Patent Publication Number: US-2018030882-A1

Title: Coupling mechanism

Description:
TECHNICAL FIELD 
     The present disclosure relates to a coupling mechanism, and more particularly to the coupling mechanism for a tie bar and a side sheet of an aftercooler. 
     BACKGROUND 
     Aftercoolers associated with an engine generally include a pair of tie bars. The tie bars are provided between a pair of side sheets of the aftercooler positioned at a top portion and a bottom portion of the aftercooler. The tie bars reduce bowing of the side sheets of the aftercooler due to internal air pressure. 
     Current aftercooler design utilizes a bolted joint between the side sheet and the tie bar. A sealant is provided in association with the bolted joint between the side sheet and the tie bar in order to prevent gas leakages through bolt threads. In addition to the sealant, a thread locking material is provided around the bolt for retaining clamp load during thermal cycle events. However, this design may be difficult to manufacture consistently and may also lead to increase in manufacturing time and associated costs. Further, the design may not provide a leak proof joint between the tie bar and the side sheet. 
     U.S. Patent Publication Number 2008/149312 describes a vehicle air conditioning system has a condenser with a header tank attached to it. A modulator attaches to the header tank using a full-length dove tail joint that is further secured and sealed to the header tank by a brazing process. A modulator inlet receives gaseous refrigerant from the condenser and discharges liquid refrigerant to a bottom, sub cooler portion of the condenser. The modulator inlet and outlet pass through the dove tail joint of the modulator and header tank. 
     SUMMARY OF THE DISCLOSURE 
     In one aspect of the present disclosure, a coupling mechanism for a tie bar and a side sheet of an aftercooler is provided. The coupling mechanism includes a male portion of a mechanical joint. The male portion is coupled with a tail end of the tie bar. The coupling mechanism also includes a female portion of the mechanical joint defined within the side sheet. The male portion is adapted to mate with the female portion for coupling the tie bar with the side sheet. 
     In another aspect of the present disclosure, an aftercooler is associated with an engine. The aftercooler includes a tie bar having a tail end. The aftercooler also includes a side sheet. The aftercooler further includes a coupling mechanism adapted to couple the tie bar with the side sheet. The coupling mechanism includes a male portion of a mechanical joint. The male portion is coupled with a tail end of the tie bar. The coupling mechanism also includes a female portion of the mechanical joint defined within the side sheet. The male portion is adapted to mate with the female portion for coupling the tie bar with the side sheet. 
     In yet another aspect of the present disclosure, an engine system is provided. The engine system includes an engine. The engine system also includes an aftercooler associated with the engine. The aftercooler includes a tie bar having a tail end. The aftercooler also includes a side sheet. The aftercooler further includes a coupling mechanism adapted to couple the tie bar with the side sheet. The coupling mechanism includes a male portion of a mechanical joint. The male portion is coupled with a tail end of the tie bar. The coupling mechanism also includes a female portion of the mechanical joint defined within the side sheet. The male portion is adapted to mate with the female portion for coupling the tie bar with the side sheet. 
     Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an exemplary engine system having an engine, according to one embodiment of the present disclosure; 
         FIG. 2  is a perspective view of an aftercooler associated with the engine of  FIG. 1 ; 
         FIG. 3  is perspective view of a portion of the aftercooler of  FIG. 2  showing a coupling mechanism for coupling a tie bar and a side sheet of the aftercooler, according to one embodiment of the present disclosure; 
         FIG. 4  is a top view of the coupling mechanism showing the tie bar and the male portion of the coupling mechanism formed as separate components, according to another embodiment of the present disclosure; 
         FIG. 5  is a top view of the coupling mechanism showing the coupling mechanism having a mechanical fastener, according to yet another embodiment of the present disclosure; and 
         FIG. 6  is a top view of the coupling mechanism showing the male portion of the coupling mechanism having a circular configuration, according to one embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts. Also, corresponding or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts. 
       FIG. 1  illustrates a perspective view of an engine system  100 . The engine system  100  includes an engine  102 . The engine  102  may be an internal combustion engine, such as a reciprocating piston engine. Further, the engine  102  may be a spark ignition engine or a compression ignition engine, such as a diesel engine, a natural gas engine, a homogeneous charge compression ignition engine, a reactivity controlled compression ignition engine, or any other engine known in the art. The engine  102  may be fueled by one or a combination of gasoline, diesel fuel, biodiesel, dimethyl ether, alcohol, natural gas, propane, or any other combustion fuel known in the art. 
