Frameless cooling module

A frameless cooling module includes a first and a second shroud panel arranged at opposing sides of the module and extending from the front of the module to the back of the module. At least one L-shaped stiffener bracket extends between the panels at an intermediate location along both the height direction and the depth direction of the module. One or more heat exchangers is arranged within the cooling module between the L-shaped stiffener bracket and the front of the module, and is at least partially secured within the cooling module by being mounted to the L-shaped stiffener bracket.

BACKGROUND

Cooling modules for internal combustion engines contain one or more heat exchangers and an air mover such as a fan, and are commonly used to reject heat from fluids and/or gases for the internal combustion engine to a flow of ambient air directed through the cooling module by the air mover. As the size and power of the internal combustion associated with the cooling module increases, the size and complexity of the cooling module likewise increases. In some cases, such as with combustion engines for power generation (sometimes referred to as gen-sets), the structure required to adequately support the heat exchangers, air mover, and other associated equipment can become complex and expensive.

FIG. 1depicts a known example of such a cooling module101for a gen-set. The cooling module101includes several heat exchangers30,31(for example, radiators, oil coolers, charge-air coolers) from which heat is to be rejected arranged at a front end of the cooling module. A fan (not shown) is arranged at the back end of the cooling module to direct a flow of cooling air through the heat exchangers.

The heat exchangers30,31are mounted into a frame150of the cooling module (as best seen inFIG. 2) in order to provide the requisite structural support for the heat exchangers. The frame150also serves as a support for shroud panels102that extend between the back of the cooling module101and the frame150. The shroud panels102serve to duct the air flow from the heat exchangers to the air mover, to ensure that the air is, to the greatest extent possible, drawn through the heat exchangers, thereby maximizing the cooling effect.

The frame150, while capable of providing adequate structural support, is a complex structure that requires many parts to be assembled in a time-intensive and costly manner.FIG. 3illustrates a detail of the frame150, with the heat exchanges removed for clarity, to illustrate this point. The frame150is constructed of multiple formed steel U-channels that are joined together with mechanical fasteners in order to form channels within which the heat exchangers can be placed and secured. In order to provide the frame150with the requisite stiffness, and to prevent angular deformation of the frame150, multiple steel gussets152are needed at the joints between the U-channels151. Each of these gussets152must also be secured to the U-channels151by multiple fasteners, thereby increasing the cost and the assembly time even more.

In order to secure the heat exchangers30,31within the frame150, the U-channels151have to be assembled around the heat exchangers, as there is no way to locate the heat exchangers within the channels once the frame150is assembled. This makes servicing and replacement of the heat exchangers within the cooling module101difficult, since the frame150needs to be at least partially disassembled in order to replace and service any one of the heat exchangers.

SUMMARY

According to an embodiment of the invention, a frameless cooling module is constructed using a first and a second shroud panel arranged at opposing side of the cooling module. The first and second shroud panels each extend entirely from a front of the cooling module to the back of the cooling module in the front-to-back direction of the cooling module. The first and second shroud panels also extend entirely from the top of the cooling module to the bottom of the cooling module in the top-to-bottom direction of the cooling module. The front-to-back direction thereby defines a first direction of the cooling module and the top-to-bottom direction thereby defines a second direction of the cooling module, with the first and second directions being perpendicular to one another. A third direction of the cooling module perpendicular to both the first and the second directions extends perpendicular to the planes of both the first and the second shroud panels, such that the cooling module is bounded in the third direction by the opposing first and second shroud panels.

An L-shaped stiffener bracket extends between the first and second shroud panels in that third direction. In some embodiments the frameless cooling module includes only a single L-shaped stiffener bracket, whereas in other embodiments the cooling module includes two or more such L-shaped stiffener brackets. The L-shaped stiffener bracket is located, along the first direction, at an intermediate location between the front of the module and the back of the module. In other words, the location of the L-shaped stiffener bracket is offset from both the front of the cooling module and from the back of the cooling module in the first direction. The L-shaped stiffener bracket is also located, along the second direction, at an intermediate location between the top of the cooling module and the bottom of the cooling module. In other words, the L-shaped stiffener bracket is offset from both the top of the cooling module and from the bottom of the cooling module in the second direction.

