Title of Invention	A SYSTEM FOR MAINTAINING INTERCOOLER AIR TEMPERATURE DURING ENGINE TESTING
Abstract	ABSTRACT A system for maintaining inercooler air temperature during engine testing Figure # 1 The invention discloses an intercooler, mounted in a top-open housing. The housing transversely is fitted with plurality of conduits, which protrude from the two sides of the housing and are exteriorly connected to a cooling water header. An air header is connected through a matrix of openings, which are provided on the interior surface of the housing. The plurality of the conduits is proximate the largest surface area of the intercooler. Water is sprayed through the conduits on the intercooler and compressed air is blown parallel to water spray to achieve evaporative water cooling.

Title of Invention

A SYSTEM FOR MAINTAINING INTERCOOLER AIR TEMPERATURE DURING ENGINE TESTING

Abstract

ABSTRACT A system for maintaining inercooler air temperature during engine testing Figure # 1 The invention discloses an intercooler, mounted in a top-open housing. The housing transversely is fitted with plurality of conduits, which protrude from the two sides of the housing and are exteriorly connected to a cooling water header. An air header is connected through a matrix of openings, which are provided on the interior surface of the housing. The plurality of the conduits is proximate the largest surface area of the intercooler. Water is sprayed through the conduits on the intercooler and compressed air is blown parallel to water spray to achieve evaporative water cooling.

