CN106801642B - Car intercooler with high compressive strength - Google Patents

Car intercooler with high compressive strength Download PDF

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Publication number
CN106801642B
CN106801642B CN201611240848.7A CN201611240848A CN106801642B CN 106801642 B CN106801642 B CN 106801642B CN 201611240848 A CN201611240848 A CN 201611240848A CN 106801642 B CN106801642 B CN 106801642B
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air chamber
intercooler
main
section
compressive strength
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CN106801642A (en
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马振超
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Shanghai Delang Auto Radiator Manufacturing Co ltd
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Shanghai Delang Auto Parts Manufacturing Co ltd
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02BINTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B29/00Engines characterised by provision for charging or scavenging not provided for in groups F02B25/00, F02B27/00 or F02B33/00 - F02B39/00; Details thereof
    • F02B29/04Cooling of air intake supply
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/10Internal combustion engine [ICE] based vehicles
    • Y02T10/12Improving ICE efficiencies

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Cooling, Air Intake And Gas Exhaust, And Fuel Tank Arrangements In Propulsion Units (AREA)

Abstract

The invention relates to an automobile intercooler with high compressive strength, which comprises a main sheet, an air chamber and a sealing gasket, wherein the main sheet is in sealing connection with the air chamber through the sealing gasket, the tail end of the air chamber is provided with a fixing part with a rectangular section, the tail end of the air chamber is in transitional connection with one corner of the rectangular section of the fixing part, the tail end of the main sheet is provided with a groove for wrapping the fixing part, the groove comprises a buckle top edge, an outer side vertical edge, a buckle bottom edge and an inner side vertical edge, and the buckle top edge, the outer side vertical edge, the buckle bottom edge and the inner side vertical edge are sequentially connected to form a rectangle with a unfilled corner in section, and the inner side vertical edge is in transitional connection with the tail end of the main sheet. Compared with the prior art, the invention has the advantages of stable structure, easy processing, low cost, long service life and the like.

