Patent Application
20170114704
The present disclosure relates generally to an air intake system and a cooling system for an engine of a work vehicle, and more specifically, to an integrated intake and deaeration assembly for a work vehicle.
Off-road vehicles, such as trucks, tractors, combines, and other vehicles for use in various construction or agricultural applications, have limited space for the numerous components that may be included under the hood of the off-road vehicle. For example, an off-road vehicle may include an engine, a radiator, a pump, a thermostat, a deaerator, an air intake, an exhaust system, a braking system, a battery, and various electronic components disposed under the hood of the off-road vehicle. Unfortunately, the components of the off-road vehicle may be expensive as well as consume relatively large amounts of space under the hood.
The present disclosure relates to an integrated intake and deaeration assembly that includes a first compartment, a second compartment, and a shared wall. The shared wall separates the first compartment from the second compartment, the first compartment is configured to direct a flow of air to an engine of a work vehicle, and the second compartment is configured to deaerate a coolant fluid configured to flow through the engine and a radiator of the work vehicle.
The present disclosure also relates to a cooling and intake system for a work vehicle that includes a pump configured to direct a flow of coolant fluid through an engine of a work vehicle, a radiator configured to be fluidly coupled to the engine and to decrease a temperature of the coolant fluid output from the engine, and an integrated intake and deaeration assembly. The integrated intake and deaeration assembly includes a first compartment, a second compartment, and a shared wall. The shared wall separates the first compartment from the second compartment, the first compartment is configured to direct a flow of air to an engine of a work vehicle, and the second compartment is configured to deaerate a coolant fluid configured to flow through the engine and a radiator of the work vehicle.
The present disclosure further relates to a method for manufacturing an integrated intake and deaeration assembly that includes forming a first component that has a first portion of a shared wall, forming a second component that has a second portion of the shared wall, and coupling the first component and the second component to one another to form a first compartment and a second compartment. The first compartment and the second compartment are separated by the shared wall, the first compartment is configured to direct a flow of air to an engine of a work vehicle, and the second compartment is configured to deaerate a coolant fluid configured to flow through the engine and a radiator of the work vehicle.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments.
The embodiments disclosed herein relate generally to an integrated intake and deaeration assembly for off-road vehicles. Off-road vehicles may employ a cooling system that may be utilized to maintain an engine at a desired temperature range during operation. In certain cases, the cooling system may include a radiator, a pump, a thermostat, and coolant fluid. The radiator is configured to facilitate heat transfer from the coolant fluid to air so that the coolant fluid may be received by the engine at a relatively low temperature. In turn, the coolant fluid may absorb thermal energy from the engine to maintain the engine at the desired temperature range. The coolant fluid may be driven through a coolant fluid loop (e.g., a flow path that includes the engine and the radiator) via the pump. Additionally, a flow rate of the coolant fluid may be controlled by the thermostat. In some cases, the thermostat may include a valve that opens and/or closes to adjust a flow rate of the coolant fluid through the engine and/or the radiator.
Additionally, the off-road vehicle may include an air intake system. The air-intake system may include an air filter, a flow sensor, and a throttle valve, for example. The air intake system may be utilized to direct air toward the combustion chamber of the engine. For example, the intake system may guide a desired amount of air from a surrounding environment of the off-road vehicle toward the combustion chamber of the engine. The air may be mixed with fuel such that a fuel-air mixture may combust in the engine and ultimately power the off-road vehicle.
In addition to the cooling system and the air intake system, the off-road vehicle may include numerous components under the hood. For example, the off-road vehicle may include an engine, various belts and gears, a braking system, a battery, a steering system, a transmission, and the like. However, an amount of space under the hood of the off-road vehicle is limited. Therefore, it is now recognized that it may be desirable to conserve space by integrating certain components. For instance, in traditional off-road vehicle configurations, an air intake duct may be separate from, and proximate to, a deaeration chamber. It is now recognized that integrating the air intake duct and the deaeration chamber may decrease a cumulative amount of space of the components (e.g., by eliminating empty space previously existing between the air intake duct and the deaeration chamber). Accordingly, the integrated air intake duct and deaeration chamber may include a complex geometry that may enable a manufacturer of the off-road vehicle to satisfy tight packaging constraints. Further, integrating the air intake duct and deaeration chamber may eliminate a device and/or hardware utilized to mount the deaeration chamber to the air intake duct.