     The engine  102  is a V-type engine. The engine  102  includes eight cylinders (not shown). Alternatively, the engine  102  may embody an inline engine, without limiting the scope of the present disclosure. It should be noted that a number of cylinders associated with the engine  102  may vary based on the type of engine application. A combustion chamber (not shown) is formed within each cylinder of the engine  102 . The combustion chamber may receive intake air from an intake manifold (not shown). Further, products of combustion created during combustion within the combustion chamber are let out of the engine  102 , via an exhaust manifold (not shown). 
     The engine  102  may be used to power a machine including, but not limited to, an on-highway truck, an off-highway truck, an earth moving machine, and an electric generator. Further, the engine system  100  may be associated with an industry including, but not limited to, transportation, construction, agriculture, forestry, power generation, and material handling. 
     The engine  102  includes a turbocharger  104  that increases an efficiency and power output of the engine  102  by forcing extra air into the combustion chamber of the engine  102 . The turbocharger  104  is driven by a turbine which is in turn driven by engine exhaust gases. The turbocharger  104  receives uncompressed atmospheric air via an air filter (not shown) of the engine system  100 . The turbocharger  104  compresses the air to high pressure intake air. Further, the turbocharger  104  delivers the compressed intake air to an aftercooler  106  associated with the engine  102 . 
     The aftercooler  106  of the engine system  100  is positioned between the turbocharger  104  and the engine  102 , with respect to a flow direction of the intake air. The aftercooler  106  is a heat exchanger that reduces heat acquired by the intake air during its compression, and thus increase a quantity of useful oxygen in a given volume of air. Cooled intake air from the aftercooler  106  is introduced in the intake manifold of the engine  102 . In the illustrated embodiment, the aftercooler  106  is embodied as an air-to-liquid aftercooler. More particularly, the aftercooler  106  is a water-cooled aftercooler. As shown, the aftercooler  106  is mounted on top of the engine  102 . However, a position of the aftercooler  106  may change, based on system requirements. 
     The engine system  100  includes an exhaust system (not shown). The exhaust system treats exhaust gases exiting from the exhaust manifold of the engine  102 . The exhaust system may trap or convert Nitrogen Oxides (NOx), Unburned Hydrocarbons (UHC), particulate matter, or its combinations, or other combustion products in the exhaust gases before exiting the engine system  100 . 
     Referring now to  FIG. 2 , a perspective view of the aftercooler  106  is shown. The aftercooler  106  includes a number of cooling tubes  108 . In operation, cooling water flows through the cooling tubes  108 , whereas, intake air flows over the cooling tubes  108 . The cooling water exchanges heat with the intake air flowing over the cooling tubes  108 , thereby lowering a temperature of the intake air. 
     The aftercooler  106  includes a first water tank  110  and a second water tank  112 . The first water tank  110  introduces cooling water into the cooling tubes  108 . The first water tank  110  includes openings  114  that allow fluid communication between the first water tank  110  and an engine cooling system (not shown). The first water tank  110  receives the cooling water from the engine cooling system. 
     Further, the second water tank  112  of the aftercooler  106  also includes openings (not shown). The openings allow the cooling water to exit the aftercooler  106 . The openings of the second water tank  112  may be in fluid communication with the engine cooling system. The cooling water exiting the aftercooler  106  flows towards the engine cooling system for removing heat therefrom. 
     The aftercooler  106  also includes a first side sheet  118  and a second side sheet  120 . The first side sheet  118 , the second side sheet  120 , the first water tank  110 , and the second water tank  112  enclose the cooling tubes  108 . The first and second side sheets  118 ,  120  allow mounting of the aftercooler  106  to a housing of the engine  102 . The first and second side sheets  118 ,  120  resist internal air pressure/deflection experienced by the aftercooler  106 . The first and second side sheets  118 ,  120  are rectangular in shape. Further, a length of the first and second side sheets  118 ,  120  is approximately equal to a length of the cooling tubes  108 . 
