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Thus, the basic thermodynamic advantage 400 BOSS
of charge air-cooling is that it provides cooler air at
higher density to the engine. The lower charge air 350
temperature results in lower peak cycle temperature
and lower turbine inlet temperature. 300
III. ADVANTAGES OF CHARGE AIR-COOLING
50 100 150 200 250 300 350
a. Increased Output: Intake manifold Temp. oF
This is often the main reason for charge air-
cooling. Since the more air at lower temperature is Fig.3: Effect of intake temperature on piston
available for combustion, more fuel can be burnt Temperature
resulting in more BHP. Since this is the most cost
effective way of increasing the power of given HC emissions are known to be the most sever at idle
engine, many engine designers have utilized charge and light load conditions. In these modes, the
turbocharger is operating at very low operating
BSNOx RATIO
proposed transient emissions conformance. This
cycle places greater importance on part load 1 BSNO2 = GMS/(BHP-HR)
operation compared to the present 13-mode cycle. In
order to meet the anticipated emissions levels on the
transient cycle, a fine tuned advanced charge air
cooling system is considered necessary. Another 0.9
consideration in deciding the level for a warm-up
feature is white smoke. White smoke control is
highly dependent on the type of engine combustion
system. In general, warm air clears white smoke 0.8
o
quickly. Intake manifold temperature of 140 F at 32 50 100 150 200 250 300 350
o INTAKE MANIFOLD TEMP. ºF
F ambient will help considerably in white smoke
control. Fig.5: Effect of intake manifold on Engine fuel
consumption.
20
INJECTION TIMING e.
Increased altitude capability:
31º BTDC One of the major limiting factors that the
15
engine designer is faced with is the exhaust
BSNOx GSM (HP-HR)
990
110 130 150 170 190 210
INTAKE MANIFOLD TEMP ºF
shows that for typically heavy-duty engine. Thus, IV. THERMAL DESIGN OF CHARGE AIR
Charge air-cooling provides a much needed safety COOLER
margin in exhaust temperature during altitude THEORY
operation.
The design of a heat exchange involves a
f. Charge Air Cooling as an aid in reducing consideration of both the heat transfer rates between
turbocharger requirements: the fluids and the mechanical pumping power
expended to overcome fluid friction and move the
For a given intake manifold air density, use fluids through the heat exchanger. For a heat
of a charge air cooler results in a lower turbocharger exchanger, operating with high-density fluids the
pressure ratio. When the charge air cooler friction power expenditure is generally small relative
effectiveness is high, the compressor efficiency to heat transfer rate, with result that the friction power
becomes less critical to achieve a given intake air expenditure is seldom of controlling influence.
density. This could result in significant practical gains. However, for low-density fluids such as gas it is very
The state-of –the-art compressor could be produced easy to expend as much mechanical energy in
economically when the efficiency is about 70%. When overcoming friction power as is transferred as heat.
a higher efficiency (~80%) is needed, the problem And it should be remembered that in most thermal
becomes very complicated. power systems mechanical energy is worth four to ten
times as much as its equivalent in heat.
Another area where the charge air cooler could be
advantageously used is to aid the compressor Increasing fluid-flow velocity can increase
requirements in altitude operation. Fig shows a typical the heat transfer rate per unit of surface area, and this
compressor map with the engine ―operating diamond‖ rate varies as something less than first power of the
superimposed upon it. It is clear from a fig that when a velocity. The friction power expenditure is also
charge air cooler is used the compressor pressure ratio increased with flow velocity, but in this behavior that
needed to meet altitude requirements is significantly allows the designer to match both heat transfer rate and
reduced. In addition, the ―surge margin‖, which is an friction (pressure-drop) specification, and it is this
indication of how close to the surge line the behavior that dictates many of characteristics of
compressor would operate, is improved with the use of different classes of heat exchangers.
a charge air cooler. It is clear that the addition of
charge air cooler would enable the designer to move If the friction power expenditure is high, we
the operating diamond to left of compressor map, can reduce flow velocities by increasing the number of
which is in the direction of higher efficiency. It should flow passages in the heat exchanger. This will also
be emphasized that the addition of charge air cooler decrease the heat transfer rate per unit of surface area,
should be accompanied by rematching the but according to the above relations, the reduction in
turbocharger to the engine in order to realize maximum heat transfer rate will be considerably less than the
benefits. friction-power reduction.
COOLER 63 K
The effective way to increase surface area density is to curves on the heat transfer- friction power plot, despite
make use of secondary surfaces, or fins, on one or both the influence of small hydraulic diameter on the
sides of surfaces. The low friction power requirement friction power.
characteristic of high density fluids, together with the
relatively high thermal conductivity of fluids, results in ASSUMPTIONS:
high convection heat transfer rates in any optimum To analyse the thermal performance of
design (high convection conductance). If fins are CAC the following assumptions are made.
employed the high heat transfer rate must be conducted
along the fins, and the conduction resistance may a. No heat loss to surrounding, i.e.,
destroy all or most of the advantage of extra surface heat transfer takes place fluid to
area gained. fluid only.
b. No phase change of fluids.