Full Text	FORM - 2 THE PATENTS ACT, 1970 (39 OF 1970) PROVISIONAL SPECIFICATION (See Section 10) TITLE OF INVENTION "A System for Maintaining Intercooler Air Temperature During Engine Testing" (a) Gawande Avinash Anandrao (b) residing at 29, Sambhaji Society, Senapati bapat Road Pune 411 016 State of Maharashtra, India The following specification particularly describes the nature of the invention and the manner in which it is to be performed. Field of Invention The present invention relates to a system for maintaining charged air temperature in the intercooler during engine testing. In particular the invention relates to a system that uses evaporative cooling heat exchange mode to maintain desired temperature of charged air / exhaust gas leaving the engine cylinder before entering turbocharger in the intercooler during engine testing. Background of Invention During engine testing as per established standards, it is necessary to maintain air inlet temperature. In particular for turbocharged engines wherein the temperature of aspirated air increases, it is necessary to maintain pre-defined temperature of the charged air, that is exhaust gas entering driving side of the turbocharger during the engine trial / test as per the established standards. To maintain the air temperature generally it is a practice to insert the intercooler \r\ the tank of water to cooi air and thereby maintain temperature of aspirated air to the engine during the trial / test. Further, the system is reported in literature wherein water / cooling medium is passed through the jacket surrounding the intercooler. However, in these systems, the lower heat transfer rate due to mere natural or forced convection imposes limitation on the desired air temperature. Related systems are reported in the prior art. They are as follows: United States Patent application 20070193731 discloses intercooler apparatus and method for better manufacturabilty of the Intercooler. It has flat tubes, corrugated ribs, collection tubes, connection pieces, and a connection plate used (for example) for the attachment of the heat exchanger in a casing through which charge air flows, whereby the individual components of the heat exchanger can be manufactured from aluminum and can be soldered together. The other configuration comprises of at least four collecting tubes define coolant collection chambers, whereby coolant follows at least one outgoing route lying between first and the second collection tubes, and at least one return route proceeding in an opposite direction lying between third and fourth collecting tubes. However, this system does not provide any means for cooling the inlet air during the course of engine testing/trials. U.S. Patent 2005 0121006 discloses intercooler system and intake air cooling method. It comprises of air duct configured to be supplied with outside air, an evaporator and a heater core of an air-conditioning system being disposed within the air duct. An intercooler is supplied with the outside air from the air duct and configured to cool intake air passing there through using the outside air. A valve unit regulates flow of the outside air such that the outside air passes at least one of the evaporators and the heater core and is then supplied to the intercooler. Also, a control unit controls operation of the air-conditioning system and the valve unit. However, this system does not facilitate air cooling during engine test or trial. US Patent 4,632,178 The cited, prior work, though relating to intercooler, substantially is different than the present invention in terms of the former employing one heat exchanger for vapourizing liquid coolant and the other heat exchanger for condensing coolant vapour (claim 1), relying upon level sensing to control liquid flow between a reservoir and twin heat exchangers (claim 2), employing twin pumps ( claim 3), employing a relief valve (claim 4) and employing a discreet reservoir and a special displacement control valve (claim 5). The present invention employs none of the afore-mentioned constructive elements of the cited work. US 2007/0261682 - This prior, cited work discloses an engine after-cooling system, employing a compressor (claim 7), an air-conditioning or refrigeration unit (claim 3), an expansion valve ( claim 4), a variable-flow-rate-pump (claim 5) to vary flow rate of the coolant in response to the sensed inlet air temperature and the sensed ambient air temperature (claims 11 and 12) and a fan (claim 16). The present invention does not employ the afore-mentioned constructional components for its working and is substantially different than the cited, prior work in terms of construction and the working. US Patent 4,949,544 - This prior work of art discloses a series intercooler, comprised of three stages (claims 3 and 10), of which the third intercooler is evaporative cooler (claim 12). The prior work employs an accelerator (claim 14) and a variable effectivity heat exchanger as the second after-cooler (claim 19). The present invention is not a series intercooler and is not constructed of the afore-mentioned components of the prior work. The former is substantially different than the prior cited work. Patent CA 2298747 (also published as US 6,098,576) - This prior work discloses a split-cooling system, employing a four-way flow directing valve (claim 10), a three-way flow directing valve (claim 10) and a plate heat exchanger as oil cooler. The present invention functionally and constructionally is different than the cited work, employing none of the afore-mentioned components of the prior work. Patent KR100309383 - This prior work of art describes half submergence of intercooler in a tank by draining out water through a hole in the centre point of one the vertical sides of the tank, while water is jetted through a pipe, placed above the water tank, onto the intercooler. The present invention is different than the cited work in terms of the function performed to achieve larger extent of cooling the charged air. The Cited work relies upon half-cooling by natural convection under induced bubbling and the remainder-half cooling by jetting water in an open tank, involving externally jetting water for cooling from above the tank. The present work achieves far greater cooling through combined functioning of evaporative cooling and forced convection by means of parallel air currents. The combined functions are carried on the surface of the intercooler, where a thin film of water is formed and is replaced as soon as it is formed. The water in the film is partly vapourized, extracting a large chunk of the heat from the charged air, while the remainder of the film of water is vigorously and continuously agitated under air currents to efficiently remove by forced convection the remainder of heat from the charged air. Much larger heat transfer rate is achieved due