Additionally, integrating the air intake duct and the deaeration chamber may reduce manufacturing costs by decreasing an amount of parts that are produced (e.g., manufacturing one component instead of two). Therefore, in certain embodiments, one mold (e.g., an injection mold template) may be utilized instead of two molds (e.g., injection mold templates) to manufacture both the air intake duct and the deaeration chamber. In other embodiments, two molds (e.g., injection mold templates) may be utilized instead of four molds (e.g., two injection mold templates for each of the air intake duct and the deaeration chamber). Accordingly, it is now recognized that an integrated intake and deaeration assembly may save space under the hood of the off-road vehicle, as well as reduce costs associated with manufacturing vehicle components.
To help illustrate the manner in which the present embodiments may be used in a system,
As discussed above, it may be desirable to integrate components that are traditionally placed under a hood of the off-road vehicle 10 to establish more space for additional features and/or components, as well as to reduce manufacturing costs. For example, the air intake duct and the deaeration chamber may be integrated (e.g., share a common wall) with one another to form a single component. The single component may substantially eliminate and/or reduce any gaps present between the air intake duct and the deaeration chamber, thereby reducing an amount of space occupied by the air intake duct and the deaeration chamber. Accordingly, in certain embodiments, establishing more space under the hood of the off-road vehicle 10 may enable the hood to be lowered such that an amount of drag experienced by the off-road vehicle 10 is reduced. Additionally, in certain embodiments, a single mold may be utilized to form the integrated component as opposed to utilizing two or more molds to form each component separately. In other embodiments, two molds may be utilized to form the integrated component as opposed to utilizing four or more molds to form each component separately (e.g., each component may be formed using two molds). Utilizing fewer molds may reduce costs for manufacturing the off-road vehicle 10 and integrating the components may improve performance of the off-road vehicle (e.g., by transferring heat between the coolant fluid and intake air). Accordingly, integrating the components into a single integrated intake and deaeration assembly may establish space for additional features to be incorporated into the off-road vehicle 10 as well as reduce manufacturing costs.
For example,
Additionally, the integrated intake and deaeration assembly 38 may be configured to receive coolant 48 from the coolant fluid loop 34. As shown in the illustrated embodiment of
The coolant fluid 48 is driven through the coolant fluid loop 34 via the pump 52. In the illustrated embodiment of
In certain embodiments, the coolant fluid 48 may include air bubbles as a result of flowing through the radiator 50 and/or the engine 46 of the off-road vehicle 10. It may be desirable to substantially eliminate and/or reduce the air bubbles to enhance the efficiency of the pump. Accordingly, the coolant fluid 48 may be directed toward a deaeration compartment 56 (e.g., separated from the intake compartment 40) of the integrated intake and deaeration assembly 38. The deaeration compartment 56 may enable any air that may have been present in the coolant fluid 48 to separate from the coolant fluid and either be trapped in a top portion 57 of the deaeration compartment 56 or vented to atmosphere via a pressure relief valve 58.
In certain embodiments, the top portion 57 of the deaeration compartment 56 may also include an opening 59. The opening 59 may be utilized to add more coolant fluid 48 to the coolant fluid loop 34 and may be capped with the pressure relief valve 58. For example, in certain embodiments, the coolant fluid 48 may be water or a mixture of water and alcohol (e.g., methanol, ethylene glycol, propylene glycol, etc.). Accordingly, as the coolant fluid 48 absorbs thermal energy from the engine 46, a portion of the coolant fluid 48 may evaporate into vapor. As such, as the coolant fluid 48 enters the deaeration compartment 56, some vapor may separate from the liquid coolant fluid and exit the coolant fluid loop 34 via the pressure relief valve 58. Additional coolant fluid 48 may be periodically added to the coolant fluid loop 34 via the opening 59 to ensure that a suitable amount of coolant fluid 48 is present in the coolant fluid loop 34 during operation of the engine 46.