The L-shaped stiffener bracket includes a first planar wall, a second planar wall, and a right angle bend joining the first and second planar walls. The first planar wall is arranged to be parallel to the front and the back of the cooling module, while the second planar wall is arranged to be parallel to the top and the bottom of the cooling module. The L-shaped bracket can, for example, be formed by bending a flat sheet of metal ninety degrees to form the right angle bend.

The L-shaped stiffener bracket is joined to the first shroud panel by a first formed corner bracket and is joined to the second shroud panel by a second formed corner bracket. Each one of the first and second formed corner brackets is provided with a planar surface, and each one of the formed corner brackets is joined to the corresponding shroud panel by way of the planar surface. The formed corner brackets are additionally provided with formed flanges that extend perpendicularly from the planar surface. A first one of the formed flanges of each of the first and second formed corner brackets is used to join the formed corner bracket to the first planar wall of the L-shaped stiffener bracket. A second one of the formed flanges of each of the first and second formed corner brackets is used to join the formed corner bracket to the second planar wall of the L-shaped stiffener bracket.

In at least some embodiments, the planar surface of the formed corner brackets is in the shape of a right triangle. In other embodiments, the planar surface is in the shape of a square, a rectangle, a rhomboid, or some other shape.

In at least some embodiments, the formed corner brackets are joined to the corresponding shroud panels by mechanical fasteners such as screws, bolts, rivets, or the like. The planar surface of the formed corner bracket is disposed against a surface of the shroud panel, and apertures extending through the planar surface of the formed corner bracket to receive the fasteners are aligned with corresponding apertures of the shroud panel so that the mechanical fasteners can be inserted through the aligned apertures in order to mechanically fasten the formed corner bracket to the shroud panel.

In at least some embodiments, the formed corner brackets are joined to the L-shaped stiffener bracket by mechanical fasteners such as screws, bolts, rivets, or the like. The first and second formed flanges of the formed corner bracket are disposed against the first and second walls, respectively, of the L-shaped stiffener bracket, and apertures extending through the formed flanges of the formed corner bracket to receive the fasteners are aligned with corresponding apertures of the L-shaped stiffener bracket so that the mechanical fasteners can be inserted through the aligned apertures in order to mechanically fasten the formed corner bracket to the stiffener bracket.

Heat exchangers are arranged within the cooling module between the first planar wall of the L-shaped stiffener bracket and the front of the cooling module in the first direction. In at least some embodiments, the intermediate location of the L-shaped stiffener bracket along the first direction is selected such that the distance between the front of the cooling module and the first wall of the L-shaped stiffener bracket is approximately equal to the depth of the heat exchangers. One or more of the heat exchangers are arranged to be between the second planar wall of the L-shaped stiffener bracket and either the top or the bottom of the cooling module in the second direction. In at least some embodiments, the intermediate location of the L-shaped stiffener bracket along the second direction is selected such that the distance between the top or the bottom of the cooling module and the second wall of the L-shaped stiffener bracket is approximately equal to the height of one or more of the heat exchangers.

At least some of the heat exchangers arranged within the module can be structurally mounted to the first planar wall of the L-shaped stiffener bracket in order to at least partially secure those heat exchangers within the cooling module.

In some embodiments, the L-shaped stiffener bracket is one of several (i.e. two or more) L-shaped stiffener brackets. Another one of the L-shaped stiffener brackets also extends between the first and second shroud panels at an intermediate location between the front of the cooling module and the back of the cooling module in the first direction, and at an intermediate location between the top of the cooling module and the bottom of the cooling module in the second direction. That L-shaped stiffener bracket is joined to the shroud panels by additional ones of the formed corner brackets. One or more heat exchangers are arranged within the cooling module between the first planar wall of that L-shaped stiffener bracket and the front of the cooling module, and are structurally mounted to the first planar wall of that L-shaped stiffener bracket to at least partially secure those heat exchanger within the cooling module.

In at least some such embodiments, the first planar wall of one of the L-shaped stiffener brackets is aligned in a common plane with the first planar wall of another of the L-shaped stiffener brackets.

In at least some such embodiments, the first planar wall of one of the L-shaped stiffener brackets extends from the second planar wall of that L-shaped stiffener bracket towards the top of the cooling module, and the first planar wall of another of the first and second L-shaped stiffener brackets extends from the second planar wall of that L-shaped stiffener bracket towards the bottom of the cooling module.

