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Car Intercooler

Optimum Design of Automotive Intercooler

During the operation of the intercooler, efficiency and pressure loss are the two most important performance parameters. In the process of optimizing the design of the automotive intercooler, it is necessary to focus on improving the heat exchange efficiency of the intercooler and reducing the pressure loss. In order to achieve this goal, in addition to paying attention to the heat transfer coefficient of the cooling element, it is also necessary to appropriately increase the resistance to achieve the purpose of sacrificing the minimum pressure to increase the maximum heat transfer coefficient.

1. The working principle of automotive intercooler

During operation, the intercooler can enable various fluids to transfer and convert energy and heat without mutual contact. Specifically, the air first flows from the supercharger, and after passing through the car's intercooler, the temperature and density are reduced, which can improve the charging efficiency of the engine. As an indispensable component in the operation process, the rationality of the internal structure of the intercooler is related to the flow of air and the heat exchange of compressed air, and these factors can have a direct impact on the operating state of the engine, which in turn will affect its power performance and gas emissions.

2. The role of the car intercooler includes two aspects

First, after the gas enters the supercharger, the temperature will also rise when the pressure increases, which will affect the circulating intake air volume in the engine. Through the cooling effect of the intercooler, the temperature of the gas can be reduced, the density of the gas can be increased, and the amount of gas inside the engine cylinder can be increased, thereby improving the operating efficiency of the engine. Second, if the gas is not cooled by the intercooler, the gas will directly enter the cylinder after being pressurized, which will result in a relatively low impulse coefficient of the engine. At the same time, these high-temperature, low-density gases may also increase the combustion temperature in the engine cylinder, and in severe cases may lead to engine deflagration and other failures, resulting in overheating of the engine itself and reducing thermal efficiency. In addition, when the combustion temperature is relatively high, the proportion of nitrogen oxides in the gas generated by the combustion increases, which will lead to air pollution. In order to alleviate this problem, it is necessary to use the car intercooler to cool the air, so that the combustion temperature in the entire cylinder is controlled within a reasonable range.

3. Optimal design of automotive intercooler

In the process of optimizing the design, in order to obtain a satisfactory intercooling effect, it is necessary to enable the intercooler to supply gas with a constant temperature under different working conditions of the engine, and the temperature of the gas has a direct relationship with the load. In order to reduce the engine temperature, it is necessary to adjust the working characteristics of the intercooler by adjusting the engine and the turbocharger, and control the intake air temperature at about 70 degrees. In order to achieve this goal, the intercooler can be optimized from the following four aspects. The first is to reduce the recent air pressure as much as possible, usually less than 2%; the second is to minimize the pressure on the cooling air side; the third is to choose high-efficiency, low-resistance heat transfer elements; The structure of the cooler is compact and has strong economic performance.

According to the above four goals, it is necessary to check and calculate the heat exchange capacity, cooling medium and pressure loss of the automotive intercooler. According to the calibration parameters, the calculation is mainly divided into the following two cases. The first is to use the logarithmic average temperature difference method to check whether the heat dissipation area meets the requirements; the second is to use the heat transfer unit number method to check whether the temperature of the charge air and cooling air at the condenser outlet meets the requirements.

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