage air-to-air cooler and the second stage air-to-air cooler are each disposed in a parallel flow arrangement relative to an air driver of the engine system.