GB2539903A

GB2539903A - Mounting assembly for turbo aftercooler modules

Info

Publication number: GB2539903A
Application number: GB1511415.0A
Authority: GB
Inventors: Stellwagen Karl; H Luft Markus; W Vormstein Holger; Berger Olaf
Original assignee: Caterpillar Energy Solutions GmbH
Current assignee: Caterpillar Energy Solutions GmbH
Priority date: 2015-06-30
Filing date: 2015-06-30
Publication date: 2017-01-04
Anticipated expiration: 2035-06-30
Also published as: GB2539903B; GB201511415D0

Abstract

A mounting assembly 34 for a turbo aftercooler module comprising a turbocharger 30 and a downwardly disposed aftercooler 32, the mounting assembly including a first mount portion 44 and a second mount portion 46. The first mount portion 44 is an aftercooler mount and defines an attachment face portion mounted to the aftercooler 32, an air chamber fluidly connected to the aftercooler, and an exit port 58. The second mount portion 46 is a turbocharger mount and includes an intake mount face mounted with the exit port 58, a base mount mounted to the base member (16, Fig. 1), and first and second outlet conduits 76, 78. The air-fuel mixture is directed to a first set of cylinders in the internal combustion engine through the first outlet conduit 76 and the remainder of the air-fuel mixture is directed to the second set of cylinders in the internal combustion engine through the second outlet conduit 78.

Description

Description MOUNTING ASSEMBLY FOR TURBO AFTERCOOLER MODULES Technical Field [0001] The present disclosure relates generally to a mounting assembly for a turbo aftercooler module of an intake air system of an internal combustion engine. More specifically, the present disclosure relates to the mounting assembly having an integrated air-fuel mixture guidance system for the internal combustion engine.

Background [0002] Internal combustion engines, such as a gas engine, are commonly known to employ an intake air system henceforth referred as an intake system, to supply compressed air-fuel mixture to intake manifolds of an internal combustion engine. Such intake systems generally include a turbo aftercooler module mounted on a base frame of the internal combustion engine, via a mounting assembly. The turbo aftercooler module generally includes a turbocharger and an aftercooler. As is customarily known, the turbocharger receives, compresses, and supplies the air-fuel mixture, to the aftercooler. The aftercooler is disposed downstream to the turbocharger and receives the compressed air-fuel mixture from the turbocharger. The aftercooler then cools the air-fuel mixture and supplies it to the intake manifolds of the internal combustion engine, via an air-fuel mixture guidance system.

[0003] In conventional intake systems, the mounting assembly is structured and arranged to mount the turbo aftercooler module onto the base frame of the internal combustion engine. Moreover, the air-fuel mixture guidance system in a conventional intake system is separately structured and arranged to route and guide the compressed air-fuel mixture to the intake manifolds of the internal combustion engine. Such arrangements have been found to increase the complexity and bulkiness of conventional intake systems. Moreover, this arrangement is generally commensurate with the overall cost and complexity of the intake system.

Summary of the Invention [0004] One aspect of the present disclosure are directed towards a mounting assembly for a turbo aftercooler module to provide air-fuel mixture to an internal combustion engine. The internal combustion engine has a first set of cylinders and a second set of cylinders. The turbo aftercooler module includes a turbocharger and an aftercooler. The turbocharger is in fluid communication with the aftercooler. The turbo aftercooler module is configured to receive intercooled air-fuel mixture from an intake side of the turbocharger. The mounting assembly includes a first mount portion and a second mount portion. The first mount portion defines an attachment face portion, an air chamber, and an exit port. The attachment face portion is mounted to the aftercooler. The air chamber is defined enclosed within the first mount portion. The air chamber is fluidly connected to the aftercooler. The second mount portion includes an intake mount face, a base mount, a first outlet conduit, and a second outlet conduit. The intake mount face is configured to mount with the exit port of the first mount portion. The base mount is configured to mount with a base member. The air-fuel mixture is directed to the first set of cylinders in the internal combustion engine through the first outlet conduit and the remainder of the air-fuel mixture is directed to the second set of cylinders in the internal combustion engine through the second outlet conduit.

