Intercoolers and water tanks have different functions. The intercooler is used to reduce the intake temperature of the engine, which can reduce the heat load of the engine and increase the intake volume. The water tank is the engine cooling device used to dissipate unnecessary (water-cooled) engine heat.
An automotive intercooler is an intake cooling device for a supercharged engine. Generally, only the car with a supercharger is installed, and the intercooler can only be seen on the car with a supercharger. The role of the intercooler is to reduce the intake temperature of the engine, which can not only ease the heat load of the engine, but also increase the intake volume, which is of great help to the power of the engine. Because the intercooler is actually a matching part of the turbo, its role is to reduce the temperature of the high-temperature air body after the turbo, thereby reducing the thermal load of the engine, increasing the intake air, and thereby increasing the power of the engine. For the supercharged engine, the intercooler is an important part of the supercharging system. Both supercharged and turbocharged engines require an intercooler to be installed between the supercharger and the intake manifold.
The water tank, also known as the radiator, is the main component of the car cooling system, which is used to dissipate excess and useless heat from the engine. When the system detects that the engine water temperature is too high, the pump repeatedly cycles to reduce the engine temperature, thereby effectively protecting the engine. Then, when the water temperature is detected to be too low, the water cycle is immediately stopped to avoid the engine temperature being too low.
1, the object of cooling is different: the intercooler is to cool the high temperature air after pressurization; The water tank cools the engine. 2, the role is different: the role of the intercooler is to improve the air exchange efficiency of the engine; The function of the water tank is to improve the cooling efficiency of the coolant. The intercooler can only be seen on vehicles that have been installed with superchargers, and it is a supporting part of the turbine increase. Automobile water tank, also known as radiator, is the main machine in the automobile cooling system, its function is to dissipate heat, cooling water absorbs heat in the jacket, and dissipates heat after flowing to the radiator, and then returns to the jacket and circulates.
In addition to the tax benefits, cars with small displacement turbocharged engines are available. It also provides better power performance than a naturally aspirated engine of the same displacement. It has also become the mainstream of the market. But relatively speaking. Turbocharged engines are more complex than naturally aspirated engines due to their peripheral components. Turbines, for example, require separate oil circuits and waterways to provide heat dissipation and lubrication. At the same time, the air after turbocharging also needs to be cooled and then fed into the intake system. Therefore, if there is a lack of effective intake cooling means. Light will affect the power output. Fuel consumption and stability. Heavy damage may result in engine damage.
In order to effectively reduce the temperature of the air entering the engine part to increase the oxygen content. Intake cooling systems were also developed. The working principle is to let the air compressed by the turbine flow to the central cooler (referred to as: intercooler). After the heat exchange, the temperature of the air flowing through the interior is greatly reduced. Thus, the negative impact of high intake temperature on engine power output and stability can be effectively solved.
Why do turbocharged engines need intercoolers?
The main role of intercooler. It lowers the temperature of the air entering the engine. So why lower the intake temperature?
This is because the turbocharger is mainly composed of a turbine chamber and a supercharger. The turbine inlet is connected to the engine exhaust manifold. The exhaust port is connected to the head section of the exhaust pipe. The supercharger inlet on the other side is connected to the air filter line. The outlet is connected to the intake manifold of the engine. The turbine located in the turbine chamber and the impeller located in the supercharger are rigidly connected by a coaxial rotor. And use the exhaust gas from the engine to move the turbine inside the turbine chamber. The turbine drives a coaxial impeller. The impeller compresses the air drawn from the air filter pipe. After pressurization, it is pressed into the cylinder through the intake manifold to burn and do work.
Therefore, the basic structure of the turbocharger can be seen. The biggest problem is the close distance between the intake part of the turbine and the high-temperature exhaust. Plus, the air gets hotter when it's compressed. High temperatures dramatically reduce the amount of oxygen in the air. Engine combustion does the work by combining the fuel with the oxygen in the air. Therefore, the influence of oxygen content in the air on the power is very obvious. There is data to show that. Under the same air-fuel ratio conditions. The temperature of the charged air drops by 10 ℃ every time. The engine power can be increased by 3% to 5%.