Description

Car intercooler with high compressive strength
Technical Field
The invention relates to an automobile intercooler, in particular to an automobile intercooler with high compressive strength.
Background
The intercooler is a matched set of the turbine-added engine, and has the functions of reducing the temperature of high-temperature air after the booster is used for boosting, reducing the heat load of the engine, improving the air inflow and increasing the power of the engine. Whether mechanically augmented or turbocharged, an intercooler is required to be installed between the supercharger and the intake manifold. The heat dissipation performance of the intercooler directly influences the power of the engine, so how to improve the heat dissipation performance of the intercooler becomes an important subject to be studied at present. At present, automobile manufacturers have own requirement indexes on the heat radiation performance of the intercooler, the conventional requirement is 60000 times, and even a high host factory is required to ensure that the heat radiation performance of the matched intercooler reaches more than 10 ten thousand times. The current situation of the intercooler is that the general heat radiation performance is low, the use requirement of customers cannot be met more and more, and the situation that whether the heat radiation performance of the intercooler is good or not becomes the bottleneck for improving the power of the turbocharged engine. Therefore, it is necessary to study the structure of the intercooler, and what factors affect the heat dissipation performance of the intercooler.
Structure of intercooler (as in fig. 1): the intercooler is composed of a main plate 2, a side plate 4, a radiating pipe 5, a core body of a radiating belt 6, a left air chamber 1, a right air chamber 1, a sealing gasket 3 and accessories, wherein a turbulent flow belt is arranged on the radiating pipe 5.
Through doing gas-gas intercooler pressure cycle test, products (taking a certain model of intercooler as an example) which are not up to standard in test are mostly undercut leakage, and sealing gasket overflow phenomenon, namely main piece biting teeth and the wall of a gas chamber are separated. Concluding that: the service lives of the main plate and the air chamber are not up to standard, so that the heat dissipation performance of the intercooler is not up to standard.
1) Air chamber: there are two factors that affect the strength of the air chamber: a. the material b of the air chamber, the air chamber reinforcing rib is related to the material c of the air chamber, the material used has good strength, hardness and pressure resistance; regarding the air chamber reinforcing ribs, the product is uniformly distributed with the reinforcing ribs, and the air chamber has better structural strength. So conclude that: the structural design of the air chamber influences the heat dissipation performance of the intercooler to a great extent.
2) Master slice: there are three factors affecting master strength: a. the main sheet material b is the main sheet material thickness c is the main sheet structure, and the heat radiation performance is not obviously improved after the improvement on the main sheet material and the material thickness. So conclude that: the structural design of the main plate influences the heat dissipation performance of the intercooler to a great extent.
Chinese patent CN204128402U discloses a vertical flow radiator for automobile, in which only one side of the end of the water chamber is fixed by the main plate, and the pressure of the air inlet is applied to the engagement teeth continuously to deform, that is, the engagement teeth of the main plate are separated from the air chamber wall, with the increase of the air cooling cycle number of the intercooler, and simultaneously, chinese patent CN205315104U discloses a water cooling radiator with an improved leakage-proof water chamber, in which, although both side surfaces of the end of the water chamber are fixed by the main plate, the inner side is inclined arc, and cannot provide high-strength supporting force, and the disengagement of the engagement teeth of the main plate and the air chamber wall is easy to occur after multiple air cooling cycles.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide the automobile intercooler with high compressive strength, which has the advantages of stable structure, easiness in processing, low cost, long service life and the like.
The aim of the invention can be achieved by the following technical scheme:
the utility model provides an automobile intercooler with high compressive strength, includes principal slice, air chamber and sealed pad, the principal slice passes through sealed pad and air chamber sealing connection, the air chamber end is equipped with the cross-section and is rectangular fixed part, and the air chamber end is with the rectangular one corner transitional coupling of fixed part cross-section, the principal slice end is equipped with the recess of parcel fixed part, the recess includes buckle topside, outside vertical flange, buckle base and inboard vertical flange, and buckle side, outside vertical flange, buckle base and inboard vertical flange connect gradually and form the rectangle that the cross-section has the unfilled corner, inboard vertical flange and the terminal transitional coupling of principal slice.
Length l of the inner vertical side 1 The value range is l 2 -0.6mm≤l 1 ≤l 2 -0.2mm,l 2 Is the length of the bottom edge of the buckle.
The tail end of the main sheet is a horizontal straight line section and is vertical to the inner side vertical side.
The space between the inner side edge and the inner vertical edge of the fixing part is 0.15-0.22 mm.
The cross section of the sealing gasket is elliptical.
A plurality of reinforcing ribs are arranged on the outer wall of the air chamber.
The reinforcing ribs are uniformly distributed.
The thickness of the groove is 1.4-1.6 mm.
The air chamber is made of PA66 and GF30 engineering plastics.
The main sheet is manufactured through five working procedures, wherein the five working procedures are as follows:
