Modular assembly for heat exchanger

A modular assembly for a heat exchanger is provided. The modular assembly includes a support assembly configured to couple to a base section of a hood structure of the heat exchanger. The support assembly includes a first slant surface and a second slant surface configured to provide support to at least a portion of the heat exchanger. The support assembly also includes a fluid reservoir integrated with and extending from the support assembly, the fluid reservoir is configured to store a fluid circulated through the heat exchanger.

TECHNICAL FIELD

The present disclosure relates to a heat exchanger assembly, and more particularly to a modular assembly for the heat exchanger assembly.

BACKGROUND

A heat exchanger, such, as a radiator is associated with a cooling system of an engine. A size of the radiator of the engine increases with an increase in size of the engine. The cooling system also includes a tank that may store cooling water. Further, large sized radiators require a sturdy support structure in order to hold the radiator and the tank. The tank is generally externally attached and bolted onto the support structure of the radiator.

In some applications, for example in a locomotive, it is desirable that the radiators are able to drain completely into the tank in order to prevent freeze damage. Thus, the tank has a large volume that occupies considerable compartment space. Additionally, in such systems, a weight of the tank is considerably high, owing to the tank adding to an overall weight of the system.

U.S. Published Application Number 2004/0025813 describes a front end structure and radiator support of a vehicle incorporating a sight glass for a reserve tank. The front end structure of the vehicle comprises a radiator support fixed on a vehicle body at the front end of the vehicle and to which at least a radiator is attached, a tank which is arranged in the front end of the vehicle, and behind the radiator support and accumulates fluid inside. Sight glasses by which a worker can see the level of cooling water, or the like, remaining in the tanks from the front side of the vehicle is also mounted on the radiator support.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a modular assembly for a heat exchanger is provided. The modular assembly includes a support assembly configured to couple to a base section of a hood structure of the heat exchanger. The support assembly includes a first slant surface and a second slant surface configured to provide support to at least a portion of the heat exchanger. The support assembly also includes a fluid reservoir integrated with and extending from the support assembly, the fluid reservoir is configured to store a fluid circulated through the heat exchanger.

In another aspect of the present disclosure, a heat exchanger assembly is provided. The heat exchanger assembly includes a heat exchanger. The heat exchanger assembly also includes a hood structure defining an interior space. The heat exchanger is received into the interior space of the hood structure. The heat exchanger assembly further includes a modular assembly coupled to the hood structure. The modular assembly includes a support assembly coupled to a base section of the hood structure. The support assembly includes a first slant surface and a second slant surface configured to provide support to at least a portion of the heat exchanger. The modular assembly also includes a fluid reservoir integrated with and extending from the support assembly. The fluid reservoir is configured to store a fluid circulated through the heat exchanger.

In yet another aspect of the present disclosure, an engine system is provided. The engine system includes an engine and a heat exchanger. The engine system also includes a hood structure defining an interior space. The heat exchanger is received into the interior space of the hood structure. The engine system further includes a modular assembly coupled to the hood structure. The modular assembly includes a support assembly coupled to a base section of the hood structure. The support assembly includes a first slant surface and a second slant surface configured to provide support to at least a portion of the heat exchanger. The modular assembly also includes a fluid reservoir integrated with and extending from the support assembly. The fluid reservoir is in communication with the engine and the heat exchanger. The fluid reservoir is configured to store a fluid circulated through the heat exchanger.

DETAILED DESCRIPTION

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts.FIG. 1is a perspective view of an exemplary engine system100, according to one embodiment of the present disclosure. In one embodiment, the engine system100may be associated with a locomotive (not shown). However, it should be noted that the application of the present disclosure is not restricted to the locomotive. The engine system100may be used to provide power to any machine including, but not limited to, an on-highway truck, an off-highway truck, an earth moving machine, and other similar machines.

The engine system100includes an engine102. The engine102provides driving power to the locomotive, in order to propel the locomotive on rails (not shown). In one embodiment, the engine102may include, for example, a diesel engine, a gasoline engine, a gaseous fuel powered engine such as, a natural gas engine, a combination of known sources of power, or any other type of power source apparent to one of skill in the art. As shown, the engine102may include an intake manifold103and an exhaust manifold105. The intake manifold103is configured to receive intake air through an air intake system107. Products of combustion may be exhausted from the engine102via the exhaust manifold105.

