Two-Stage Charge Air Cooler Assembly for Low-Volume Air Routing
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Solution Overview
Problem
Existing turbocharged engine systems face challenges in efficiently cooling and transferring charge air due to the need for additional plumbing hardware, which increases volume and can affect engine performance and emissions.
Innovation Solution
A two-stage air-to-air cooler system is employed, with each cooler directing charge air along different directions to eliminate the need for additional plumbing, reducing volume and improving engine performance by minimizing transient effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional single-stage cooling system with common plumbing hardware is used, then system volume increases and transient effects are amplified, but device complexity is reduced
Solution Approach 1:
The charge air cooling system is divided into two independent stages, each with its own cooler and plumbing hardware. The first stage cooler cools charge air from the first turbocharger, and the second stage cooler cools charge air from the second turbocharger. This segmentation eliminates the need for a common plumbing system, reducing overall system volume while maintaining functional independence to minimize transient effects.
Solution Approach 2:
The patent introduces a spatial dimension by orienting the first and second coolers at different angles relative to the engine axis. The first cooler is arranged at a first angle and the second cooler at a second angle, creating a three-dimensional charge air distribution system. This angular arrangement optimizes charge air delivery to different engine zones, improving cooling effectiveness without requiring additional plumbing volume.
2Ease of operation
If additional plumbing hardware is added to distribute charge air, then charge air distribution is improved, but system volume increases and transient effects are amplified
Solution Approach 1:
Instead of using extensive common plumbing to distribute charge air to multiple zones, the system segments the charging function into two independent stages. Each stage has dedicated plumbing from its turbocharger to its cooler, eliminating the need for complex distribution manifolds and reducing overall plumbing volume while maintaining effective charge air delivery to the engine.
Solution Approach 2:
The patent uses the two independently controlled coolers as intermediary devices between the turbochargers and the engine. By positioning and orienting these coolers strategically in the exhaust stream, they serve as mediators that directly deliver cooled charge air to the engine intake without requiring extensive intermediate plumbing infrastructure.
3Device complexity
If common plumbing hardware is used for both coolers, then device complexity is reduced, but transient effects are amplified and engine performance is affected
Solution Approach 1:
The charging system is segmented into two independent stages with separate plumbing for each cooler. This independence allows each stage to be controlled separately, preventing transient effects from propagating between stages. The first stage can be optimized for low-pressure charging while the second stage handles high-pressure charging, improving overall engine performance without requiring complex inter-stage coordination.
Solution Approach 2:
The patent enables dynamic control of each cooling stage independently. By having separate plumbing and independent cooler positioning, the system can dynamically adjust the operation of each stage to match varying engine demands, improving responsiveness and performance while maintaining simpler individual stage designs that don't require complex coordinated control.
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
The system effectively cools and transfers charge air with reduced hardware, enhancing engine performance and reducing fuel consumption and emissions.
Implementation Method 1
a first stage air-to-air cooler arranged to direct the first charge air along a first direction from an inlet of the first stage air-to-air cooler to an outlet of the first stage air-to-air cooler
Data Source
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.