In at least some such embodiments, the second planar wall of one of the L-shaped stiffener brackets abuts against, and is joined to, the second planar wall of another of the L-shaped stiffener brackets. In some such embodiments the two L-shaped stiffener brackets are joined together at least in part by one or more fasteners that extend through aligned apertures in the second planar walls of the L-shaped stiffener brackets and in formed flanges of the formed corner brackets that join those L-shaped stiffener brackets to the shroud panels.

In some embodiments, the cooling module includes a top panel arranged at the top end of the cooling module, and a bottom panel arranged at the bottom end of the cooling module. The top and bottom panels each extend between, and are joined to, the first and second shroud panels. At least one of the top and bottom panels extends from the back of the cooling module to an intermediate location between the front of the cooling module and the back of the cooling module in the first direction.

In at least some such embodiments, that one of the top and bottom panels includes a flange aligned in a common plane with the first planar wall of the L-shaped stiffener bracket. The heat exchanger or heat exchangers that are structurally mounted to that first planar wall are also structurally mounted to the flange of the top or bottom panel in order to at least partially secure the heat exchanger or heat exchangers within the cooling module.

In at least some such embodiments, both of the top and the bottom panels include a flange, with the flange of one of the panels aligned in a common plane with the first planar wall of one of the L-shaped stiffener brackets and the flange of the other one of the panels aligned in a common plane with the first planar wall of another one of the L-shaped stiffener brackets. In at least some embodiments, those flanges and planar walls are all aligned within one common plane. At least some heat exchangers are structurally mounted to the first planar wall of one of the L-shaped stiffener brackets and the flange of the top panel in order to secure those heat exchangers within the cooling module, and at least some of the heat exchangers are structurally mounted to the first planar wall of the other one of the L-shaped stiffener brackets and the flange of the bottom panel in order to secure those heat exchanger within the cooling module.

DETAILED DESCRIPTION

A cooling module1according to an embodiment of the invention is depicted inFIGS. 4 and 5. The cooling module1is particularly well-suited for use in a stationary power generation system, such as a diesel generator (or “gen-set”) system. Such a system will typically have one or more fluids from which heat needs to be rejected, such as, for example, engine coolant and lubricating oil. Heat exchangers to accomplish the required heat rejection are arranged within the cooling module1, which can be located in generally close proximity to the diesel engine of the gen-set and which can be fluidly connected thereto by hoses and other fluid conduits. It should be understood, however, that the cooling module1is not restricted to being used in conjunction with such a system, and could similarly find use in other systems where heat rejection from fluids is desirable.

The exemplary cooling module1includes a set of heat exchangers30arranged at a front end20of the cooling module, along with another set of heat exchangers31also arranged at the front end20. In some cases, the heat exchangers30can cool one type of fluid (for example, engine coolant) while the heat exchangers31cool another type of fluid (for example, lubricating oil). In other cases the cooling module might contain only heat exchangers for a single fluid. In certain cases a fluid is cooled in multiple heat exchangers, such as when the size of a single heat exchanger for cooling the fluid makes it more desirable—for reasons of cost, manufacturability, or other reasons—to divide the total heat transfer duty amongst multiple heat exchangers arranged in parallel. In other cases it might be desirable to have multiple heat exchangers arranged in parallel because the heat sources are similarly distributed. By way of example, a single cooling module1can be used to simultaneously cool the fluids for multiple diesel engines, each of which has one or more dedicated heat exchangers within the cooling module.

A fan (not shown) can be arranged at a back end21of the cooling module opposite the front end20. The fan can be mounted to a back panel16of the cooling module1, which is provided with a circular aperture17that generally conforms to the swept area of the fan. In this way, cooling air to which the heat from the fluids traveling through the heat exchangers30,31can be rejected is directed from the front20to the back21in a depth direction24of the cooling module.

In contrast to the cooling module101ofFIGS. 1-3, the cooling module1is a frameless cooling module. As will be described in greater detail hereafter, the heat exchangers are indirectly supported within the cooling module1by a first shroud panel2and a second shroud panel3, each of which extends from the front20of the cooling module1to the back21of the cooling module1in the depth direction24. The shroud panels2,3are arranged at opposing sides of the cooling module1in a width direction so that, when viewing the front20of the cooling module1, the first shroud panel2is arranged at the right hand side and the second shroud panel3is arranged at the left hand side. Each of the shroud panels2,3also extends from a top22of the cooling module1to a bottom23of the cooling module1in a height direction25of the cooling module1.