In compact gas-to-gas heat exchangers, large area c. Fluid properties are evaluated at
density is desirable on both fluids side, and method for their mean operating temperature.
accomplishing this objective with fins is illustrated by d. Airflow distribution is uniform
the plate-fin arrangement. The heat exchanger is built across CAC core.
up as a sandwich of flat plates bonded to e. The amount of coolant flow in
interconnecting fins. The two fluids are carried each tube is constant.
between alternate pairs of plates and can be arranged in f. Flow rates and fluid properties are
either counter flow or cross flow, which provides an constant throughout the pass.
added degree of flexibility in this arrangement.A g. Fouling factor are as per standards.
compact surface has small flow passages and
convection conductance h always varies as a negative
power of hydraulic diameter of the passage. Thus
compact surfaces tend, by their very nature, to have DESIGN PROCEDURE OF CAC:
high conductance. This leads to high performance
COREGEOMETRY THEORETICALLY CALCULATED:
Input
19. Inside Fin Depth Fdi =0.05 m louvered fins it is not possible to model the air side of a
heat exchanger in detail. Therefore porous media is
20. Efficiency of fan =80 % used for the core of the heat exchangers to simulate the
21. 21. Efficiency of pump =80 % pressure drop. The porous media provides resistance to
air flow which is dependent on the local flow velocity.
Two permeability coefficients, which have to be
V. CFD RESULTS defined, are obtained by pressure drop measurements
Apart from routine experimental of the individual components on a component test
development, recent years have seen a rapid growth of setup.
computer simulation of heat transfer phenomenon .
One of the major concerns of CAC designer is air is SIMULATION STEPS OF CAC
heat transfer medium on both sides which has low heat While simulating the radiator model
carrying capacity which enables the use of secondary following steps are involved.
heat transfer surface on both sides. The key to
1. Preparation of CAC core (Tube +
improving both performance measure which generally
louvered fin package) model using
lie in making changes in CAC geometry. The CFD
GAMBIT 2.2.30 2. Grid generation.
analysis that is a numerically solution provides a new
tool for design and optimization. Computational Fluid 3. Meshing the model with
Dynamics (CFD) can be a great help in analyzing the accompanied by defining
geometry changes and analyze the design and to do the different zones.
optimization. In this case of CAC, prediction of Charge
air flow patterns is very important. With this approach 4. Import mesh file into Fluent.
of CFD, it is possible to simulate the real CAC
behavior (internal flow and external heat exchange) 5. Selection of type of Solver.
and to get information for the designer to improve both
the CAC performance and also its efficiency. 6. Insertion of energy options.
Here a CAC core (tubes and louvered fin 7. Selection of materials and setting
arrangement) is considered to find out its thermal their various properties values.
performance and temperature profile in tubes, in
surrounding air and velocity profile of air.In this 8. Setting the operating conditions.
analysis of CAC, we have to do the analysis in two
different regions as 9. Fixing the boundary conditions.
Parameters Specification
Spacing (mm) 20
No of fins / tube 14
Results
Note
Pressure 2 bar
18 Heat Rejection
16Rejection (Kw)
Heat Cooling Air Side pressure drop
14
12 800
10 Pressure Drop (Pa)
700Side
Cooling Air
8 600
6 500
4 400
2 300
0 200
100
0 2 4 6 8 10 12
Ram Air Speed (m/s) 0
0 2 4 6 8 10 12
Similar manufg. 65.3 mm Deep core
Design 50 mm Deep core Ram Air Speed (m/s)
Design CAC 50 mm deep core Similar manufg. 65.3 mm deep core
We have compared the results of designed (1) By increasing the size of combustion
CAC with other manufacturer of similar CAC.To cylinders and burning the more fuel.
obtain the comparable heat rejection in core the similar
(2) By supplying more air in existing
design requires Almost 30% more surface area.
cylinders so that we can burn more fuel to obtain more
Graph 2 shows the variation of Charge air power.
pressure drop against cooling air velocity at constant
By second way, we can use CAC to
mass flow rate of charge air (540 Kg/h). It shows that
increase the density of charge air supplied to cylinder.
pressure drop is more at low velocity of cooling air.
And it is evident from the graph that it is constant at We have Designed CAC, which has fins on
higher speed of cooling air. both sides since cooled and cooling medium is air. Our
design has almost 30% less heat transfer area
Charge Air Side pressure Drop compared to other suppliers of CAC for comparable
6000 heat duty. The theoretical-model Computer-code (VB
Charge
5000Air Side Pressure Program) has been developed for simulation of
4000 pressure drop and temperature distribution. The
Drop (Pa) Computer model has been developed in VISUAL
3000
BASICS, because it is user-friendly tool.
2000
1000 The test model is developed with
0 aluminium fins and aluminium tubes, which gives
somewhat lower performance than copper fin and brass
0 2 4 6 8 10 12
Ram Air Seed (m/s) fin assembly, but this copper brass assembly requires
more cost than aluminium fin and tube assembly. Also
Design50 mm Deep Core
Similar manufg. 65.3 mm Deep Core there are some good qualities of aluminium as it is
light weighted, strong, reliable, and corrosion resistant.
Also this test model is developed with Nocoloc brazing
Graph: 2 Charge airside pressure drop Vs
process.
Cooling air velocity.
Then wind tunnel test results of that
The graph 3 shows the variation of cooling
radiator are compared with theoretical results. These
air pressure drop Vs velocity. The parabolic nature of
results are having good agreement.
graph shows the pressure drop is less at low velocities
of cooling air.
REFERENCES
A: BOOKS
[1] HeinzHeisler, ―Vehicle and Engine Technology‖, 2nd
Edition.Society of Automotive Engineers Inc,1998
B: PAPERS
[1] In KwangYoo, Kenneth Simpson, Myron Bell and
Stephen Majkowski―An Engine Coolant Temperature Model
and Application for Cooling System diagnosis‖, SAE Paper
no. 2000-01-0939.