a forming step, namely stamping the material plate to form a plurality of embryonic main sections with wavy sections, wherein two ends of each embryonic main section are in a step shape with inclination;
a second shaping step of shaping the stepped shape with inclination into a right-angled stepped shape;
three trimming steps, namely trimming the main sections of the multi-section embryonic form according to the required size;
four flanging procedures, namely carrying out right-angle flanging on the tail end of each embryonic main segment;
and five punching processes, namely punching holes at the wavy part of the main section of each embryonic form to form a main sheet with a main sheet hole.
Compared with the prior art, the invention has the following advantages:
1) The tail end of the air chamber is designed into a rectangular shape, the tail end of the main sheet is designed into a rectangle with a unfilled corner, namely, the main sheet surface contacted with the air chamber is corrected into a straight surface for positioning of the air chamber, the tail end of the main sheet is a horizontal straight line section and is vertical to the inner side vertical line, a larger force support is provided for the air chamber, after the main sheet is meshed, the air chamber is firmly clamped and positioned in the main sheet groove, and the air chamber and the main sheet are ensured to be stably fixed in multiple pressure cycle tests, so that the purpose of prolonging the service life of the intercooler is realized.
2) Design the value of the inner vertical edge, l 2 -0.6mm≤l 1 ≤l 2 The value range is 0.2mm, so that the supporting force generated by the inner vertical side is effectively matched with the supporting force of the buckle bottom plate, the larger pressure difference on two sides cannot be generated, and stable and balanced supporting force can be provided.
3) The gap between the air chamber and the main sheet is reduced, the fixing part is matched with the inner vertical side of the main sheet, and the air chamber has enough effective supporting force, so that the air chamber can be always stable after being impacted by air inlet pressure, and the service life of the intercooler is greatly prolonged. Meanwhile, the thickness of the groove is 1.4-1.6 mm, so that the high yield force is provided.
4) The air chamber is made of PA66 and GF30 engineering plastic, and has the advantages of high strength, special thermal stability, hydrolysis resistance and the like. The rigidity of the air chamber structure can be further enhanced by matching with the reinforcing rib structure.
5) The cross section of the sealing gasket is elliptical, and compared with a rectangular sealing gasket, the sealing gasket is more suitable for the shapes of the tail end of the water chamber and the main piece, and the two sides of the sealing gasket can bear the intersected pressure and are not easy to deform.
6) The manufacturing is convenient, and easy popularization and utilization, and the intercooler heat dispersion of main plate production after the use improvement is more superior, very big improvement the power of engine, reduced the energy consumption. After 100000 times of pressure cycle test of the air-air intercooler, the test piece is subjected to leakage detection, and no leakage exists.
Drawings
FIG. 1 is a schematic diagram of an intercooler of an automobile;
FIG. 2 is a schematic diagram of a connection structure of a main sheet and an air chamber in the prior art;
FIG. 3 is a schematic view of the snap teeth and plenum wall disengagement of a prior art master;
FIG. 4 is a schematic view of the connection structure of the main sheet and the air chamber in the intercooler of the present invention;
FIG. 5 is a schematic view of the force bearing area of the air chamber;
FIG. 6 is a schematic diagram of a conventional force analysis of the end of a gas cell;
FIG. 7 is a schematic view of a primary sheet forming process according to the present invention;
FIG. 8 is a schematic diagram of a two-pass shaping process of a master according to the present invention;
FIG. 9 is a schematic view of three trimming steps of a master sheet according to the present invention;
FIG. 10 is a schematic diagram of a four-pass flanging process for a main sheet according to the present invention;
fig. 11 is a schematic diagram of five punching steps of the master according to the present invention.
In the figure: 1. the heat dissipation belt comprises an air chamber, 2, a main piece, 3, a sealing gasket, 4, a side plate, 5, a heat dissipation pipe, 6, a heat dissipation belt core body, 7, a reinforcing rib, 11, a fixing part, 21, a buckle top edge, 22, an outer side vertical edge, 23, a buckle bottom edge, 24 and an inner side vertical edge.
Detailed Description
The invention will now be described in detail with reference to the drawings and specific examples. The present embodiment is implemented on the premise of the technical scheme of the present invention, and a detailed implementation manner and a specific operation process are given, but the protection scope of the present invention is not limited to the following examples.
Analysis is carried out on the state (figure 2) of the normal matching of the existing main sheet 2 and the air chamber 1:
the vertical section of the inner wall of the air chamber 1 (see fig. 5) is in a trapezoid+rectangular shape, d1=67 mm, d2=215 mm, d3=20 mm, d4=45 mm, and the stress area of the inner wall of the air chamber 1 is as follows:
S=S1+S2=215x20+(67+215)x25x1/2=7825mm 2 =78.25cm 2
the charge pressure of the intercooler is known as F Feeding in =2kgf/cm 2 Pressure applied to the inner wall of the air chamber 1:
F1=F feeding in ×S=2×78.25=156.5kgf
As shown in fig. 6: 10%4343/3003/10%7072t1.5 of the main sheet 2 is known to have a yield strength F Flexor bend 130kgf, g=0.5 kgf, fn1=fn2=29.5 kgf;
in the X direction:
F1x+FN2-F flexor bend =F1×Sin40°+FN2-F Flexor bend =156.5×0.64+29.5-130=0.1≈0,
I.e. fn2+f1x=f Flexor bend The air chamber 1 is in a balanced state in the horizontal direction;
in the Y direction:
FN1+F1y-G-F flexor bend =FN1+F1Cos40°-G-F Flexor bend =29.5+156.5×0.77-0.5-130=18.9kgf>0,