As best seen inFIG. 6, which shows the cooling module1as it is depicted inFIG. 4but with the heat exchangers30,31removed for clarity, the cooling module1is also provided with at least one L-shaped stiffener bracket4that extends in the width direction between the shroud panel2and the shroud panel3. A portion of the L-shaped stiffener bracket4can be seen inFIG. 7from the same perspective as that ofFIG. 5. The stiffener bracket4is referred to as “L-shaped” on account of it having a first planar wall6, and a second planar wall7arranged perpendicular to the first planar wall6, with the walls6,7joined together by a right angle bend8. The L-shaped stiffener bracket6can be readily formed by bending a flat sheet of metal material to form the right-angle bend8.

The L-shaped stiffener bracket4is arranged within the cooling module in such a way that the planar wall6is perpendicular to the depth direction24, e.g. parallel to the front20and the back21, and the planar wall7is perpendicular to the height direction25, e.g. parallel to the top22and the bottom23. Furthermore, the L-shaped stiffener bracket4is located within the cooling module1such that the planar wall6is at an intermediate location along the depth direction24between the front20and the back21of the cooling module1. In addition, the L-shaped stiffener bracket4is located within the cooling module1such that the planar wall7is at an intermediate location along the height direction25between the top22and the bottom23of the cooling module1.

The L-shaped stiffener bracket4is structurally joined to the shroud panel3by a formed corner bracket9, as depicted inFIG. 7, and is joined to the shroud panel2by another formed bracket9in a similar fashion. The formed corner bracket9—shown in isolation inFIG. 8—includes a planar surface10which, during assembly of the cooling module1, is disposed against the shroud panel to thereby join the formed corner bracket9to the shroud panel. The planar surface10can be in a triangular shape, and particularly in the shape of a right triangle. In alternative embodiments, however, the planar surface10can be in some other shape such as, for example, a square or a rectangle. Formed flanges11extend perpendicularly from two adjacent edges of the planar surface10. The formed flanges11are perpendicular to one another, and the formed corner bracket9is joined to the first planar wall6of the L-shaped stiffener bracket4by a first one of the formed flanges11, and to the second planar wall7of the L-shaped stiffener bracket by a second one of the formed flanges11. In this manner, the L-shaped stiffener bracket4is joined to the first shroud panel2by a first one of the formed corner brackets9, and is joined to the second shroud panel3by a second one of the formed corner brackets9.

In the exemplary embodiment, the structural connections between the formed corner bracket9and both the L-shaped stiffener bracket4and the shroud panels are achieved by way of fasteners12that extend through aligned apertures in the components to be joined. The fasteners12can take the form of threaded bolt and nut fasteners, as shown in the exemplary embodiment, or can take other known forms of mechanical fastening such as, for example, thread-cutting screws, rivets, threaded studs, threaded inserts, self-clinching fasteners, captive fasteners, and the like. In still other embodiments the parts can be joined without the use of fasteners, such as by welding.

A second L-shaped stiffener bracket5is also provided in the exemplary embodiment, and is joined to the shroud panels2,3by formed corner brackets9in a similar fashion to the first L-shaped stiffener bracket4. As best seen inFIG. 9, the L-shaped stiffener bracket5can be arranged so that the second planar walls7of the brackets4and5are disposed against one another with the first planar walls6extending in opposite directions, i.e. with the first planar wall6of the first L-shaped stiffener bracket4extending towards the top22of the cooling module1and with the first planar wall6of the second L-shaped stiffener bracket5extending towards the bottom23of the cooling module1. The first planar walls6can be, but need not be, aligned in a common plane. It should be observed that the second L-shaped stiffener bracket5, while advantageous in certain embodiments of the invention, is optional and need not be present in all embodiments of the invention.

As best shown inFIG. 7andFIG. 9, one or more fasteners12can extend through both of the abutting planar walls7of the first and second L-shaped stiffener brackets4,5in order to join the brackets together at one or more locations along the width of the cooling module1. Such a joining of the brackets4,5can further increase the structural rigidity of the brackets and the cooling module1. In addition, at least some of the fasteners12that are used to connect a flange11of a formed corner bracket9to the planar wall7of the first L-shaped stiffener bracket4can additionally extend through the planar wall of the second L-shaped stiffener bracket5and through a flange11of the formed corner bracket9used to join that second L-shaped stiffener bracket5to a shroud panel, thereby reducing the total number of fasteners that would otherwise be needed to join the L-shaped stiffener brackets to the shroud panels as well as enhancing the structural rigidity of the cooling module1.

