Technical Encyclopedia —— Characteristics and Modification of Intercooler

Cooling can control knocking, reduce piston heat load, improve power, increase torque platform, reduce fuel consumption and reduce nitrogen and oxygen emissions.

Many turbo players will change to intermediate cooling.

Some people say that they don't think the power is better after modification, and some people say that the turbine delay is greater after modification. Why?

With these questions, we enter the text. ......

The reason for these problems is probably that the brand model of intercooler you choose is not suitable for your use scenario. Which one should I choose among different brands?

The key points of choosing intercooler are: cooling effect, volume and shape.

List all the brands that can be bought first, and it is best to find the loading map and some detailed pictures. See what is the difference between different brands of intercooling.

If you are going to change a big turbine, choose a bigger intercooler.

If you still want to use the original turbine and only slightly increase the turbine pressure, it is not recommended to use an intercooler with a large volume.

Color intermediate cooling is not recommended.

If it is cold in water, it is necessary to strengthen the heat dissipation of coolant.

Intermediate cooling is used for cooling.

The position of the temperature sensor of each vehicle is different, so when we talk about the intake temperature ITA, we should distinguish where the temperature is.

Usually cars have two or three air temperature sensors (identified as ITA in the data stream? 1、ITA？ 2、ITA？ 3) Some are filtered by air, some are intercooled, and some are on the intake manifold.

The air filtered sensor is closest to the ambient temperature. In summer, the data may be higher than the ambient temperature 10- 15℃ during normal driving, and 20-40℃ higher than the ambient temperature during parking or traffic jam.

When driving in winter, the difference between the data and the ambient temperature is generally around 5℃.

The first sensor after intercooling is usually set between intercooling and throttle. For individual players, if you want to judge the effect of an intercooler, the simple method is to compare the data difference between this sensor and the sensor after air filtration.

The smaller the difference, the better the cooling effect of intercooling on pressurized fresh air.

What needs to be clearly pointed out here is that it is impossible to explain the problem only by looking at the "inlet temperature" on the original instrument or the OBD instrument connected later. We must compare the data of the two sensors before and after intercooling to know the effect of intercooling.

If you are just an individual player, without data stream recording equipment or adventure computer equipment, you can see a lot of real-time data by spending tens of dollars on a WIFI or Bluetooth OBD device and connecting it to your mobile phone. The recommended mobile phone software is Torque.

Since intercooling is used to cool down, we should try our best to cool down.

Usually, the length and width of the original intercooler are the same as those of the original intercooler, but it will be thicker. Some will be designed in two thicknesses. This design is to make full use of the space near the intercooler and increase the overall size of the intercooler as much as possible.

Increasing the thickness means increasing the time for cold air in the external environment to flow through the intercooler, increasing the cooling time for hot air in the internal high pressure and increasing the cooling effect.

Silver has good heat dissipation.

Some intercoolers will spray colors such as black and blue on the surface of aluminum or stainless steel, or spray their own brand LOGO. Adding barriers will reduce the heat exchange efficiency. These spray paints are harmful to cooling.

The louder the volume, the greater the delay.

Some people say that the turbine delay will increase after changing the medium and large cooling, while others say that it will not. For this problem, we can look at the internal volume of Coolpad. The method of measuring the volume is to inject water into the intercooling pipeline, and the volume can be known by looking at the injected water.

The torque of turbine engine is mainly provided by intake pressure. Under the condition that the target pressure of the turbine itself and the ECU program are unchanged, the supercharging action and charging amount of the turbine are basically unchanged.

Therefore, the pipeline volume between the turbine and the valve largely determines the turbine delay. The turbine blows the same volume of air into the pipeline, and the larger the volume, the more difficult it is to reach high pressure.

The design of fins is very important.

The so-called "large, medium and large cooling" can be that the intercooler has a larger shape or a larger volume.

Some large, medium and large refrigeration capacity is slightly larger than the original factory, and the shape is much larger than the original factory. Some large, medium and cold coils are also much larger than the original factory. Be sure to carefully screen when choosing intermediate cooling.