The high temperature of the intake will reduce the oxygen content and affect the power output. This is followed by increased fuel consumption. As a result, the engine operating temperature becomes higher. When the external temperature is high and the driving condition is high load for a long time. It's easy to increase the probability of engine failure. Like increasing the probability of detonation. And increase the NOx content in the exhaust gas. Besides. A higher boost value can be used after controlling the intake temperature. Or increase the engine compression ratio. It is also more adaptable to high altitudes and different oils.
What does a common intercooler look like? What are the different structures?
Intercoolers are commonly found in vehicles with turbocharged engines. It is also one of the necessary supporting parts. The function is to reduce the air temperature after pressurization. To reduce engine heat load. Increase intake oxygen content. This increases the power output of the engine. And whether it's a supercharged or a turbocharged engine. A suitable intercooler is required between the supercharger and the intake manifold.
In a nutshell. An intercooler is an efficient heat sink. The main function is to reduce the temperature of the supercharged hot air before entering the engine. Generally speaking. The intercooler is located in front of the cooling water tank. Convenient direct access to the relatively low temperature air outside. At the same time, the vehicle can also use the flow of external air to increase the efficiency of heat dissipation. Intercoolers are usually made of lightweight aluminum alloy materials. It is basically consistent with the material and structure of the automobile cooling water tank. For example, according to the cooling medium. It can be divided into two types: air-cooled and water-cooled. And according to the layout position can be divided into front and top two.
Water cooled intercooler
In terms of cooling medium. Air cooling needs to rely on air flow to dissipate heat. Water cooling means circulating water to dissipate heat. The air-cooled structure is relatively simple. The turbocharged hot air passes through the aluminum alloy air duct in the intercooler. The contact area of the air duct is increased with the help of cooling fins. The cooling effect is then provided by the flow of outside air between the fins. The lower the outside temperature. The higher the speed, the more the cooling effect will be increased. The principle of water-cooled intercooler is the same. But it relies on liquid flow to dissipate heat. Simply put, it is equivalent to a water tank for cooling outside the air-cooled intercooler. Therefore, separate coolant lines need to be arranged. The structure is more complex.
What are the advantages and disadvantages of air cooling and water cooling? Although the air-cooled intercooler structure is simpler. It costs less. But it is more sensitive to the flow rate and temperature of the outside air. When the outside temperature is higher. At low speed. The heat dissipation effect will be worse. The water-cooled intercooler has a compact structure. Can be more convenient in the engine compartment layout. It also provides better temperature stability. The outside temperature is higher. It also provides a stable cooling effect at lower speeds. Besides. The intake pipe of the water-cooled intercooler can be shorter than the overhead air-cooled intercooler. This results in relatively minimal turbine hysteresis.
Front intercooler
In terms of placement. The front layout is to set the intercooler in front of the vehicle. Generally located in front of the cooling water tank. The advantage is that you can directly contact the cold air outside the vehicle. At the same time, the heat dissipation efficiency is increased by the impact of the front wind when the vehicle is running. So the cooling effect is more obvious. Can handle higher engine output at the same time. It's also less susceptible to the heat in the engine compartment. But the downsides are also obvious. Due to the longer distance between the intercooler and the turbocharger. The air has to travel a longer distance through the pipe. So the turbine lag becomes relatively more pronounced.
Overhead intercooler
The overhead layout places the intercooler on top of the engine. Air intakes need to be provided in the hood to allow outside air in. The advantage is that the distance from the turbocharger is very close. After the distance of the air line is shortened. It makes turbine hysteresis very slight. Faster power output response. But because it's on top of the engine. The efficiency of heat dissipation is affected by the heat inside the engine compartment. It was also limited by the space problems in the engine bay. The cooling area will also be limited. The cooling effect of intake air is not as good as the front layout.