[0005] Another aspect of the present disclosure is directed towards a turbocharger mount including a first mounting portion, a second mounting portion, and a conduit. The first mounting portion attaches a turbocharger to the turbocharger mount. The second mount portion attaches the turbocharger mount to a base member or an engine. The conduit is fluidly connected to a first air intake manifold and a second intake manifold of the engine.

[0006] Yet another aspect of the present disclosure is directed towards an aftercooler mount including a first portion, a second portion, and an air chamber. The first portion attaches an aftercooler to the aftercooler mount. The second portion attaches a base member or an engine to the aftercooler mount. The air chamber is fluidly connected with an aftercooler outlet.

Brief Description of the Drawings [0007] FIG. 1 is a schematic view of a power generator system or generator system that illustrates a generator, an engine, and an intake air system associated with the engine, in accordance with the concepts of the present disclosure; [0008] FIG. 2 is a perspective view of a turbo aftercooler module of the intake air system of FIG. 1 that illustrates a mounting assembly for the turbo aftercooler module, in accordance with the concepts of the present disclosure; [0009] FIG. 3 is a perspective view of a first mount member of the mounting assembly of FIG. 2, in accordance with the concepts of the present disclosure; and [0010] FIG. 4 is a perspective view of a second mount member of the mounting assembly of FIG. 2, in accordance with the concepts of the present disclosure.

Detailed Description [0011] Referring to FIG. 1, there is shown a generator system 10 that produces electrical power required to run one or more electrically operated machines (not shown). The generator system 10 may be a stationary unit, although mobile units are envisioned. The electrically operated machine (not shown) may include electrical drives, industrial drive motor, or electrically operated cranes. The generator system 10 commonly includes an internal combustion engine 12 and a generator 14. For ease in reference, the internal combustion engine 12 will be referred to as the engine 12, interchangeably hereinafter. Both the engine 12 and the generator 14 are installed on a base member 16. In an embodiment of the present disclosure, the base member 16 is a base frame of the engine 12 that supports both the engine 12 and the generator 14 of the generator system 10. The engine 12 is drivingly coupled to the generator 14. This is enabled by having a crankshaft (not shown) of the internal combustion engine 12 drivingly coupled to a rotor shaft (not shown) of the generator 14. The engine 12 is adapted to produce mechanical power by combustion of an air-fuel mixture. The generator 14 is adapted to receive mechanical power from the engine 12, convert the mechanical power into electrical energy, and supply the electrical energy to the electrically operated machine (not shown).

[0012] The engine 12 may be a gaseous fuel engine that includes a first set of cylinders 18 and a second set of cylinders 20. Each of the first set of cylinders 18 and the second set of cylinders 20 may include at least one cylinder, which includes a combustion chamber where the compressed air-fuel mixture is burnt to produce mechanical power. Additionally, the engine 12 employs an intake air system 22 to supply the compressed air-fuel mixture to each of the first set of cylinders 18 and the second set of cylinders 20. For ease in reference, the intake air system 22 will be referred to as the intake system 22, interchangeably herein after. The intake system 22 includes a turbo aftercooler module 24. The turbo aftercooler module 24 is adapted to receive the air-fuel mixture, compress the air-fuel mixture, and supply the compressed air-fuel mixture to each of the first set of cylinders 18 and the second set of cylinders 20. The turbo aftercooler module 24 is fluidly connected to the first set of cylinders 18, via a first intake manifold 26. Similarly, the turbo aftercooler module 24 is fluidly connected to the second set of cylinders 20, via a second intake manifold 28. Moreover, the turbo aftercooler module 24 supplies the compressed air-fuel mixture to each of the first set of cylinders 18 and the second set of cylinders 20, respectively via the first intake manifold 26 and the second intake manifold 28. Although the present disclosure contemplates the use of a gaseous fuel engine, as a type of the engine 12, usage of several other types of engines, such as but not limited to, diesel fuel engine, petrol fuel engine, or a dual fuel engine, may also be contemplated. Although the present disclosure contemplates inclusion of a V-layout of the engine 12 with two sets of cylinders 18, 20, various other layouts of the engine 12, such as the inline layout, may also be contemplated.