Ambient air may be drawn into the engine102through an air filter128of the air intake system107. The air intake system107of the engine system100may include a turbocharger130. The intake air may be introduced into the turbocharger130via line134, for compression purposes leading to a higher pressure thereof. The compressed intake air may then flow towards an aftercooler132via line136. The aftercooler132is configured to decrease a temperature of the intake air flowing therethrough. In the illustrated embodiment, the aftercooler132is embodied as an air to air aftercooler. Alternatively, the aftercooler132may embody an air to liquid aftercooler. The intake air may be introduced into the intake manifold104via line138. The line138may be fluidly coupled to the intake manifold103.

The engine system100also includes an aftertreatment system126. The aftertreatment system126is provided in fluid communication with the exhaust manifold105via line140. The aftertreatment system126is configured to treat the exhaust gases exiting the exhaust manifold105. The engine102may include other components (not shown) such as a fuel system.

A cooling system104is associated with the engine system100. A portion of the cooling system104is shown inFIG. 1. The cooling system104may include two cooling circuits, namely an engine cooling circuit (not shown) and an aftertreatment cooling circuit (not shown). The cooling system104is configured to cool various engine parts. In one example, the cooling system104is configured to allow a fluid, such as water, to flow into the engine cooling circuit and/or the aftertreatment cooling circuit.

Referring toFIGS. 1 and 2, a heat exchanger assembly106is associated with the cooling system104. The heat exchanger assembly106is configured to exchange heat with the fluid leaving the engine102. In one example, the heat exchanger assembly106may be configured to cool the water leaving the engine102via line142.

As shown inFIG. 2, the heat exchanger assembly106includes a heat exchanger108. In the illustrated embodiment, the heat exchanger assembly106includes four packs of heat exchangers108. However, in alternate embodiments, the number of packs of the heat exchanger108may vary based on system requirements. The heat exchanger108may include heat exchanger tubes (not shown) that allow the fluid to flow therethrough. The heat exchanger108may embody a radiator.

The heat exchanger108may embody any liquid to air heat exchanger or liquid to liquid heat exchanger, without limiting the scope of the present disclosure. In one example, ambient air may flow over the heat exchanger tubes to cool the fluid flowing therethrough. In some example, fins (not shown) may be provided between adjacent heat exchanger tubes in order to increase contact surface of the heat exchanger tubes to the ambient air, thereby increasing efficiency of the heat exchanger108.

Referring toFIGS. 2 and 3, a hood structure110is associated with the heat exchanger assembly106.FIG. 3illustrates the hood structure110without the heat exchanger108to depict the structure and construction of the hood structure110for purposes of clarity and explanation. The hood structure110includes frame members112(seeFIG. 3) arranged in a V-type configuration to support the heat exchanger108thereon. Further, a pair of plates114extends between each of the frame members112. The frame members112and the plates114of the hood structure110together define an interior space116. The heat exchanger108is received into the interior space116of the hood structure110. The hood structure110also includes vertical members118(seeFIG. 2) to mount the hood structure110on a surface of the locomotive.

Referring toFIGS. 3, 4, and 5, a modular assembly400for the heat exchanger108is illustrated. The modular assembly400is coupled to the hood structure110. Only a top edge401of the modular assembly400is visible inFIG. 2, while a portion of the modular assembly400is visible inFIG. 3, showing how the modular assembly400is arranged with respect to the hood structure110.FIGS. 4 and 5show standalone views of the modular assembly400.

As shown inFIGS. 3, 4 and 5, the modular assembly400includes a support assembly402. In one example, as shown inFIG. 3, a length of the support assembly402and a length of the hood structure110is the same so that the support assembly402sits within the interior space116of the hood structure110. The support assembly402is coupled to a base section120(seeFIG. 3) of the hood structure110. In one example, the support assembly402is coupled to the hood structure110by welding. Alternatively, any other joining process may be used to couple the support assembly402to the hood structure110.

