All cars are a set of parts, mechanisms that, when properly installed, work smoothly and stably. For example, between the compressor and the intake manifold there is a radiator, which is called so: intercooler. What is it, he who knows how to repair his car on his own knows. Why do we need this element, let's try to figure it out.
Heat exchange must take place correctly
The main purpose of the intercooler is to extract heat from the air stream, which is heated in the compressor during compression. That is, the better this heat is removed, the better the heat exchanger works. In order for the intercooled turbo system to be correctly assembled, it is very important to maximize the useful properties of the described device. In addition, the proper installation of an intercooler will guarantee that during the operation of the car there will be no problems. When creating this unit, several criteria must be taken into account, the main of which are the following:
- maximum heat dissipation;
- minimal turbocharging pressure loss;
- increased inertia of the air flow.
How does an airflow cooler work?
To ensure that heat is removed from the system correctly and in a timely manner, the plates and shells in the heat exchanger are responsible. They also make up the area of the heat exchanger, on which the intercooler's efficiency depends. True, you should not think that if the area is twice as large, then the efficiency of the unit will double. But if you make the heat exchanger area more than ten percent, then exactly the same will be higher than the efficiency. To understand how the intercooler works, what kind of device it is, it is important to know the features of its device.
So, air passes through it, and if it is difficult for him to do this, then a lot of heat will be lost. On the other hand, it is important to avoid large boost pressure losses. To compensate for the obstructed flow of air through our device, you need to make sure that the internal cross-section is large: this will allow you to hold the air in the intercooler and reduce the air flow. Accordingly, the pressure will be lost at an acceptable level. Thus, choosing this unit, it is worth taking care of low internal pressure losses.
Internal volume is important
The operation of the intercooler will be stable if it is correctly selected. So, the volume inside this device must be completely filled with air, and before pressure arises in the intake manifold. This volume is one of the parameters that should be optimized when creating a competent system of intermediate cooling. This indicator can be calculated as follows:
- the internal volume of the intercooler is divided by the volume of air flow;
- we multiply the resulting amount by two (this number is taken approximately: that is, it turns out that the air flow on the way to acceleration doubles).
When designing an intercooler, it is important to take into account the maximum capabilities of the system to remove heat from the charge air, so as not to lower the boost pressure and not to prevent the air pressure from building up.
Power and efficiency are key indicators
The cooling system in the car should work smoothly. To do this, you need to know how much power is lost when the intercooler pressure is lost. We correlate the absolute pressure indicator with and without the device. It is also worth remembering that it is not at all necessary to restore the lost power, since in this case the pressure in the exhaust manifold will become higher, which will lead to an increase in the exhaust gas reverse to the combustion chamber and an increase in temperature in it.
To calculate the efficiency of the intercooler, it is necessary to compare the increase in air temperature, which causes the turbine to work, and the decrease in temperature, which causes the cooler. Today you can buy two types of this device: air-to-air or air-to-water. A simpler design is the first option, while it also has a higher efficiency at high speed. In addition, it has higher reliability, and it’s much easier to maintain such a device. An air-water intercooler shows good efficiency at low speed, while it has a complex structure and costs more. But at the same time, the air-to-air intercooler pipe is more difficult to supply, the unit needs more space, therefore such a device is not suitable for every car.
Balanced intercooler: what is it?
In order for the cooler to be optimally balanced, it is important that it meets certain requirements:
1. The internal bore should be good. It is the cross section of the core of the heat exchanger that affects how much pressure will be lost during the passage of air. It is almost impossible to calculate the correct section, but you can at least predict what it should be. For example, you can use turbulators that prevent air from clinging to the walls of the unit and transfer thermal energy to it. Improved heat transfer and low flow losses depend on the density of the turbulizers.
2. A large role is played by the size of the core. The shorter the channels through which air passes, the lower the cross section will be.
3. Frontal area, reflecting the amount of ambient air, helps to cool the inflatable air. Accordingly, the greater the ambient air mass, the higher will be the cooling ability of the intercooler.
4. Streamlined shape of the core. The free movement of air through the device depends on this parameter, while the lighter the air, the greater its volume will pass through the intercooler (that this will directly affect the cooling effect, no doubt).
5. The characteristics of the cooler can be improved by channels that will supply cooling air. Experts believe that using a good channel, you can achieve an increase in the efficiency of the heat exchanger by about 20%.
6. The quantity and speed of the air flow depend on the size and shape of the pipe.
7. Such indicators as bends and transitions of sections, as well as the presence of nozzles, affect the stability of the intercooler. By the way, any bending in the system is a potential loss of flow. And if the pipes are not connected tightly, then the boost pressure will be lost.
Where is the intercooler radiator located?
Usually this unit is in free space, where there is a lot of space. The main thing is not to install it in the engine compartment or behind the cooling radiator, since the boost pressure will be low, the air will not warm up. In such cases, the cooler acts as a kind of intermediate heater. It is worth remembering that heating the intercooler from heat under the hood can lead to serious problems. Therefore, it is necessary to isolate this unit and carefully place all the pipes. As a rule, an air-type intercooler is installed in a free place, for example, behind the front bumper in the center, above the engine under the hood or in the side of the wings (from either side).
The main problems during operation
One of the serious problems is the oil in the intercooler. Such situations can be caused by the fact that the turbine bushings wear out, which, by the way, can be repaired. In addition, a similar problem may arise due to the fact that, at high speeds, the engine, even in a new turbine, can pass oil into the inlet channel. During the operation of the oil in the intercooler, a lot can be accumulated, but this problem is easily solved - you just need to clean the unit.
Each car has its own intercooler
Today it is very common to create a cooler for a specific engine. For example, the Nissan intercooler is different for each model of this brand. Therefore, choosing a cooler, you need to take into account many details: the frontal area of the heat exchanger and its thickness, the direction of flow, the internal flow area, and much more. At the same time, new Nissan cars are equipped with “clean” engines, which are not equipped with either an intercooler or a turbocharger.
The Mercedes intercooler is a heat exchanger that reduces the temperature of the air passing through it. In most models of this brand, the heat exchanger is located in front of the engine compartment and naturally blows around while the vehicle is in motion.
Why do I need an intercooler?
What is it, many will ask - another twist in the car or a really necessary thing? And is it worth it to install? Most experts agree that it is necessary for turbocharged engines. In addition, today you can choose a variety of configurations of this device, which, however, in no way affect the efficiency of its work. That is, any aesthetic delights, say, some kind of original form or design of intercoolers, the role is played more decorative than functional.
Experts also advise choosing aggregates made of thin sheet metal, since it will contribute to maximum heat conservation. The type of intercooler should be selected depending on the specific features of the existing turbine.