[0013] Referring to FIG. 2, there is shown the turbo aftercooler module 24 of the intake system 22. The turbo aftercooler module 24 includes a turbocharger 30, an aftercooler 32, and a mounting assembly 34.

[0014] The turbocharger 30 may be a positive displacement air-compressor that utilizes a portion of energy from exhaust gases to compress the air-fuel mixture. The turbocharger 30 includes an intake side 36 and an air-fuel mixture outlet 38. The intake side 36 is fluidly connected to a air-fuel mixture supply 40 (FIG. 1), while the air-fuel mixture outlet 38 is fluidly connected to the aftercooler 32 of the turbo aftercooler module 24. The turbocharger 30 is adapted to pump the air-fuel mixture from the air-fuel mixture supply 40 (FIG. 1), compress the air-fuel mixture, and supply the compressed air-fuel mixture to each of the first intake manifold 26 (FIG. 1) and the second intake manifold 28 (FIG. 1) through the aftercooler 32 and the mounting assembly 34, along the mixture flow direction. Flow arrows 42 (FIG. 1) depict the mixture flow direction.

[0015] The aftercooler 32 of the turbo aftercooler module 24 is fluidly connected to the turbocharger 30, and is disposed downstream to the turbocharger 30 in the mixture flow direction, depicted by flow arrows 42 (FIG. 1). The aftercooler 32 includes a number of cooling chambers adapted to cool the inflowing compressed air-fuel mixture, to improve operational efficiency of the engine 12. The aftercooler 32 includes an aftercooler outlet (not shown) of the aftercooler 32, which facilitates an exit of the compressed air-fuel mixture to the mounting assembly 34. From the aftercooler outlet (not shown) of the aftercooler 32, the compressed air-fuel mixture is supplied to each of the first intake manifold 26 and the second intake manifold 28, via the mounting assembly 34.

Although, concepts of the present disclosure are defined as applied to the turbo after cooler module 24, an extension of the application to intercooler-based modules may also be contemplated.

[0016] The mounting assembly 34 is structured and arranged to serve dual purposes. First, the mounting assembly 34 supports the turbocharger 30 and the aftercooler 32 of the turbo aftercooler module 24. Second, the mounting assembly 34 routes the compressed air-fuel mixture to each of the first intake manifold 26 and the second intake manifold 28. The mounting assembly 34 includes a first mount portion 44 and a second mount portion 46. The first mount portion 44 will be referred to as an aftercooler mount 44, interchangeably hereinafter. The first mount portion 44 is adapted to support the aftercooler 32 on the base member 16. The second mount portion 46 will be referred to as a turbocharger mount 46, interchangeably hereinafter. The second mount portion 46 is adapted to support the turbocharger 30 on the base member 16. In an embodiment, the base member 16 is a base frame of the engine 12 and the turbocharger 30 and the aftercooler 32, respectively are supported on the base frame of the engine 12 via the first mount portion 44 and the second mount portion 46.

[0017] Referring to FIG. 3, there is shown the first mount portion 44 of the mounting assembly 34. The first mount portion 44 and the second mount portion 46 are generally casted steel components that may be suitably structured and arranged to serve a dual-purpose of supporting the aftercooler 32 and the turbocharger 30, and of routing the air-fuel mixture. Although the present disclosure contemplates casted components, it may be contemplated that the first mount portion 44 and the second mount portion 46 may be manufactured by various other processes, such as fabrication, forging milling, or the like.

