The invention relates to a heat exchanger having the features of patent claim 1.
Heat exchangers for cooling gases are used as hot gas coolers, e.g. in the form of exhaust gas recirculation coolers or charge air coolers. Hot gas coolers allow mixing of recirculating exhaust gases with combustion gases at the lowest possible temperature for medium- or low-speed engines. Hot gas coolers are therefore a decisive element in the exhaust gas recirculation systems in enabling the applicable emissions directives to be met. In high-pressure exhaust gas systems, exhaust gases can be cooled from over 700° C. to 50° C. The thermal loading of such hot gas coolers is very high. High thermal stresses arise in the components of the exhaust gas flow.
DE 10 2008 011 558 B4 discloses a heat exchanger with cooling fins which have turbulators stamped in the form of troughs. The turbulators improve heat exchange and enhance the effectiveness of the heat exchanger. By means of cooling fins, it is possible to provide a heat exchanger area on the gas side which is larger by a factor of about 8 to 20 than on the coolant side. In the case of hot gas coolers, it should be noted that, in some cases of operation, the gas flow often enters the heat exchanger at very high speed and in a point-oriented manner. In some cases, this leads to insufficient homogeneity factors, with values <0.95, in the individual stages following one another in the flow direction of the gas. These very high point loads lead as it were locally to very high thermal stresses. Fin arrangements in which the stiffness is too high can lead to fatigue fractures in the cooling tubes, especially at the transition to the tube sheet. In DE 10 2012 217 323 A1, the proposal was therefore made for a fin to have an expansion bead for stress compensation and, in addition, for the material thickness to be reduced or a slit for stress compensation to be introduced in the region of the expansion bead. The production of expansion beads in combination with the reduction of the material thickness or the additional introduction of slits in the region of the expansion bead is technically relatively complex.
Taking this as a starting point, it is the underlying object of the invention to specify a heat exchanger which exhibits lower stress loads in the cooling tubes, even at very high temperature gradients, and in which consequently the creep strength is improved.
This object is achieved in the case of a heat exchanger having the features of patent claim 1.
The dependent claims relate to advantageous developments of the invention.
The heat exchanger according to the invention for cooling hot gases is, in particular, an exhaust gas recirculation cooler or, alternatively, a charge air cooler. It has a gas inlet and, at a distance from the gas inlet, a gas outlet.
A plurality of cooling tubes is arranged between the gas inlet and the gas outlet. They extend transversely to the flow direction of the gas, The cooling medium is, in particular, water.
The cooling tubes are surrounded by fins. The fins may also be referred to as lamellae. According to the invention, it is envisaged that a fin of this kind has a plurality of openings, a plurality of cooling tubes thus being passed simultaneously through one fin or lamella. This is therefore not a question of individual ribbing of the individual cooling tubes, but a question of an assembly. An assembly of this kind preferably extends over virtually the entire inflow cross section of the heat exchanger.
In the invention, these fins have slits. These slits serve to compensate thermal stresses and to make the gas flow more uniform. The gas flow flows through the slits. The slits are at a distance from the openings in which the cooling tubes are located. In the invention, a special arrangement of the slits is employed: the slits are arranged in a honeycomb shape. That is to say that a plurality of slits surrounds each opening or each cooling tube in a hexagonal arrangement. One hexagon surrounds each opening. The slits follow the edge profile of the hexagon, and therefore the slits are preferably straight. The invention does not exclude a slit profile that is not straight as long as the arrangement remains hexagonal overall and is not circular, for example. The ends of slits at a corner of the hexagon are therefore at an angle to one another. In particular, the hexagon is equilateral and equiangular, as in the case of a regular hexagon.
Each slit ends at a deformation point of the fin. This deformation point is located at the corner of the hexagon. This deformation point is a special feature in comparison with constructions in which there are passages in the fins. The deformation region has the positive effect that the stiffness of the fin is reduced and allows plastic deformation in the case of high (thermal) loads. Creating a deformation point within the fin makes it possible for the flexible point to be plastically deformed in the case of necessity, i.e. when there is a high point load. However, this does not lead to continuous deformations within the entire fin, nor to functional impairments of other parts of the heat exchanger. This reduction in stiffness ensures lower thermally induced stresses in the cooling tubes. Studies have shown that instances of plastification at the transition from the cooling tube to a tube sheet in which the cooling tube is secured can be reduced by up to 80%. As a result, a higher creep strength for the entire heat exchanger can be obtained, this being a direct consequence of the reduced stiffness of the fins or lamellae.
In an advantageous development of the invention, a width of the slits is greater than the minimum width of the deformation point. The deformation points should therefore be relatively narrow. The width of the slits depends on the desired mixing of the gas flow above and below the sits. It is not envisaged that the slits be arranged in the region of a bead of the fins. In a first preferred embodiment, the fin itself is substantially flat, apart from collars or rim holes for resting the cooling tubes against the fin. The slits the lead to an effect on the flow and to minimization of stresses induced by thermal expansion on the openings and tubes. In this context, “flat” means that the fin is not corrugated or grooved.