The deaeration compartment 56 also includes a first inlet port 60 and a second inlet port 62. The first and second inlet ports 60, 62 are configured to receive coolant fluid 48 into the deaeration compartment 56. The first inlet port 60 may enable coolant fluid 48 from the radiator 50 (e.g., exiting an inlet tank of the radiator 50) to enter the deaeration compartment 56. Similarly, the second inlet port 62 may receive coolant fluid 48 from the engine 46. When the coolant fluid 48 enters the deaeration compartment 56 air bubbles that may be present in the coolant fluid 48 may separate, thereby enhancing an efficiency of the cooling system 30.
As shown in the illustrated embodiment of
Additionally, the cooling system 30 may include a cab heater 66. For example, the cab heater 66 may be a heat exchange device configured to transfer heat to the cabin 14 of the off-road vehicle 10. Accordingly, warm coolant fluid 48 exiting the engine 46 may be directed toward the cab heater 66 where heat may be transferred from the coolant fluid 48 to air or another medium that may be utilized to heat or warm the cabin 14. In certain embodiments, the cab heater 66 may enhance an efficiency of the cooling system 30 by providing excess heat to the cabin 14 during cold weather rather than allowing such heat to escape to the atmosphere.
As discussed above, integrating the intake air duct (e.g., the intake compartment 40) and the deaeration chamber (e.g., the deaeration compartment 56) into a single component may establish additional space for features under the hood of the off-road vehicle 10, as well as decrease manufacturing costs of the off-road vehicle 10. For example, in certain embodiments, a single mold may be utilized to form the integrated component as opposed to utilizing two or more molds to form each component separately. In other embodiments, two molds may be utilized to form the integrated component as opposed to utilizing four or more molds to form each component separately (e.g., each component may be formed using two molds). Accordingly, fewer molds may be used to manufacture both the intake compartment 40 and the deaeration compartment 56, which may save costs as well as time (e.g., less time to mold one component than to mold two components). In certain embodiments, the integrated component may include a first portion 80 of the integrated intake and deaeration assembly 38 and a second portion 82 of the integrated intake and deaeration assembly 38, as shown in
As shown in the illustrated embodiment of
Additionally, the shared wall 84 includes a first surface 86 that faces the intake compartment 40 and forms a portion of the intake compartment 40 (e.g., the first surface 86 of the shared wall 84 forms a portion of a wall of the intake compartment 40). Additionally, the shared wall 84 includes a second surface 88 that faces the deaeration compartment 56 and forms a portion of the deaeration compartment 56 (e.g., the second surface 88 of the shared wall 84 forms a portion of a wall of the deaeration compartment 56).
In certain embodiments, it may be desirable for the intake compartment 40 and the deaeration compartment 56 to be sealed such that fluid flow (e.g., air, coolant fluid, etc.) is blocked between the intake compartment 40 and the deaeration compartment 56. Accordingly, the first portion 80 and the second portion 82 of the integrated intake and deaeration assembly 38 (and thus the first section and the second section 85 of the shared wall 84) may be coupled to one another in a manner that facilitates a substantially fluid-tight connection. For example, in certain embodiments, the first portion 80 and the second portion 82 may be laser welded to one another. In the laser welding process, the first portion 80 and/or the second portion 82 may partially melt and re-harden, such that the first portion 80 adheres to the second portion 82, thereby establishing a seal between the portions. In other embodiments, the first portion 80 and the second portion 82 may be coupled to one another via fasteners (e.g., screws, bolts, rivets, etc.). In such embodiments, the fasteners may couple the first portion 80 and the second portion 82 to one another, while substantially eliminating gaps and/or openings between the first portion 80 and the second portion 82, thereby establishing a seal between the portions.
When the first portion 80 and the second portion 82 are coupled to one another, the intake compartment 40 and the deaeration compartment 56 are formed, and each compartment may be sealed from one another via a substantially fluid-tight seal between the first section and the second section 85 of the shared wall 84. For example,
In the illustrated embodiment, the intake compartment 40 includes a cross-section that is substantially rectangular. In other embodiments, the intake compartment 40 may have a cross-section that includes any suitable shape for directing air toward the engine 46 (e.g., square, circular). Additionally, the cross-section of the intake compartment 40 may be substantially uniform along a length of the intake compartment 40 (e.g., from the inlet portion 42 to the outlet portion 44). In other embodiments, the cross-section of the intake compartment 40 may vary along the length of the intake compartment 40. Further, as illustrated, the intake compartment 40 includes the outlet portion 44 that directs the air 36 toward the engine 46.
Additionally, in the illustrated embodiment of
As illustrated in
Furthermore, as illustrated in the embodiment of
The shared wall 84 also facilitates a transfer of thermal energy between the air 36 in the intake compartment 40 and the coolant fluid 48 in the deaeration compartment 56. For example, the temperature of the coolant fluid 48 in the deaeration compartment 56 may be greater than a temperature of the air 36 in the intake compartment 40. Accordingly, thermal energy may be transferred from the coolant fluid 48 to the air 36 via the shared wall 84. The thickness of the shared wall 84 may be particularly selected to facilitate thermal energy transfer while establishing a substantially fluid-tight seal between the intake compartment 40 and the deaeration compartment 56.
In other embodiments, thermal energy transfer between the coolant fluid 48 in the deaeration compartment 56 and the air 36 in the intake compartment 40 may be undesirable because the temperature of the air 36 may increase. Accordingly, in such embodiments, the thickness of the shared wall 84 may be selected to insulate the intake compartment 40 from the deaeration compartment 56 (e.g., the thickness reduces the transfer of thermal energy between the deaeration compartment 56 and the intake compartment 56). It should be noted that while the thickness of the shared wall 84 may be increased to insulate the intake compartment 40 from the deaeration compartment 56, the thickness may still be substantially smaller than any gaps present between a separate intake air duct and deaeration chamber.
As discussed above, manufacturing the integrated intake and deaeration assembly 38 may reduce costs of manufacturing the off-road vehicle 10. For example,
At block 104, the second portion (e.g., a second component) of the integrated intake and deaeration assembly is formed (e.g., via injection molding). In certain embodiments, the second portion (e.g., the second component) may be formed from a polymeric material such as polypropylene, nylon, or another suitable polymeric material.
When the first and second portions have been formed, the first and second portions (e.g., the first and second components) are coupled to one another to form the integrated intake and deaeration assembly, as shown at block 106. As discussed above, coupling the first and second portion (e.g., the first and second components) to one another forms the intake compartment (e.g., a first compartment) and the deaeration compartment (e.g., a second compartment). In certain embodiments, the first and second portions may be coupled to one another by laser welding the first portion to the second portion of the integrated intake and deaeration assembly. In other embodiments, the first and second portions (e.g., the first and second components) may be coupled to one another via fasteners (e.g., screws, bolts, rivets, etc.). In certain embodiments, the first and second portions are configured to form a substantially fluid-tight seal such that the intake compartment (e.g., the first compartment) and the deaeration compartment (e.g., the second compartment) are substantially fluidly isolated from one another (e.g., air from the intake compartment may be substantially blocked from entering the deaeration compartment, and/or coolant fluid from the deaeration compartment may be substantially blocked from entering the intake compartment).
At block 108, the integrated intake and deaeration assembly is disposed underneath the hood of the off-road vehicle. As discussed above, the integrated intake and deaeration assembly may reduce an amount of space occupied under the hood, as compared to a separate intake air duct and deaeration chamber. Accordingly, additional components may be included underneath the hood of the off-road vehicle. Additionally or alternatively, the hood of the off-road vehicle 10 may be lowered as a result of the increased space, such that an amount of drag experienced by the off-road vehicle is reduced.
While only certain features of the present disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