Namely FN1+F1y>G+F Flexor bend Therefore, as the number of air cooling cycles of the intercooler increases, the pressure of the intake air continuously applies pressure to the engagement teeth, and when the main sheet 2 reaches the yield strength, deformation, cracking and engagement leakage occur (see fig. 3).
Based on the above study results, further analytical measurements found (see fig. 2): the gap a1 between the air chamber 1 and the main sheet 2 is larger and reaches 0.8mm, and the edge of the main sheet 2 has no straight edge, l 1 The size is smaller, the forming height is lower, the air chamber 1 lacks effective supporting force (namely FN1 and FN2 are small), so the air chamber can shake left and right after being impacted by air inlet pressure, the service life of the intercooler is greatly reduced, leakage occurs when the circulation times are only 3000 times in a pressure circulation test, the functional requirements of the intercooler cannot be met, and therefore the structures of the main sheet 2 and the air chamber 1 are required to be improved, so the service life of the intercooler is prolonged, and the specific scheme is as follows:
as shown in fig. 4, an intercooler with high compressive strength for an automobile comprises a main sheet 2, an air chamber 1 and a sealing gasket 3, wherein the main sheet 2 is in sealing connection with the air chamber 1 through the sealing gasket 3, the tail end of the air chamber 1 is provided with a fixing part 11 with a rectangular cross section, the tail end of the air chamber 1 is in transitional connection with one corner of the rectangular cross section of the fixing part 11, the tail end of the main sheet 2 is provided with a groove for wrapping the fixing part 11, the groove comprises a fastening top edge 21, an outer vertical edge 22, a fastening bottom edge 23 and an inner vertical edge 24, the fastening top edge, the outer vertical edge 22, the fastening bottom edge 23 and the inner vertical edge 24 are sequentially connected to form a rectangular with a unfilled corner on the cross section, the inner vertical edge 24 is in transitional connection with the tail end of the main sheet 2, the tail end of the main sheet 2 is a horizontal straight line section and is perpendicular to the inner vertical edge 24, the cross section of the sealing gasket 3 is elliptic, and more caters to the shape of the water chamber tail end and the main sheet 2 compared with the rectangular sealing gasket 3, and both sides of the sealing gasket 3 can bear the intersecting pressure and is not easy to deform.
Length l of inner vertical edge 24 1 The value range is l 2 -0.6mm≤l 1 ≤l 2 -0.2mm,l 2 For the length of the bottom edge 23 of the buckle, the value range effectively ensures that the supporting force generated by the inner vertical edge 24 is matched with the supporting force of the bottom plate of the buckle, and the large pressure difference on two sides can not be generated, so that stable and balanced supporting force can be provided. The distance between the inner side edge of the fixing part 11 and the inner side vertical edge 24 is 0.15-0.22 mm, namely the distance at the a1 position is 0.2mm, the gap between the air chamber 1 and the main sheet 2 is smaller, and the fixing part 11 is matched with the inner side vertical edge 24 of the main sheet 2, and the air chamber 1 has enough effective supporting force, so that the air chamber can be always stable after being impacted by air inlet pressure, and the service life of the intercooler is greatly prolonged. The thickness of the groove is 1.4-1.6 mm, 1.5mm is selected in the embodiment, and the groove provides enough large yield force.
The air chamber 1 is made of PA66 and GF30 engineering plastic and has the advantages of high strength, special thermal stability, hydrolysis resistance and the like. A plurality of horizontal reinforcing ribs 7 are arranged on the outer wall of the air chamber 1 at intervals along the vertical direction, and the plurality of reinforcing ribs 7 are uniformly distributed.
The main sheet 2 has four conventional procedures: shaping, trimming, flanging and punching, wherein the improved main sheet 2 is manufactured through five working procedures, namely:
a forming step, namely stamping the material plate to form a plurality of embryonic main segments with wavy cross sections, wherein two ends of each embryonic main segment are in a step shape with inclination, as shown in fig. 7;
a second shaping step of shaping the stepped shape with inclination into a rectangular stepped shape, and obtaining a length l after shaping, wherein the length c=5mm in fig. 7 1 =7mm, as shown in fig. 8;
three trimming steps, namely trimming the main sections of the multi-section embryonic form according to the required size, as shown in figure 9;
four flanging procedures, namely carrying out right-angle flanging on the tail end of each embryonic main segment, as shown in fig. 10;
five punching processes are performed to punch holes at the wavy parts of the main section of each embryonic form to form a main sheet 2 with main sheet holes, as shown in fig. 11.
In this embodiment, l is added by the shaping step 1 Dimension is raised to 7mm, l 2 The corresponding dimension is designed to be 7.4mm, l 3 The size is designed to be 9.5mm correspondingly, and the main sheet surface (the position shown by an arrow A in fig. 2) contacted with the air chamber 1 is corrected to be a straight surface for positioning the air chamber 1, so that a larger force support is provided for the air chamber 1, the size a1 is reduced from 0.8mm to 0.2mm, the gap between the air chamber 1 and the main sheet 2 is greatly reduced, and after the main sheet 2 is meshed, the air chamber 1 is firmly clamped and positioned in a groove of the main sheet 2.
And (3) using the improved main sheet 2 for trial production of products, and performing a gas-gas intercooler pressure cycle test again to obtain test results: after 100000 times of test, the test piece is subjected to leakage detection, and no leakage exists.
The reliability and the correctness of the invention are demonstrated through a pressure circulation test of the gas-gas intercooler, the heat dissipation performance of the intercooler produced by using the improved main sheet 2 is more excellent, the power of an engine is greatly improved, and the energy consumption is reduced.