to the combined functioning of the evaporative cooling and the forced convection under air turbulence. The present invention is substantially different from the cited work. The study of the related prior art reveals several technological gaps such as: • lack of substantially high heat transfer rate as only natural or forced convection heat transfer is used; • lack of flexibility of using other than heat transfer by forced convection. Necessity has been felt to develop a system that facilitates substantially higher heat transfer rate so as to facilitate substantial temperature reduction of air in the intercooler during engine testing. Objects of the Invention: Main object of the present invention is to provide a system to facilitate substantial temperature reduction of air in the intercooler during engine testing. Yet, another object of the present invention is to provide a system that uses evaporative cooling for heat exchange so as to achieve effective heat extraction from air in the intercooler. Yet another object of the invention is to devise a system that facilitates a combination of forced convection as well as evaporative cooling means for heat extraction from charged air in the intercooler. Yet another object of the invention is to maintain charged air pressure across the system. Summary of the Invention: A system (100) for maintaining charged air temperature during engine testing comprises: (a) a housing (1); (b) an intercooler (2), mounted in the closed space defined by said housing (1); (c) a cooling water header (6). fitted along the side of said housing (1); (d) a plurality of conduits (5), interiorly fitted in said housing (1); (e) an air header (10), connected to centre of said housing (1); (f) a control unit, mounted in open space above said housing (1). Description of Drawings: Drawing # 1 illustrates front view and a sectional side view of the intercooler apparatus (100). Drawing # 2 illustrates assembly of the control unit (20) with the intercooler apparatus (100). Detailed Description of the Invention: Features and advantages of the present invention become apparent in the following detailed description and the preferred embodiments with reference to the accompanying drawings. The system (100) comprises of a housing (1), in which the intercooler (2) is mounted, as illustrated in the accompanying figure # 1. An inlet (3) and an outlet (4) are provided for charged air (hot air) on the housing (1). Cooling water is circulated through plurality of conduits (5), which are disposed in the vicinity of the intercooler (2) on the inner surface of the housing (1). The conduits are perforated with holes (51) to spray water on the intercooler (2). Header (6) supplies the cooling water to the plurality of the conduits (5) through the inlet terminal (7) and the outlet terminal ($), provided along the housing (1). Air is supplied to the intercooler (2) through a matrix of openings, as provided on the interior surface (11), sandwiched between the plurality of the conduits (5) and space (9), into which the housing header (10) opens, as further illustrated in the accompanying drawing # 1. A control unit (20) is mounted above the housing (1) to control cooling operation of the intercooler (2), as illustrated in the accompanying drawing# 2. The control unit (20) is comprised of a charged air temperature - sensing-and - signal-transmitting element (21) and a charged air pressure-sensing-and-signal transmitting element (22), installed on the outlet terminal (4) for the charged air. A flow control element (25) for the charged air is provided on the outlet terminal (4) that controls charged air pressure in conjunction with the sensing element (22) of the control unit (20). One control valve (23) is fitted on the inlet terminal of the housing header (10) and regulates flow of air through the header under the command of the control unit (20), as illustrated in the accompanying figure # 2. Another control valve (24) is fitted on the outlet terminal (8) of the cooling water header (6). The control valve (24) controls flow of cooling water through the header (6) under the command of the control unit (20). In another embodiment of the present invention, pump is used to supply water to the plurality of conduits (5). In another embodiment of the present invention, compressed air is fed through the housing header (10). Claims: I claim, 1. A system (100) for maintaining charged air temperature during engine testing comprising: (a) housing (1), characterized in that said housing defines an open-top-space of square cross section and is bounded by four sides and a bottom ; (b) an intercooler (2), characterized in that said intercooler (2) is mounted in the closed space defined by said housing (1); (c) a plurality of conduits (5), characterized in that said conduits (5) are interiorly and transversely fitted end-to-end in and protrude from two sides of said housing (1); (d) a cooling water header (6), characterized in that said header (6) is fitted exteriorly along the side of said housing (1) with said protruding, plurality of water conduits ; (e) an air header (10), connected to said housing (1), said housing (1) is characterized to provide on the interior surface thereof a matrix of plurality of openings to which said air header (10) is exteriorly fitted with respect to said housing (1); (f) a control unit (20), mounted in open space above said housing (1). 2. A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1. wherein said housing (1) is characterized to provide an inlet terminal (3) on one end thereof and is characterized to provide an outlet terminal (4) on the other opposite end thereof for respective connection with the incoming and outgoing charged air ends of said intercooler (2). 3. A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said plurality of said conduits (5) is characterized to open on curved exterior surface of said housing (1). 4. A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said plurality of said conduits (5) is characterized to fit on the inner surface of said housing (1) proximate the largest surface area of said intercooler (2). 5. A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said plurality of said conduits (5) is characterized to be fitted with plurality of spray nozzles for spraying coolant water on said intercooler (2). 6. A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said air header (10) is characterized to blow compressed air parallel to water spray for evaporative water cooling. 7 A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said water header (6) is characterized to provide variable water flow by means of said control valve (24) to said plurality of conduits (5) and said air header (10) is characterized to provide variable compressed air flow by means of said control valve (23) for cooling the charged air.