     The aftercooler  106  includes a first tie bar  122  and a second tie bar (not shown). It should be noted that the aftercooler  106  may include more than two tie bars, without any limitations. A total number of the tie bars associated with the aftercooler  106  may vary based on the length of the cooling tubes  108  or a size of the aftercooler  106 . The first tie bar  122  and the second tie bar reduces bowing of the side sheets  118 ,  120  due to internal air pressure. As shown in the accompanying figures, the first tie bar  122  is provided at a top portion  126  of the aftercooler  106 . The second tie bar may be provided at a bottom portion  128  of the aftercooler  106 . Each of the first tie bar  122  and the second tie bar extend between the first and second side sheets  118 ,  120  at the top and bottom portions  126 ,  128  of the aftercooler  106  respectively. A length “L” of each of the first tie bar  122  and the second tie bar is equal to a distance between the first and second side sheets  118 ,  120 . 
     A design of the tie bar will now be explained in detail with reference to the first tie bar  122 . However, it should be noted that the details of the first tie bar  122  disclosed herein are equally applicable to the second tie bar, or any other tie bar associated with the aftercooler  106 , without any limitations. The first tie bar  122  includes a first tail end  130  and a second tail end  132 . The first tail end  130  of the first tie bar  122  couples with the first side sheet  118 . Whereas, the second tail end  132  of the first tie bar  122  couples with the second side sheet  120 . Further, the first tie bar  122  includes a bar member  134  extending between the first and second tail ends  130 ,  132 . The bar member  134  has a rectangular cross-section. 
     Each of the first tie bar  122  and the second tie bar are coupled to the first and second side sheets  118 ,  120  using a coupling mechanism  300  (see  FIG. 3 ). Referring to  FIG. 3 , the coupling mechanism  300  for coupling the first tail end  130  of the first tie bar  122  with the first side sheet  118  will now be described in detail. It should be noted that the coupling mechanism  300  can also be used to couple the second tail end  132  of the first tie bar  122  with the second side sheet  120 , a first tail end of the second tie bar with the first side sheet  118 , and a second tail end of the second tie bar with the second side sheet  120 , without any limitations. 
     As shown in the accompanying figures, the coupling mechanism  300  includes a mechanical joint  302 . In one example, the mechanical joint  302  is a dovetail joint, and more particularly, a half-blind dovetail joint. Alternatively, the mechanical joint  302  may be embodied as any other type of mechanical joint that creates tortious path for the air and allows coupling of the first tail end  130  with the first side sheet  118 , without limiting the scope of the present disclosure. 
     The mechanical joint  302  includes a male portion  304  and a female portion  306 . The male portion  304  of the mechanical joint  302  is coupled with the first tail end  130  of the first tie bar  122  and projects therefrom. The male portion  304  includes a projecting portion  308 . In the illustrated embodiment, the male portion  304  of the mechanical joint  302  has a trapezoidal shape extending from the first tail end  130  of the first tie bar  122 . Further, the male portion  304  of the mechanical joint  302  and the first tie bar  122  are formed as a unitary component. The male portion  304  and the first tie bar  122  may be formed by molding, casting, or any other forming process known in the art. 
     Further, the mechanical joint  302  includes the female portion  306 . The female portion  306  is defined within the first side sheet  118 . During the coupling of the first tie bar  122  and the first side sheet  118 , the male portion  304  of the mechanical joint  302  mates with the female portion  306 . In one example, the female portion  306  is a socket  310  that is formed within the first side sheet  118 . The socket  310  corresponds to the projecting portion  308  of the male portion  304  in terms of shape and size, such that the male and female portions  304 ,  306  of the mechanical joint  302  mate within the first side sheet  118  to couple the first tail end  130  with the first side sheet  118 . In the illustrated example, the socket  310  is trapezoidal in shape. Further, a height (not shown) and a depth “d 1 ” of the socket  310  may be approximately equal to a height “h” and a depth “d 2 ” of the projecting portion  308 . 
       FIG. 4  illustrates another embodiment of the coupling mechanism  400 . In this embodiment, the male portion  404  of the mechanical joint  402  and the first tail end  130  are formed as separate units that are coupled using a mechanical joining technique known in the art. As shown in the accompanying figures, a pair of mechanical fasteners  412  may be used to couple the male portion  404  with the first tail end  130 . Alternatively, a single mechanical fastener may also be used to couple the male portion  404  with the first tail end  130 . The mechanical fasteners  412  may include, but is not limited to, a bolt, a screw, a rivet, and a pin. In another example, the male portion  404  may be welded to the first tail end  130  at an outer periphery  414  of the first tail end  130 . Further, any joining process such as brazing or soldering may also be used to couple the male portion  404  with the first tail end  130 . It should be noted that other design details of the coupling mechanism  400  are similar that of the coupling mechanism  300  described in connection with  FIG. 3 . 