Claims (8)

1. The utility model provides an automobile intercooler with high compressive strength, includes main part (2), air chamber (1) and sealed pad (3), main part (2) are through sealed pad (3) and air chamber (1) sealing connection, a serial communication port, air chamber (1) end is equipped with the fixed part (11) that the cross-section is rectangular, and air chamber (1) end and the rectangular one corner transitional coupling of fixed part (11) cross-section, main part (2) end is equipped with the recess of parcel fixed part (11), the recess includes buckle topside (21), outside vertical flange (22), buckle base (23) and inboard vertical flange (24), and buckle side, outside vertical flange (22), buckle base (23) and inboard vertical flange (24) connect gradually and form the rectangle that the cross-section has the unfilled corner, inboard vertical flange (24) and main part (2) end transitional coupling;
length l of the inner vertical edge (24) 1 The value range is l 2 -0.6mm≤l 1 ≤l 2 -0.2mm,l 2 Is the length of the bottom edge (23) of the buckle;
the space between the inner side edge of the fixed part (11) and the inner vertical edge (24) is 0.15-0.22 mm.
2. An intercooler for a motor vehicle having a high compressive strength according to claim 1, wherein the main sheet (2) terminates in a horizontal straight section and is perpendicular to the inner vertical side (24).
3. An intercooler for a motor vehicle having a high compressive strength according to claim 1, wherein the gasket (3) has an elliptical cross section.
4. An intercooler for a motor vehicle having a high compressive strength according to claim 1, wherein a plurality of reinforcing ribs (7) are provided on the outer wall of the air chamber (1).
5. The intercooler of a vehicle having high compressive strength as claimed in claim 4, wherein the plurality of reinforcing ribs (7) are uniformly distributed.
6. An intercooler for an automobile having high compressive strength according to claim 1, wherein the thickness of the groove is 1.4 to 1.6mm.
7. An intercooler for a motor vehicle having a high compressive strength according to claim 1, wherein the air chamber (1) is made of PA66+ GF30 engineering plastic.
8. The intercooler for a vehicle having high compressive strength according to claim 1, wherein the main sheet (2) is manufactured by five processes, which are respectively:
a forming step, namely stamping the material plate to form a plurality of embryonic main sections with wavy sections, wherein two ends of each embryonic main section are in a step shape with inclination;
a second shaping step of shaping the stepped shape with inclination into a right-angled stepped shape;
three trimming steps, namely trimming the main sections of the multi-section embryonic form according to the required size;
four flanging procedures, namely carrying out right-angle flanging on the tail end of each embryonic main segment;
five punching processes are carried out, and punching is carried out at the wavy part of the main section of each section of the embryonic form, so as to form a main sheet (2) with a main sheet hole.
CN201611240848.7A 2016-12-29 2016-12-29 Car intercooler with high compressive strength Active CN106801642B (en)

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Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108443008A (en) * 2018-06-04 2018-08-24 上海德朗汽车零部件制造有限公司 A kind of charge air cooler gas chamber that bottom is reinforced
CN110487103A (en) * 2019-09-10 2019-11-22 南宁八菱科技股份有限公司 A kind of high-temperature and high-presure resistent buckle teeth slot structure

Citations (5)

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Publication number Priority date Publication date Assignee Title
CN201443432U (en) * 2009-07-02 2010-04-28 泰安鼎鑫冷却器有限公司 Air-cooled intercooler of turbocharged engine
CN203664525U (en) * 2013-11-27 2014-06-25 上海德朗汽车零部件制造有限公司 Automobile intercooler main leaf side edge clamping mechanism
CN105157467A (en) * 2015-09-28 2015-12-16 湖北雷迪特冷却系统股份有限公司 Main piece for intercooler
CN205341689U (en) * 2015-12-24 2016-06-29 上海德朗汽车零部件制造有限公司 Monodentate undercut machine
CN206458535U (en) * 2016-12-29 2017-09-01 上海德朗汽车零部件制造有限公司 A kind of vehicle intercooler with high compressive strength

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN201443432U (en) * 2009-07-02 2010-04-28 泰安鼎鑫冷却器有限公司 Air-cooled intercooler of turbocharged engine
CN203664525U (en) * 2013-11-27 2014-06-25 上海德朗汽车零部件制造有限公司 Automobile intercooler main leaf side edge clamping mechanism
CN105157467A (en) * 2015-09-28 2015-12-16 湖北雷迪特冷却系统股份有限公司 Main piece for intercooler
CN205341689U (en) * 2015-12-24 2016-06-29 上海德朗汽车零部件制造有限公司 Monodentate undercut machine
CN206458535U (en) * 2016-12-29 2017-09-01 上海德朗汽车零部件制造有限公司 A kind of vehicle intercooler with high compressive strength

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