In a development of the invention, a fin can have individual embossed features. The slits are preferably arranged outside the embossed features, individual embossed features can improve the guidance of the flow. Slits outside the embossed features are easier to manufacture. The slits are not covered by projections of the fin of the kind which are formed when the stamped out pail for producing the slit is secured on one side of the slit or at at least one end of the slit.
The aim is that the fins should have a very high elongation at break. In particular, it should be above 25%.
It is advantageous if only a single slit is arranged between two adjacent openings. This slit is at the same distance from each of the adjacent openings. The invention also includes the single slit having constrictions, narrow points or interruptions between two adjacent openings, with the result that a plurality of shorter slits that follow one another in the longitudinal direction thereof together form functionally the single longer slit extending between two adjacent openings. It is not the number of slits which is critical but the honeycomb arrangement along the edge profile of a hexagon.
The cooling tubes of two successive tube rows are arranged offset transversely to the flow direction of the gas. If all the slits are of the same length, a uniform hexagonal or honeycomb pattern that repeats itself within a fin is obtained.
The opening for the cooling tube is the center of such a hexagon or such a honeycomb. The deformation point is the center of a star-shaped arrangement of three slits. In this sense, the deformation point is also star-shaped.
To reduce stresses caused by a notch effect, the slits are preferably rounded, in particular fully rounded, at the ends. The diameter of the rounding preferably corresponds to the width of the slits. Three slits, which are preferably arranged offset relative to one another by 120° in each case in the honeycomb shape, delimit a star-shaped deformation point. The ends of the three slits adjoin a common circle. It is simultaneously the incircle of the star-shaped deformation point. The diameter of this incircle is preferably approximately the same as the diameter of the end roundings of the slits. Owing to the mutual offsetting of the slits by 120° in the preferred honeycomb shape, however, the smallest distance between adjacent slits is somewhat less than said diameter. In this configuration, therefore, the width of the Tits is greater than the width of the deformation point.
Within the scope of the invention, it is possible to select an even smaller deformation point or to make the slits longer. The slits are not so long that the deformation point is eliminated. In the case of slits of equal length, each slit in the preferred honeycomb shape extends over an angle of about less than 60° relative to the adjacent opening. In the case of the preferred honeycomb shape, there are no hexagonal individual fins but fins through which in all cases a plurality of cooling tubes are simultaneously passed.
The term “hexagon” or “honeycomb shape” in the context of the patent application should not be understood to mean that all sides of the hexagon must be of equal length or at the same angle to one another. Within the scope of the invention, it is possible that the mutually opposite slits are of equal length, wherein one pair of the opposite slits has a different length from the two other pairs of opposites slits. Such an arrangement of hexagons, which are as it were elongated, can be obtained if the distance of the tube rows is not equal to the distance between the tubes within a row. In this case, the slits that point from tube row to tube row are longer than the other pairs of slits. If the tube rows are at a shorter distance from one another than the distance between the tubes within a row, the slits that point from tube row to tube row are somewhat shorter than the other two pairs of slits.
In a development of the invention, a plurality of groups of cooling tubes is arranged between the gas inlet and the gas outlet of the heat exchanger. At least one first group of cooling tubes adjacent to the gas inlet is penetrated by said fins. A second and third group of said cooling tubes is preferably also penetrated. The formation of groups allows adaptation of the design of the individual groups to the locally prevailing thermal conditions. The groups are arranged at short distances from one another. In the case of three successive groups or stages, for example, there are therefore also three fins arranged in succession and at a distance from one another. In particular, all the groups of cooling tubes are provided with the said fins.
According to the invention, an individual group of cooling tubes comprises at least two tube rows, which are in series in the flow direction of the gas. The tube rows are arranged offset relative to one another, ensuring that an inflow area of the tubes is as large as possible.
In a development of the invention, the fins have edge sides lying in the flow direction of the gas, wherein at least one edge side has a sawtooth profile (about ±30° to the inflow area of the preferred honeycomb shape). The profiled shape can correspond to the pattern of the slits. The said fins can be produced from relatively large sheet-metal blanks. They are separated at the edge sides of the fins. The separating process can take place in the region of the deformation points, thus ensuring that very little material has to be cut for separation. The effort for separation of the fins into smaller units is very small.
In addition, a recess for the formation of a deformation point can be provided at the edge sides. This deformation point is intended to interact with the respective slit that is adjacent to the at least one edge side. These are the slits which point in the flow direction. The recess reduces the area of extent of the deformation point. The greatest point loads occur in the inflow region of the heat exchanger. Here, particularly low bending stiffness levels are advantageous. Consequently, the recesses should admittedly remain intact and at the same time also should simplify assembly. Nevertheless, they have the function of being plastically deformed in the case of necessity without having a negative effect on other regions of the fin or of the cooling tube.
In another embodiment of the invention, it is possible as it were to round or smooth the sawtooth shaped edge sides, ensuring that there are no particularly sharp or pointedly projecting corners on the edge sides. In another embodiment of the invention, it is possible for the slits, particularly on the edge side facing the flow, to extend as far as the edge side, with the result that there are no deformation points at all at the edge. In this case, the slits leading toward the edge side are open. The slits can even be widened somewhat further at their mouth. These widened portions can be produced by removing the originally present deformation points, e.g. by stamping. Here, the size selected for the region stamped out can be somewhat greater than the region of the deformation point, with the result that there are no constrictions at the transition from the edge side to the width of the slit. The stamped out areas are therefore preferably larger in width or diameter than the width of the slit.