[0018] The first mount portion 44 may be a hollow cube shaped container like structure designed to be arranged between the base member 16 and the aftercooler 32, during operation. The first mount portion 44 includes a first portion 48 and a second portion 50, to mount the aftercooler 32 on the base member 16. For ease in reference, the first portion 48 will be referred to as the attachment face portion 48, interchangeably herein after. The attachment face portion 48 is attached to the aftercooler 32. The attachment face portion 48 includes a flange 52, to attach the aftercooler 32 to the first mount portion 44. Several attachment means to attach the aftercooler 32 to the flange 52 of the first mount portion 44 may be contemplated, such as but not limited to, a bolt attachment, a rivet attachment, or a weld attachment. Notably, a sealing member (not shown) is employed between the aftercooler 32 and the flange 52, to prevent any leakage of the air-fuel mixture. Moreover, the second portion 50 is attached to the base member 16 with use of an attachment means, such as but not limited to, a bolt attachment, a rivet attachment, or a weld attachment. This attaches the first mount portion 44 to the base member 16. This facilitates the aftercooler 32 to be supported onto the base member 16.

[0019] Additionally, the first mount portion 44 includes an air chamber 54 defined within the first mount portion 44. The air chamber 54 is fluidly connected to the aftercooler outlet (not shown) of the aftercooler 32 and is disposed downstream to the aftercooler 32 in the mixture flow direction, depicted by flow arrows 42 (FIG. 1). The air chamber 54 includes one inlet (inlet port 56), one outlet (exit port 58), and one bypass port 60. The inlet port 56 is defined surrounded by the flange 52 of the attachment face portion 48. The exit port 58 and the bypass port 60 are defined at a face between the first portion 48 and the second portion 50 of the first mount portion 44. In an operational state, the inlet port 56 is fluidly connected to the aftercooler outlet (not shown) of the aftercooler 32 while facing the aftercooler 32. This facilitates fluidly connection between the first mount portion 44 and the aftercooler 32. Notably, a direction of flow of the air-fuel mixture at the exit port 58 is perpendicular to a direction of flow of the air-fuel mixture at the inlet port 56. The bypass port 60 is in fluid communication with the turbocharger 30, via a by-pass valve (not shown), which facilitates a certain amount of air-fuel mixture to flow back to the turbocharger 30, when required. For example, the by-pass valve (not shown) may be actuated to bypass certain amount of compressed air-fuel mixture back to the turbocharger 30, to control a temperature or mixture ratio of the compressed air-fuel mixture supplied to each of the first set of cylinders 18 and the second set of cylinders 20.

[0020] Referring to FIG. 4, there is shown the second mount portion 46 of the mounting assembly 34. The second mount portion 46 is structured and arranged to support the turbocharger 30 on the base member 16. More specifically, the second mount portion 46 includes a base mount 62 with an intake mount face 64, to support and mount the turbocharger 30 on the base member 16. The base mount 62 portion may be a substantially cuboidal structure that includes a first mounting portion 66 and a second mounting portion 68 defined opposite to the first mounting portion 66. The first mounting portion 66 includes a multiplicity of threaded mounting holes 70 that facilitates mounting of the turbocharger 30 on the second mount portion 46. Threaded fasteners (not shown) may pass through a portion of the turbocharger 30 and the threaded mounting holes 70, to attach the turbocharger 30 with the base mount 62 of the second mount portion 46. The second mounting portion 68 of the base mount 62 may be attached to the base member 16 with use of bolted fasteners (not shown), to mount the second mount portion 46 on the base member 16. This facilitates the second mount portion 46 to support the turbocharger 30 on the base member 16.