Full Text

FORM - 2
THE PATENTS ACT, 1970
(39 OF 1970)
PROVISIONAL SPECIFICATION
(See Section 10)
TITLE OF INVENTION
"A System for Maintaining Intercooler Air Temperature During
Engine Testing"
(a) Gawande Avinash Anandrao
(b) residing at
29, Sambhaji Society, Senapati bapat Road Pune 411 016 State of Maharashtra, India
The following specification particularly describes the nature of the invention and the manner in which it is to be performed.

Field of Invention
The present invention relates to a system for maintaining charged air temperature in the intercooler during engine testing. In particular the invention relates to a system that uses evaporative cooling heat exchange mode to maintain desired temperature of charged air / exhaust gas leaving the engine cylinder before entering turbocharger in the intercooler during engine testing.
Background of Invention
During engine testing as per established standards, it is necessary to maintain air
inlet temperature. In particular for turbocharged engines wherein the
temperature of aspirated air increases, it is necessary to maintain pre-defined temperature of the charged air, that is exhaust gas entering driving side of the turbocharger during the engine trial / test as per the established standards. To maintain the air temperature generally it is a practice to insert the intercooler \r\ the tank of water to cooi air and thereby maintain temperature of aspirated air to the engine during the trial / test. Further, the system is reported in literature wherein water / cooling medium is passed through the jacket surrounding the intercooler. However, in these systems, the lower heat transfer rate due to mere natural or forced convection imposes limitation on the desired air temperature.
Related systems are reported in the prior art. They are as follows:
United States Patent application 20070193731 discloses intercooler apparatus and method for better manufacturabilty of the Intercooler. It has flat tubes, corrugated ribs, collection tubes, connection pieces, and a connection plate used (for example) for the attachment of the heat exchanger in a casing through which charge air flows, whereby the individual components of the heat exchanger can be manufactured from aluminum and can be soldered together. The other configuration comprises of at least four collecting tubes define coolant collection chambers, whereby coolant follows at least one outgoing route lying between first and the second collection tubes, and at least one return route proceeding in an opposite direction lying between third and fourth collecting tubes. However, this

system does not provide any means for cooling the inlet air during the course of engine testing/trials.
U.S. Patent 2005 0121006 discloses intercooler system and intake air cooling method. It comprises of air duct configured to be supplied with outside air, an evaporator and a heater core of an air-conditioning system being disposed within the air duct. An intercooler is supplied with the outside air from the air duct and configured to cool intake air passing there through using the outside air. A valve unit regulates flow of the outside air such that the outside air passes at least one of the evaporators and the heater core and is then supplied to the intercooler. Also, a control unit controls operation of the air-conditioning system and the valve unit. However, this system does not facilitate air cooling during engine test or trial.
US Patent 4,632,178 The cited, prior work, though relating to intercooler, substantially is different than the present invention in terms of the former employing one heat exchanger for vapourizing liquid coolant and the other heat exchanger for condensing coolant vapour (claim 1), relying upon level sensing to control liquid flow between a reservoir and twin heat exchangers (claim 2), employing twin pumps ( claim 3), employing a relief valve (claim 4) and employing a discreet reservoir and a special displacement control valve (claim 5). The present invention employs none of the afore-mentioned constructive elements of the cited work.
US 2007/0261682 - This prior, cited work discloses an engine after-cooling system, employing a compressor (claim 7), an air-conditioning or refrigeration unit (claim 3),