The support assembly402includes a first slant surface404and a second slant surface406. The first and second slant surfaces404,406are arranged in an inverted “V” type manner. The first and second slant surfaces404,406of the support assembly402communicate with the interior space116of the hood structure110(seeFIG. 3). As shown inFIG. 2, the first and second slant surfaces404,406are configured to provide support to at least a portion of the heat exchanger108. More particularly, the first and second slant surfaces404,406are configured to support bottom surfaces of the heat exchanger108.

Referring toFIGS. 4 and 5, the modular assembly400includes a fluid reservoir408. The fluid reservoir408is configured to store the fluid, such as water, which is circulated through the engine102and the heat exchanger108. The fluid reservoir408is fluidly coupled to the engine102via the line144(seeFIG. 1). Further, the fluid reservoir408is fluidly coupled to the aftertreatment system126via line146(seeFIG. 1).

Referring toFIG. 5, the fluid reservoir408is integrated with and extends from the support assembly402. The fluid reservoir408includes a first section410and a second section412extending from the first section410. The first section410of the fluid reservoir408has a triangular cross section conforming to the first and second slant surfaces404,406. Whereas, the second section412has a rectangular cross section. The second section412of the fluid reservoir408stores the fluid therein.

Additionally or optionally, the fluid reservoir408may include baffles (not shown) arranged at intervals within the second section412of the fluid reservoir408. It should be noted that the parameters related to the fluid reservoir408such as size, shape, location, and material used may vary as function system design and requirements. As shown in the accompanying figures, a length of the fluid reservoir408is lesser than the length of the support assembly402. Alternatively, in one embodiment, the length of the fluid reservoir408may be equal to the length of the support assembly402, based on system requirements.

The fluid reservoir408includes a first supply port414and a second supply port416. The first and second supply ports414,416are provided at a bottom surface418of the fluid reservoir408. The first and second supply ports414,416are configured to supply the fluid to the engine cooling circuit and/or the aftertreatment cooling circuit respectively. The first and second supply port414,416is coupled to a first fluid line420and a second fluid line422respectively. The first fluid line420is configured to supply the fluid from the fluid reservoir408to the engine cooling circuit via the line144(seeFIG. 1). Whereas, the second fluid line422is configured to supply the fluid to the aftertreatment cooling circuit via the line146(seeFIG. 1). Further, when the engine102is shut down, the fluid within each of the engine cooling circuit and the aftertreatment cooling circuit drains back into the fluid reservoir408through the first and second supply ports414,416respectively.

The fluid reservoir408includes a fill port424. The fill port424is provided at a side surface426of the fluid reservoir408. When a level of the fluid within the fluid reservoir408decreases, the fluid reservoir408may be refilled with the fluid through the fill port424. The fill port424may be coupled to an external source of fluid supply (not shown) to refill the fluid reservoir408. After the refill of the fluid reservoir408, the fill port424may be sealed using a pressure cap (not shown). Further, a sight glass428is associated with the fluid reservoir408. The sight glass428may allow an operator or maintenance personnel to view the level of the fluid present within the fluid reservoir408. The sight glass428may be mounted on the side surface426of the fluid reservoir408.

As shown inFIGS. 4 and 5, the modular assembly400includes vent lines430. The vent lines430are provided in fluid communication with the fluid reservoir408to vent the fluid reservoir408of any air trapped therein. Further, the hood structure110also includes vent lines124(seeFIGS. 2 and 3). The vent lines124provide fluid communication between the heat exchanger108and the fluid reservoir408. More particularly, the vent lines124are configured to vent air or water from the heat exchangers108into the vent lines430of the modular assembly400.

INDUSTRIAL APPLICABILITY

The present disclosure describes the modular assembly400for the heat exchanger assembly106. The modular assembly400integrates the fluid reservoir408associated with the cooling system104of the engine system100with the support assembly402. The fluid reservoir408disclosed herein has a flexible design and can accommodate more volume of the fluid therein by adjusting a width, a depth, or a length of the fluid reservoir408.

The design of the modular assembly400disclosed herein enables pre-production quality testing of the modular assembly400before the modular assembly400is incorporated into the hood structure110. Also, the modular assembly400has a compact design and saves compartment space by packaging the fluid reservoir408volume tightly into the hood structure110. Further, the modular assembly400has a lightweight structure, thereby reducing the overall engine system weight.