It should be observed that the heights of the first planar walls6of the first and second L-shaped stiffener brackets need not be the same. As best seen inFIG. 9, the height of the planar wall6of the L-shaped stiffener bracket5is less than the height of the planar wall6of the L-shaped stiffener bracket4. Consequently, the dimensions of the formed corner brackets9used for each of the two L-shaped stiffener brackets also need not be uniform, as is the case in the exemplary embodiment.

The L-shaped stiffener brackets4,5are used to at least partially support and secure the heat exchangers30,31within the cooling module1. The heat exchangers30,31are preferably of a style wherein the fluid to be cooled is directed through flow channels between an inlet tank and an outlet tank in a direction generally corresponding to the height direction25of the cooling module, with air being directed over the outer surfaces of the flow channels in a direction generally corresponding to the depth direction24of the cooling module. Such heat exchangers can be, for example, of a tube and fin or a bar-plate construction, as is known in the art. The tanks of the heat exchangers are preferably equipped with mounting features that align with mounting locations19provided on the planar walls6of the brackets4,5so that the heat exchangers can be affixed thereto, e.g. by mechanical fasteners.

The cooling module1is further provided with a top shroud panel13and with a bottom shroud panel14. As can be seen inFIG. 6, the top shroud panel13can be securely attached to the shroud panels2,3by way of additional formed corner brackets9. Although not visible, the bottom shroud panel14can be attached to the shroud panels2,3in a similar fashion. The top shroud panel13preferably extends from the back end21of the cooling module to the location of the planar wall6of the first L-shaped stiffener bracket4, and preferably terminates at that location with a formed flange15that is generally aligned in a common plane with that planar wall6. Similarly, the bottom shroud panel14preferably extends from the back end21of the cooling module to the location of the planar wall6of the second L-shaped stiffener bracket5, and preferably terminates at that location with a similar formed flange that is generally aligned in a common plane with that planar wall6. These formed flanges can additionally be provided with mounting locations for the heat exchangers similar to those provided in the formed flanges6. The heat exchangers30can thereby be secured within the cooling module by way of the first L-shaped stiffener bracket4and the top shroud panel13, while the heat exchangers31can thereby be secured within the cooling module by way of the second L-shaped stiffener bracket5and the bottom shroud panel14.

As at least one benefit of the described cooling module construction over that of the prior art cooling module101, the heat exchangers30,31can be readily removed from the cooling module1for service, cleaning, repair, replacement, and the like. After removal of the fasteners used to retain the heat exchangers to the L-shaped stiffener brackets4,5and the top and bottom shroud panels13,14, the heat exchangers can be easily removed from the front end20of the cooling module1. In contrast, the heat exchangers as depicted inFIG. 2are retained within the frame150, requiring substantial disassembly of the cooling module101in order to remove the heat exchangers.

It should be understood that, while the exemplary embodiment shown in the figures and described above includes a second L-shaped stiffener bracket5, such a second L-shaped stiffener bracket is optional and need not be included. In certain embodiments it may be preferable for the flange6of the L-shaped stiffener bracket4to be of a suitable length for the mounting of both the heat exchangers30and the heat exchangers31, thereby avoiding the expense of the second bracket5.

The cooling module1can additionally be provided with one or more front brackets26that are joined to the shroud panels2,3and extend therebetween at the front20of the cooling module1. In the exemplary embodiment ofFIG. 4, two such front brackets26are depicted—one at the location (along the height direction25) of the L-shaped stiffener brackets4,5, and the other at the bottom end23of the cooling module1. Although not shown, yet another such a front bracket can be provided at the top end22of the cooling module1. The front brackets can provide additional structural rigidity to the cooling module1, and can additionally block the undesirable bypassing of air around the cores of the heat exchangers. The front brackets26can be readily removed as needed to allow for the removal, repair, or replacement of the heat exchangers.

Various alternatives to the certain features and elements of the present invention are described with reference to specific embodiments of the present invention. With the exception of features, elements, and manners of operation that are mutually exclusive of or are inconsistent with each embodiment described above, it should be noted that the alternative features, elements, and manners of operation described with reference to one particular embodiment are applicable to the other embodiments.