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1、 SURFACE VEHICLE RECOMMENDED PRACTICE (R) Engine Charge Air Cooler (CAC) Nomenclature SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and
2、 suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.
3、 Copyright 2004 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUM
4、ENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: custsvcsae.org SAE WEB ADDRESS: http:/www.sae.org J1148 REV. MAY2004 Issued 1976-06 Revised 2004-05 Superseding J1148 MAR97 1. Scope This SAE Recommended Practice is intended to outline basi
5、c nomenclature and terminology in common use for engine charge air coolers, related charge air cooling system components, and charge air cooling system operational performance parameters. 1.1 Description An engine charge air cooler is a heat exchanger used to cool the charge air of an internal combu
6、stion engine after it has been compressed by an exhaust gas driven turbocharger or a mechanically or electrically driven blower (supercharger). The use of a charge air cooler offers increased engine horsepower output, reduced exhaust emission levels, and improved fuel economy through a more complete
7、 combustion process due to increased intake air density. Typical cooling media include the engines coolant, ambient air, or an external coolant source. 2. References There are no referenced publications specified herein. 3. Definitions For purposes of this SAE Recommended Practice, charge air may be
8、 referred to as a fluid when in fact it is a gas. The cooling medium may be referred to as a fluid when in fact either liquids or gases can be employed. 3.1 Hardware 3.1.1 AFTERCOOLER A charge air heat exchanger located after the compressor (see Intercooler). 3.1.2 AIR-TO-AIR COOLER A charge air hea
9、t exchanger that uses ambient air as the cooling medium. SAE J1148 Revised MAY2004 - 2 - 3.1.3 CORE The portion of the heat exchanger that includes the principal heat transfer surface areas. The main core components include the tubes, external fins, internal fins, and oftentimes, the header. Some de
10、signs include the header as part of the inlet and outlet tanks. The core components are either brazed or mechanically fastened together. Mechanically fastened core components are connected with expanded joints, sealants or interference fit elastomeric gaskets. These gaskets are sometimes called resi
11、lient grommets. Some cores have brazed tube-to-fin joints in combination with elastomeric gaskets between the tubes and headers. Most OEM cores are brazed with one of the following manufacturing processes: 3.1.3.1 Air Braze Brazing the heat transfer components of the core in an air atmosphere and ty
12、pically employing a corrosive type flux. 3.1.3.2 Vacuum Braze Brazing the heat transfer components of the core in a nearly zero atmosphere and typically without the use of liquid flux. 3.1.3.3 Controlled Atmosphere Braze (C.A.B.) Brazing the heat transfer components of the core in a controlled atmos
13、phere and typically employing a non-corrosive flux. Typical examples of this brazing process include aluminum alloy brazing by the NOCOLOK process and copper alloy brazing by the CUPROBRAZE process, which typically employ a nitrogen atmosphere. 3.1.3.4 Dip Braze Brazing the heat transfer components
14、of the core in a molten metal or salt bath. 3.1.3.5 Exothermic Braze Brazing the heat transfer components of the core through the employment of an exothermic compound sufficient to reach the brazing temperature of the filler metal. 3.1.3.6 Torch Braze The heat transfer components of the core are joi
15、ned mechanically by expanding the tubes. The tube-to- header joints are torch brazed. 3.1.4 EXTERNAL FINS Secondary surfaces that increase the area to transfer heat to the cold fluid. 3.1.5 HEADER The portion of the core that connects the inlet and outlet tanks to the core matrix. The ferrules are t
16、ypically formed or pierced. SAE J1148 Revised MAY2004 - 3 - 3.1.6 INLET DUCTS The portions of the cooling system that direct the fluids into the inlet tanks of the heat exchanger. 3.1.7 INLET TANKS The portions of the heat exchanger located between the compressor and the intake manifold or between s
17、eries compressors that direct the fluids into the core matrix. 3.1.8 INTERCOOLER A charge air heat exchanger located between the compressor and the intake manifold or between series compressors. 3.1.9 INTERNAL FINS Secondary surfaces that increase the area that is to transfer heat from the hot fluid
18、. 3.1.10 AIR-TO-COOLANT COOLER A charge air heat exchanger that uses the engine coolant or other external liquid coolant as the cooling medium. 3.1.11 MULTIPASS A charge air heat exchanger that passes the fluids through the core matrix more than once. 3.1.12 OUTLET DUCTS The portions of the cooling