When the volume is close, the more fins there are, the more heat transfer is sufficient, but the larger the external size is. Many factors, such as the number of fins, effective area, gap and thermal conductivity of materials, will affect heat transfer. It is difficult to directly judge the design of intercooler fin.

Temperature distribution is also important.

Under the same intercooling volume, the shape of the internal air channel and the chambers at both ends will also affect the cooling effect and turbine delay.

If the design is not good, the pressurized gas may not completely flow through the whole intercooler in a certain state (starting pressure or depressurization) or within a certain pressure range, and only part of the pipeline is used. This will lead to poor cooling effect.

For this problem, the manufacturer's solution is to establish a fluid model and analyze the airflow path and heat transfer efficiency.

As a refit shop or individual player in the aftermarket, you can know the general situation by measuring the temperature distribution on the intercooler. Simple can use infrared temperature measuring gun, more intuitive can use thermal imager.

Ideally, the temperature at the beginning of each pipeline should be as consistent as possible, and the temperature difference between the beginning and the end should be as large as possible.

Pay attention to one problem when measuring: let the car be hit by the wind when testing.

During the driving process, the smashed external cold air completely flows through the front. When the car is parked in the same place, the intercooling temperature will be greatly affected by high-temperature components such as condenser, water tank, steering oil pipe and exhaust pipe.

In order to measure as accurately as possible, the vehicle can be driven after fixing the thermal camera before intercooling, or a suitable blower can be placed in front of the vehicle to simulate the driving state.

Don't be too prominent in appearance.

From the cooling point of view, try to choose a thicker intercooler.

But the thick intercooler also has a problem, that is, its front end will be more prominent than the original intercooler. If it is a street car, it is not recommended that the front end of the intercooler exceed the anti-collision beam. The intercooler is mostly located under the anti-collision beam and at the lowest position of the front of the car.

If there is a collision, the intercooler is easy to be damaged and broken. When it breaks, the engine will suck air from the crack. It will also inhale some pollutants such as dust, which may lead to serious wear and cylinder pulling.

If the pressure is not very high, try to use rubber hoses at both ends of the intercooler.

If metal pipe is selected, slight collision may lead to intercooling or pipe joint rupture. Therefore, rubber hoses should be used as much as possible to minimize the possibility and severity of intercooling rupture.

How to modify water cooling?

The advantages of underwater cooling are mainly shortening the intake pipe and reducing the volume of the intake pipe, which can make the turbine delay smaller. Its disadvantage is mainly that the cooling effect of intake air is not good.

Cooling air generally collides with the ambient atmosphere, and its temperature is the ambient air temperature. Even in summer, it is about 50-60℃ at most.

It is the coolant that cools the water, and the coolant blows to the front of the car to cool down. This principle leads to the temperature of coolant must be higher than the ambient temperature, and its cooling effect on intercooling is not as good as that of wind hitting cold directly.

Moreover, some models are also equipped with independent water cooling pipes when they are localized. In some cases, its effect on the pressurized gas is not necessarily cooling.

When the design water of the main engine plant is cold, its position, shape and size may be relatively compact. Therefore, for those models whose original factory is water-cooled, there is not much room for modification of the intercooler, and the size of the intercooler may not increase any more.

If your car is cold in the water, it is a reasonable way to restore the independent pipeline and strengthen the heat dissipation of the coolant. Thickening the water tank, increasing the air impact area of the front of the car and adjusting the starting conditions of the electronic fan can also reduce the intake temperature after intercooling.

More?

#? Open the bible? Volume 35? -? It's not easy to drive fast? |? Kule racing academy

I drive a Mazda 3 with a 2.5T four-wheel drive. Why is there a traffic jam?

For people who want to buy a Porsche Taycan? Turbo man

Lady? Z, beauty cannot be square

Sign today

This article comes from car home, the author of the car manufacturer, and does not represent car home's position.