For large diesel engines in the off-highway field (Non-Road Mobile Machinery, NRMM), turbocharging the charge air by means of charge air cooling combined with engine-internal measures is a key opportunity to optimize packaging, reduce emissions and fuel consumption, and increase performance. Indirect charge air cooling (i.e., with coolant) has been used for a long time in high-speed, high-performance diesel engines (HSD). To-date, NRMM applications in the HSD engine class ranging from 560 kW to 10 MW have used indirect charge air coolers (iCAC) with round-tube technology (nonferrous metal, stainless steel) or bar-and-plate systems (aluminum) with cross-counterflow. For commercial vehicles with engines of up to 560 kW, compact aluminum iCAC stacked-plate designs with counterflow are available. Based on existing on-highway technology, a new iCAC stacked-plate geometry is to be developed for HSD engines in the NRMM field that can be used to meet future requirements, e.g. charge air inlet temperatures of up to 300 °C, charge air pressures up to 4.9 to 7.9 bar, charge air mass flows of up to 3.5 kg/s, and coolant volume flow rates of up to 35 m3/h. The newly developed iCAC stacked-plate system for high-speed, high-performance diesel engines successfully implements a counterflow arrangement of charge air and coolant for these applications for the first time. Thereby resulting in a significant increase in efficiency compared with previous round-tube or bar-and-plate cross-counterflow coolers; uses a circumferential coolant channel to reduce thermal stresses while meeting SOLAS II requirements without additional insulation; provides effective modularity by changing the number of plates to individually match the charge air cooler performance to the number of cylinders within an engine class; incorporates alternative material designs in aluminum, nonferrous metal, or stainless steel with identical connections to the engine; ensures resistance to vibration, pressure, and thermal cycling; offers an advantage with respect to efficiency, weight (including that of the entire charge air group), packaging, and costs.
New design of iCAC for engine cooling of off-highway diesel engines
2013
15 Seiten, 12 Bilder
Conference paper
Storage medium
English
New design of iCAC for engine cooling of off-highway diesel engines
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