       FIG. 5  illustrates yet another embodiment of the present disclosure. In this embodiment, the coupling mechanism  500  includes a mechanical fastener  516 . The mechanical fastener  516  attaches the male portion  504  of the mechanical joint  502  within the socket  510  of the female portion  506 . More particularly, the mechanical fastener  516  ensures further locking of the male portion  504  with the female portion  506  so that the male and female portions  504 ,  506  may not decouple easily during aftercooler operation. 
     The mechanical fastener  516  extends perpendicular to the length “L” of the first tie bar  122 . The male portion  504  of the mechanical joint  502  includes a through hole  518  that extends perpendicular to the length “L” of the first tie bar  122 . The through hole  518  of the first tie bar  122  is in communication with the socket  510  of the female portion  506 . Further, the first side sheet  118  includes a blind hole (not shown) that extends perpendicular to the length “L” of the first tie bar  122 . The blind hole is in communication with the socket  510 . The through hole  518  and the blind hole are aligned with each other to receive the mechanical fastener  516  for attaching the male portion  504  within the socket  510  of the female portion  506 , thereby coupling the first tail end  130  of the first tie bar  122  and the first side sheet  118 . 
     The mechanical fastener  516  may include any one of a bolt, a screw, a rivet, a dowel pin, and the like. The mechanical fastener  516  may have a screw connection or may be press fitted for attaching the male portion  504  within the socket  510  of the female portion  506 . In this embodiment, the male portion  504  and the first tail end  130  are manufactured as a unitary component. Alternatively, the male portion  504  and the first tie bar  122  may be formed as separate components that can be coupled using any joining processes known in the art. It should be noted that other design details of the coupling mechanism  500  are similar to that of the coupling mechanism  300  described in connection with  FIG. 3 . 
     Referring now to  FIG. 6 , another design of the coupling mechanism  600  is illustrated. In this design, the male portion  604  of the mechanical joint  602  includes the projecting portion  608  having a circular shape extending from the first tail end  130  of the first tie bar  122 . The male portion  604  and the first tie bar  122  are formed as a unitary component. Alternatively, the male portion  604  and the first tie bar  122  may be formed as separate components that are coupled using any known joining technique known in the art. In the illustrated embodiment, the socket  610  formed within the first side sheet  118  has a circular cross-section, such that the male and female portions  604 ,  606  of the mechanical joint  602  are adapted to mate within the first side sheet  118  to couple the first tie bar  122  with the first side sheet  118 . 
     It should be noted that the projecting portion  608  may include any other shape that allows mating of the male and female portions  604 ,  606  of the mechanical joint  602 , without limiting the scope of the present disclosure. The coupling mechanism  600  also include the mechanical fastener  616  similar to the mechanical fastener  516  described in connection with  FIG. 6  to ensure further interlocking of the male and female portions  604 ,  606 . It should be noted that other design details of the coupling mechanism  600  are similar to that described in connection with the coupling mechanism  300  of  FIG. 3 . 
     INDUSTRIAL APPLICABILITY 
     The present disclosure relates to the coupling mechanism for attaching each of the first tie bar  122  and the second tie bar of the aftercooler  106  with the first and second side sheets  118 ,  120 . For explanatory purposes, this section will now be explained in reference to the coupling mechanism  300  that is used to couple the first tail end  130  of the first tie bar  122  with the first side sheet  118 . The coupling mechanism  300  eliminates usage of bolts that are driven through the first side sheet  118  and the first tail end  130  to attach the first side sheet  118  with the first tie bar  122 . Instead, the coupling mechanism  300  includes the male portion  304  that sealingly engages and interlocks with the female portion  306  in order to couple the first tie bar  122  with the first side sheet  118 . Thus, the coupling mechanism  300  eliminates a leak path that exists through bolt threads towards the outside environment. 
     Further, the coupling mechanism  300  eliminates requirements of sealants or any additional thread locking material, thereby reducing overall manufacturing cost of the aftercooler  106  and also reducing assembly time of the aftercooler  106 . The coupling mechanism  300  includes fewer components that are easy to manufacture and also provides an easy coupling method. Also, the coupling mechanism  300  eliminates the requirement of skilled labor for coupling the first tie bar  122  with the first side sheet  118 . It should be noted that the description provided herein is equally applicable to the other coupling mechanisms  400 ,  500 ,  600  that are illustrated in  FIGS. 4, 5, and 6  respectively, without limiting the scope of the present disclosure. 
     While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.