an expansion valve ( claim 4), a variable-flow-rate-pump (claim 5) to vary flow rate of the coolant in response to the sensed inlet air temperature and the sensed ambient air temperature (claims 11 and 12) and a fan (claim 16). The present invention does not employ the afore-mentioned constructional components for its working and is substantially different than the cited, prior work in terms of construction and the working.
US Patent 4,949,544 - This prior work of art discloses a series intercooler, comprised of three stages (claims 3 and 10), of which the third intercooler is evaporative cooler (claim 12). The prior work employs an accelerator (claim 14) and a variable effectivity heat exchanger as the second after-cooler (claim 19). The present invention is not a series intercooler and is not constructed of the afore-mentioned components of the prior work. The former is substantially different than the prior cited work.
Patent CA 2298747 (also published as US 6,098,576) - This prior work discloses a split-cooling system, employing a four-way flow directing valve (claim 10), a three-way flow directing valve (claim 10) and a plate heat exchanger as oil cooler. The present invention functionally and constructionally is different than the cited work, employing none of the afore-mentioned components of the prior work.
Patent KR100309383 - This prior work of art describes half submergence of intercooler in a tank by draining out water through a hole in the centre point of one the vertical sides of the tank, while water is jetted through a pipe, placed above the water tank, onto the intercooler. The present invention is different than the cited work in terms of the function

performed to achieve larger extent of cooling the charged air. The Cited work relies upon half-cooling by natural convection under induced bubbling and the remainder-half cooling by jetting water in an open tank, involving externally jetting water for cooling from above the tank. The present work achieves far greater cooling through combined functioning of evaporative cooling and forced convection by means of parallel air currents. The combined functions are carried on the surface of the intercooler, where a thin film of water is formed and is replaced as soon as it is formed. The water in the film is partly vapourized, extracting a large chunk of the heat from the charged air, while the remainder of the film of water is vigorously and continuously agitated under air currents to efficiently remove by forced convection the remainder of heat from the charged air. Much larger heat transfer rate is achieved due to the combined functioning of the evaporative cooling and the forced convection under air turbulence. The present invention is substantially different from the cited work.
The study of the related prior art reveals several technological gaps such as:
• lack of substantially high heat transfer rate as only natural or forced convection heat
transfer is used;
• lack of flexibility of using other than heat transfer by forced convection.
Necessity has been felt to develop a system that facilitates substantially higher heat transfer rate so as to facilitate substantial temperature reduction of air in the intercooler during engine testing.

Objects of the Invention:
Main object of the present invention is to provide a system to facilitate substantial temperature reduction of air in the intercooler during engine testing.
Yet, another object of the present invention is to provide a system that uses evaporative cooling for heat exchange so as to achieve effective heat extraction from air in the intercooler.
Yet another object of the invention is to devise a system that facilitates a combination of forced convection as well as evaporative cooling means for heat extraction from charged air in the intercooler.
Yet another object of the invention is to maintain charged air pressure across the system.
Summary of the Invention:
A system (100) for maintaining charged air temperature during engine testing comprises:
(a) a housing (1);
(b) an intercooler (2), mounted in the closed space defined by said housing (1);
(c) a cooling water header (6). fitted along the side of said housing (1);
(d) a plurality of conduits (5), interiorly fitted in said housing (1);
(e) an air header (10), connected to centre of said housing (1);
(f) a control unit, mounted in open space above said housing (1).

Description of Drawings:
Drawing # 1 illustrates front view and a sectional side view of the intercooler apparatus
(100). Drawing # 2 illustrates assembly of the control unit (20) with the intercooler apparatus
(100).
Detailed Description of the Invention:
Features and advantages of the present invention become apparent in the following detailed description and the preferred embodiments with reference to the accompanying drawings.
The system (100) comprises of a housing (1), in which the intercooler (2) is mounted, as illustrated in the accompanying figure # 1. An inlet (3) and an outlet (4) are provided for charged air (hot air) on the housing (1). Cooling water is circulated through plurality of conduits (5), which are disposed in the vicinity of the intercooler (2) on the inner surface of the housing (1). The conduits are perforated with holes (51) to spray water on the intercooler (2). Header (6) supplies the cooling water to the plurality of the conduits (5) through the inlet terminal (7) and the outlet terminal ($), provided along the housing (1). Air is supplied to the intercooler (2) through a matrix of openings, as provided on the interior surface (11), sandwiched between the plurality of the conduits (5) and space (9), into which the housing header (10) opens, as further illustrated in the accompanying drawing # 1.
A control unit (20) is mounted above the housing (1) to control cooling operation of the intercooler (2), as illustrated in the accompanying drawing# 2. The control unit (20) is