[0021] Furthermore, the base mount 62 of the second mount portion 46 includes a conduit 72 defined within the base mount 62 and between the first mounting portion 66 and the second mounting portion 68. The conduit 72 is fluidly connected to the exit port 58 of the first mount portion 44, to facilitate a flow of air-fuel mixture to the second mount portion 46. The conduit 72 is disposed downstream to the aftercooler 32 and upstream to the engine 12. The conduit 72 includes an inlet 74 and two outlets (a first outlet conduit 76 and a second outlet conduit 78). Each of the first outlet conduit 76 and the second outlet conduit 78 are in fluid communication with the inlet 74 of the second mount portion 46. In an embodiment of the present disclosure, the inlet 74 is defined at the intake mount face 64 of the second mount portion 46 and is fluidly connected to the exit port 58 of the first mount portion 44. This facilitates the intake mount face 64 to be mounted with the exit port 58 of the first mount portion 44. As shown in FIG. 2, a connection conduit 80 fluidly connects the exit port 58 of the first mount portion 44 with the inlet 74 of the second mount portion 46. Therefore, the inlet 74 is disposed downstream to the exit port 58 in the mixture flow direction (depicted by flow arrows 42). The air-fuel mixture is supplied to the second mount portion 46 through the inlet 74 of the second mount portion 46. Moreover, the first outlet conduit 76 and the second outlet conduit 78, respectively are fluidly connected to the first intake manifold 26 and the second intake manifold 28 of the engine 12. Therefore, the air-fuel mixture is supplied to the first intake manifold 26 and the second intake manifold 28, respectively through the first outlet conduit 76 and the second outlet conduit 78 of the second mount portion 46. The facilitates the first intake manifold 26 and the second intake manifold 28, respectively to facilitate the flow of the air-fuel mixture to the first set of cylinders 18 and the second set of cylinders 20 of the engine 12.

Industrial Applicability [0022] In operation, the turbo aftercooler module 24 of the intake system 22 may be actuated by the supply of exhaust gases from the engine 12 to the turbocharger 30 of the turbo aftercooler module 24. As the exhaust gases pass through the turbocharger 30, the turbocharger 30 pumps the air-fuel mixture from the air-fuel mixture supply 40 (FIG. 1) and receives the air-fuel mixture at the intake side 36 of the turbocharger 30. Thereafter, the turbocharger 30 compresses the air-fuel mixture and supplies the compressed air-fuel mixture to the aftercooler 32 in the mixture flow direction (depicted by flow arrows 42). Then, the turbocharger 30 facilitates the flow of compressed air-fuel mixture to the aftercooler 32, the mounting assembly 34, the first intake manifold 26, and the second intake manifold 28 in the mixture flow direction (depicted by flow arrows 42). While the compressed air-fuel mixture flows through the aftercooler 32, the compressed air-fuel mixture is cooled and is directed to the first intake manifold 26 and the second intake manifold 28, via the mounting assembly 34. Notably, the mounting assembly 34 mounts and supports both the aftercooler 32 and the turbocharger 30 on the base member 16. In addition, the mounting assembly 34 routes and guides the air-fuel mixture to the first intake manifold 26 and the second intake manifold 28.

[0023] Within the mounting assembly 34, the compressed air-fuel mixture flows through the first mount portion 44 and the second mount portion 46 of the mounting assembly 34. The first mount portion 44 includes the air chamber 54, which receives the compressed air-fuel mixture from the aftercooler 32 of the turbo aftercooler module 24. The air-fuel mixture received by the first mount portion 44 is then supplied to the second mount portion 46 through the exit port 58 of the first mount portion 44. Notably, an amount of air-fuel mixture supplied to the second mount portion 46 may be selectively adjusted based on the operational requirements of the engine 12. This may be accomplished by manipulating the bypass valve (not shown) connected to the bypass port 60 of the first mount portion 44. For example, at high speed running operations of the engine 12, the engine 12 may require a relatively lower amount of the air-fuel mixture. In those situations, the bypass valve (not shown) is actuated to bypass certain amount of air-fuel mixture back to the turbocharger 30.

[0024] Furthermore, the air-fuel mixture from the exit port 58 of the first mount portion 44 is received by the second mount portion 46 through the inlet 74 of the second mount portion 46. From the inlet 74, the air-fuel mixture flows to the first outlet conduit 76 and the second outlet conduit 78. Thereafter, the first outlet conduit 76 and the second outlet conduit 78, respectively facilitate the flow of the air-fuel mixture to the first intake manifold 26 and the second intake manifold 28 of the engine 12. The first intake manifold 26 and the second intake manifold 28 then direct the compressed air-fuel mixture to the first set of cylinders 18 and the second set of cylinders 20. At this point, the air-fuel mixture is combusted to produce mechanical power.

[0025] In effect, the mounting assembly 34 facilitates a dual-function of supporting the turbocharger 30 and the aftercooler 32 and of guiding the compressed air-fuel mixture to the first set of cylinders 18 and the second set of cylinder 20 of the engine 12. An arrangement as shown reduces the overall size and bulkiness of the intake system 22. In addition, this arrangement of the mounting assembly 34 reduces the overall space of the intake system 22, which results in reduced overall cost of the mounting assembly 34.

[0026] It should be understood that the above description is intended for illustrative purposes only and is not intended to limit the scope of the present disclosure in any way. Those skilled in the art will appreciate that other aspects of the disclosure may be obtained from a study of the drawings, the disclosure, and the appended claim.

Claims

Claims What is claimed is:

1. A mounting assembly for a turbo aftercooler module to provide an air-fuel mixture to an internal combustion engine, the internal combustion engine having a first set of cylinders and a second set of cylinders, the turbo aftercooler module configured to receive the air-fuel mixture from an intake side of a turbocharger, the turbocharger being in fluid communication with an aftercooler, the mounting assembly comprising: a first mount portion defining an attachment face portion being mounted to the aftercooler and defining an air chamber enclosed within the first mount portion and an exit port, wherein the air chamber is fluidly connected to the aftercooler; and a second mount portion including: an intake mount face configured to mount with the exit port of the first mount portion; a base mount configured to mount with a base member; and a first outlet conduit and a second outlet conduit, wherein the air-fuel mixture is directed to the first set of cylinders in the internal combustion engine through the first outlet conduit and the remainder of the air-fuel mixture is directed to the second set of cylinders in the internal combustion engine through the second outlet conduit.

2. A turbocharger mount comprising a first mounting portion to attach a turbocharger to the turbocharger mount, a second mounting portion to attach the turbocharger mount to a base member or an engine and a conduit to be fluidly connected to a first air intake manifold and a second intake manifold of the engine.

3. The turbocharger mount of claim 2, wherein the conduit is downstream of an aftercooler and upstream of the engine.

4. The turbocharger mount according to one of the claims 2 or 3, wherein the first mounting portion to attach the turbocharger is opposite to the second mounting portion to attach the turbocharger mount to the base member.

5. The turbocharger mount according to one of the claims 2 to 4, wherein the conduit is between the first mounting portion and the second mounting portion of the turbocharger mount.

6. The turbocharger mount according to one of the claims 2 to 5, wherein the conduit comprises one inlet and two outlets.

7. An aftercooler mount comprising a first portion to attach an aftercooler to the aftercooler mount and a second portion to attach a base member or an engine to the aftercooler mount and an air chamber to be fluidly connected with an aftercooler outlet.

8. The aftercooler mount according to claim 7, wherein the air chamber comprises one inlet and one outlet and the inlet is designed to be connected to the aftercooler outlet.

9. The aftercooler mount according to one of the claims 7 and 8, whereby a direction of flow defined by the inlet is perpendicular to a direction of flow defined by the outlet.

10. The aftercooler mount according to one of the claims 7 to 9, whereby the first portion comprises a flange to attach the aftercooler thereto and the inlet is surrounded by the flange.

11. The aftercooler mount according to one of the claims 7 to 10, whereby the outlet is arranged between the first portion and the second portion.

12. The aftercooler mount according to one of the claims 7 to 11, whereby the inlet is in an operational state facing the aftercooler.

13. The aftercooler mount according to one of the claims 7 to 12 whereby the aftercooler mount is designed to be arranged between the base member and the aftercooler during operation.