If plastic deformations occur in a deformation point with the arrangement according to the invention of cooling tubes and fins, it is nevertheless impossible for a fin of this kind to move in the longitudinal direction of the cooling tube. The fins are preferably held in a stacked arrangement and fully surround the cooling tube. For this purpose, a collar arranged on the fins serves as a spacer. The height of the collar determines the spacing between adjacent fins. The collar surrounds the openings.
Apart from the collars which extend transversely to the plane of the fins and surround the cooling tubes, the fins are substantially flat. The high number of slits and openings, and the small deformation points, lead to fins of this kind being relatively light, but at least lighter than fins on which turbulators are extended in the same direction or alternately. Ultimately, the weight saving has a positive effect on the overall weight of the heat exchanger. Said fins have a thickness of a few tenths of a millimeter. The fins preferably have a thickness of less than 0.16 mm. The thickness is preferably 0.10 mm to 0.15 mm. Owing to the relatively low thickness, the term “lamellae” is also used in the case of such fins. The diameters of the openings and hence of the cooling tubes are preferably in a range of from 6 mm to 10 mm. The openings preferably have a diameter of from 7 to 8 mm. The spacing between adjacent tubes is approximately twice the diameter of the cooling tubes or the diameter of the opening. The width of the slits is about 15% to 25% of the diameter of the openings. However, the high proportion of openings and apertures does not have a negative effect on the effectiveness of heat transfer. In particular, a heat exchanger with a high creep strength is provided by said configuration of the fins.
The invention is explained below by means of an illustrative embodiment, which is illustrated schematically in the drawings. In the drawings;
The perspective illustration in
The special feature of the structure according to the invention of the heat exchanger 10 is the geometry of the fins 1. Next to the openings 2 for the cooling tubes 13, the fins 1 have regularly arranged slits 4. The slits 4 have the shape of elongate holes with fully rounded ends. All the slits 4 are straight, of the same length and of uniform width. They are arranged in a polygonal shape, more specifically in this case in a hexagon shape or honeycomb shape. The polygon shape described is a regular hexagon. There is one slit 4 between every two adjacent cooling tubes 13 or openings 2. The cooling tubes 13 or openings 2 are arranged in series in rows R1, R2, R3. The rows R1, R2, R3 etc. are each arranged offset transversely to the preceding row. As a result, there is an opening 2 or cooling tube 13 in each cell bounded by the six straight slits 4. The slits 4 have a length L1 The length L1 is slightly less than the diameter D1 of the circular opening 2. In this illustrative embodiment, the length L1 is 7.5 mm in comparison with the diameter D1 of 8 mm. The width B1 of the slits 4 is 1.5 mm. The ratio of the length L1 to the width B1 of the slits 4 is therefore 5:1. All the adjacent slits are at an angle W of 120° to one another.
The distance between the central longitudinal axis MLA of a slit 4 from a central point M of an opening 2 is denoted by D2 in
There are therefore circular-arc-shaped recesses 8 of diameter D3 at the ends of the slits 4 which face the edge sides 5, 6. The recess 8 can be produced very easily by using a stamping tool that removes the actual core region of the deformation point 7.
In principle, the deformation point 7 is narrower at its narrowest point B3 (
Variations within the scope of the invention are possible by modifying the length L1 of the individual slits 4. Longer slits 4 result in smaller deformation points 7 and increase the elasticity of the fin 1. Shorter slits 4 would increase the stiffness of the fin 1.
The illustrative embodiment in
Whereas the illustrative embodiment in
The illustrative embodiment in
The illustrative embodiment in
Another difference is that the deformation regions 7 are no longer symmetrical. The longer slit 4 of the three adjoining slits 4 extends as it were somewhat deeper into the deformation point 7. The central point of the deformation point 7 is thereby displaced somewhat out of the central position toward one of the adjacent openings 2. In this case, it is those openings 2 which are arranged in series in the flow direction P. By varying the length of the mutually opposite slits 4 arranged in pairs, it is possible to position the central point of the deformation point 7 in a manner appropriate to requirements. It can also be seen that the width of the slits 4 is greater than a minimum width of the respective deformation point 7.
The edge side 5 facing the flow is partially rounded. Where the slits 4 extending parallel to the flow direction P are arranged, the deformation point 7 that is usually present there is split transversely to the inflow direction. At that location, there is a region of the edge side 5 which is perpendicular to the inflow direction P. The slits 4 adjacent to the edge side 5 are not open to the edge side 5, as in the illustrative embodiment in
On the opposite edge side 6, which faces away from the flow direction P, there are rounded regions in the region of the openings 2, as also shown in
Number | Date | Country | Kind |
---|---|---|---|
10 2018 117 457.8 | Jul 2018 | DE | national |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/DE2019/100570 | 6/19/2019 | WO | 00 |