19、system that direct the fluids out of the outlet tanks of the heat exchanger. 3.1.13 OUTLET TANK The portion of the heat exchanger that direct the fluids out of the core matrix. 3.1.14 REMOTE MOUNTED A charge air heat exchanger that is located (mounted) in an area not normally associated with or conv
20、enient to the cooling medium. 3.1.15 SINGLE PASS A charge air heat exchanger that passes the fluids through the core only once. 3.1.16 TUBES The portions of the heat exchanger core matrix that are used to separate the fluids and are also the primary heat transfer surface areas. (See Figure 1 for typ
21、ical tube types.) SAE J1148 Revised MAY2004 - 4 - 3.1.17 TURBULATOR Secondary surfaces that increase the turbulence and mixing of the cold or hot fluids. 3.2 Operating and Performance Parameters 3.2.1 AMBIENT TEMPERATURE The temperature of the air surrounding the engine or vehicle before such air is
22、 influenced by heat or work energy from the engine or vehicle. 3.2.2 BOOST PRESSURE The pressure of the charge air as it leaves the turbocharger, supercharger, or other compressor. 3.2.3 DENSITY RECOVERY EFFICIENCY The ratio of the charge air density increase achieved from cooling the charged air, t
23、o the density decrease due to the temperature rise in the process of compressing the charge air. 3.2.4 DENSITY RECOVERY RATIO The ratio of the charge air density at the engine intake manifold to the air density at conditions of ambient temperature and boost pressure. 3.2.5 INLET PRESSURE The pressur
24、e of the charge air as it enters the heat exchanger. 3.2.6 INLET TEMPERATURE The temperature of the fluids as they enter the heat exchanger. 3.2.7 INLET TEMPERATURE DIFFERENTIAL (ITD) The inlet temperature difference between the hot and cold fluids. 3.2.8 INTAKE MANIFOLD PRESSURE The charge air pres
25、sure in the intake manifold. 3.2.9 INTAKE MANIFOLD TEMPERATURE The charge air temperature in the intake manifold. 3.2.10 INTAKE MANIFOLD TEMPERATURE DIFFERENTIAL (IMTD) The difference between the charge air temperature in the intake manifold and the ambient temperature. SAE J1148 Revised MAY2004 - 5
26、 - FIGURE 1CHARGE AIR COOLER TUBES 3.2.11 MASS FLOW RATE The rate of flow of the hot and cold fluids through the heat exchanging system expressed in terms of mass units per unit time. 3.2.12 OPERATING CONDITIONS The conditions under which the heat exchanger must operate; usually determined or set as
27、 the most severe conditions the heat exchanger will operate under continuously. 3.2.13 OUTLET PRESSURE The pressure of the fluids as they exit the heat exchanger. 3.2.14 OUTLET TEMPERATURE The temperature of the fluids as they exit the heat exchanger. SAE J1148 Revised MAY2004 - 6 - 3.2.15 PRESSURE
28、DROP The difference in fluid pressures as measured between the inlet and outlet of the heat exchanger or heat exchanging system. 3.2.16 TEMPERATURE DROP The difference in the fluid temperatures as measured between the inlet and outlet of the heat exchanger or heat exchanging system. 3.2.17 TEMPERATU
29、RE EFFECTIVENESS The ratio of the inlet charge air temperature minus the outlet charge air temperature divided by the inlet temperature differential. 3.2.18 TEST CONDITIONS The conditions under which the heat exchanger is tested to determine its effectiveness and pressure drop, usually the same as t
30、he operating conditions. 4. Schematics of Typical Charge Air Coolers 4.1 Air-to-Coolant Heat Exchangers a. Mounted in the intake manifold (see Figures 2 and 3) b. Mounted remotely (see Figures 4 and 5) FIGURE 2AIR-TO-COOLANTMOUNTED IN INTAKE MANIFOLD SAE J1148 Revised MAY2004 - 7 - FIGURE 3AIR-TO-CO
31、OLANTMOUNTED IN INTAKE MANIFOLD FIGURE 4AIR-TO-COOLANTMOUNTED REMOTELY SAE J1148 Revised MAY2004 - 8 - FIGURE 5AIR-TO-COOLANTMOUNTED REMOTELY 4.2 Air-to-Air Heat Exchangers a. Engine fan cooled (see Figure 6) b. Auxiliary blower cooled (see Figure 7) SAE J1148 Revised MAY2004 - 9 - FIGURE 6AIR-TO-AI
32、RENGINE FAN COOLEDMOUNTED REMOTELY FIGURE 7AIR-TO-AIRAUXILIARY BLOWER COOLEDMOUNTED REMOTELY SAE J1148 Revised MAY2004 - 10 - 5. Notes 5.1 Marginal Indicia The change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions have been made to t
33、he previous issue of the report. An (R) symbol to the left of the document title indicates a complete revision of the report. PREPARED BY THE SAE COOLING SYSTEMS STANDARDS COMMITTEE SAE J1148 Revised MAY2004 Rationale Updated hardware information, operating information, grammar, and formatting. Rela
34、tionship of SAE Standard to ISO Standard Not applicable. Application This SAE Recommended Practice is intended to outline basic nomenclature and terminology in common use for engine charge air coolers, related charge air cooling system components, and charge air cooling system operational performance parameters. Reference Section There are no referenced publications specified herein. Developed by the SAE Cooling Systems Standards Committee