comprised of a charged air temperature - sensing-and - signal-transmitting element (21) and a charged air pressure-sensing-and-signal transmitting element (22), installed on the outlet terminal (4) for the charged air. A flow control element (25) for the charged air is provided on the outlet terminal (4) that controls charged air pressure in conjunction with the sensing element (22) of the control unit (20).
One control valve (23) is fitted on the inlet terminal of the housing header (10) and regulates flow of air through the header under the command of the control unit (20), as illustrated in the accompanying figure # 2. Another control valve (24) is fitted on the outlet terminal (8) of the cooling water header (6). The control valve (24) controls flow of cooling water through the header (6) under the command of the control unit (20).
In another embodiment of the present invention, pump is used to supply water to the plurality of conduits (5). In another embodiment of the present invention, compressed air is fed through the housing header (10).

Claims: I claim,
1. A system (100) for maintaining charged air temperature during engine testing
comprising:
(a) housing (1), characterized in that said housing defines an open-top-space of square cross section and is bounded by four sides and a bottom ;
(b) an intercooler (2), characterized in that said intercooler (2) is mounted in the closed space defined by said housing (1);
(c) a plurality of conduits (5), characterized in that said conduits (5) are interiorly and transversely fitted end-to-end in and protrude from two sides of said housing (1);
(d) a cooling water header (6), characterized in that said header (6) is fitted exteriorly along the side of said housing (1) with said protruding, plurality of water conduits ;
(e) an air header (10), connected to said housing (1), said housing (1) is characterized to provide on the interior surface thereof a matrix of plurality of openings to which said air header (10) is exteriorly fitted with respect to said housing (1);
(f) a control unit (20), mounted in open space above said housing (1).
2. A system (100) for maintaining charged air temperature during engine testing as
claimed in claim 1. wherein said housing (1) is characterized to provide an inlet
terminal (3) on one end thereof and is characterized to provide an outlet terminal
(4) on the other opposite end thereof for respective connection with the incoming

and outgoing charged air ends of said intercooler (2).
3. A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said plurality of said conduits (5) is characterized to open on curved exterior surface of said housing (1).
4. A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said plurality of said conduits (5) is characterized to fit on the inner surface of said housing (1) proximate the largest surface area of said intercooler (2).
5. A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said plurality of said conduits (5) is characterized to be fitted with plurality of spray nozzles for spraying coolant water on said intercooler (2).
6. A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said air header (10) is characterized to blow compressed air parallel to water spray for evaporative water cooling.
7 A system (100) for maintaining charged air temperature during engine testing as claimed in claim 1, wherein said water header (6) is characterized to provide variable water flow by means of said control valve (24) to said plurality of

conduits (5) and said air header (10) is characterized to provide variable compressed air flow by means of said control valve (23) for cooling the charged air.

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Patent Number

269031

Indian Patent Application Number

2558/MUM/2007

PG Journal Number

40/2015

Publication Date

02-Oct-2015

Grant Date

29-Sep-2015

Date of Filing

26-Dec-2007

Name of Patentee

GAWANDE AVINASH ANANDRAO

Applicant Address

29, SAMBHAJI SOCIETY, SENAPATI BAPAT ROAD, PUNE

Inventors:

#	Inventor's Name	Inventor's Address
1	GAWANDE AVINASH ANANDRAO	29, SAMBHAJI SOCIETY, SENAPATI BAPAT ROAD, PUNE-411016.

PCT International Classification Number

F28D15/00

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA