Intercooler, what is it? Installation and operation. Intercooler for Nissan and Mercedes

All cars are a set of parts, mechanisms, which, when properly installed, work smoothly and stably. For example, there is a radiator between the compressor and the intake manifold , which is called an intercooler. What is it, knows the one who is engaged in repair of the car independently. Why this element is needed, let's try to figure it out.

Heat exchange must be done correctly

The main purpose of the intercooler is to extract heat from the air flow, which during the compression process in the compressor heats up. That is, the better this heat is removed, the better the heat exchanger works. For an intercooled turbo system to be properly assembled, it is very important to use the useful properties of the described device to the maximum. In addition, a competent installation of the intercooler will be a guarantee that during the operation of the car there will be no problems. Creating this unit, you need to consider several criteria, the main of which are as follows:

• Maximum heat dissipation;
• Minimum pressure losses of the turbocharger;
• Increase in inertia of the air flow.

How does the air flow cooler work?

To ensure that the heat from the system is correctly and timely, the plates and shells in the heat exchanger meet. They also make up the area of the heat exchanger, on which the intercooler's efficiency depends. True, do not think that if the area is twice as large, then the efficiency factor of the unit will double. But if you make the heat exchanger area more by ten percent, then exactly the same will be higher efficiency. To understand how an intercooler works, what kind of device it is, it is important to know the features of its device.

So, through it passes the air, and if it is difficult for him to do, then a lot of heat will be lost. On the other hand, it is important to avoid large losses of boost pressure. To compensate for the hindered flow of air through our device, care must be taken to ensure that the internal passage section is large: this will hold the air in the intercooler and reduce the airflow. Accordingly, the pressure will be lost at an acceptable level. Thus, when choosing this unit, it is worthwhile to take care of low internal pressure losses.

The 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 filled with air completely, and before the pressure in the intake manifold arises. That volume is one of the parameters that should be optimized when creating a competent intermediate cooling system. This indicator can be calculated as follows:

• The internal volume of the intercooler is divided by the volume of the air flow;
• Multiply the sum by two (this number is taken approximately: that is, it turns out that the air flow on the way to acceleration is doubled).

When designing an intercooler, it is important to take into account the maximum capabilities of the system to divert heat from the charge air, so as not to reduce the boost pressure and not to interfere with the air pressure to build up.

Power and efficiency - the main indicators

The cooling system in the car must work together. To do this, you need to know how much power is lost when the intercooler pressure is lost. We correlate the absolute pressure with and without the instrument. It is also worth remembering that it is not necessary to restore the lost power, since in this case the pressure in the exhaust manifold becomes higher, which will lead to an increase in the reverse of the exhaust gases to the combustion chamber and an increase in the temperature in it.

To calculate the efficiency of the intercooler, one must compare the rise in air temperature that causes the turbine to work and the temperature drop that the cooler causes. 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 is much easier to service such a device. The intercooler type "air-to-water" shows good efficiency at low speed, while it has a complex design and costs more. But at the same time, the intercooler's "air-to-air" connection is more complicated, the unit needs more space, so this device does not fit for every car.

Balanced intercooler: what is it?

To ensure that the cooler is optimally balanced, it is important that it meets certain requirements:

1. The internal cross-section must be good. It is the cross section of the heat exchanger core that affects how much pressure will be lost when air passes. Calculate the correct cross-section is almost impossible, but you can at least foresee what it should be. For example, it is possible to use turbulators that do not allow air to press against the walls of the unit and transmit heat energy to it. From the density of turbulators, both improved heat transfer and low flow losses depend.

2. A large role is played by the size of the nucleus. The shorter the channels through which air passes, the lower the cross section will be.

3. The frontal area, reflecting the amount of ambient air, helps to cool the inflatable air. Accordingly, the more ambient air by mass, the higher the cooling capacity of the intercooler.

4. Streamline the shape of the nucleus. This parameter determines the free movement of air through the device, while the lighter the air, the greater its volume will pass through the intercooler (which is directly reflected in the cooling effect, there is 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, it is possible to achieve an increase in 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. Influence on the stability of the intercooler performance such indicators as bends and section transitions, as well as the presence of nozzles. By the way, any bending in the system is a potential loss of flow. And if the pipes are not connected tightly, 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, because 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 the heat under the hood can lead to serious problems. Therefore, you need to isolate this unit and carefully place all the pipes. Typically, an air 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).

Main operational issues

One of the serious problems is the oil in the intercooler. Such situations can be caused by the fact that the turbine sleeves wear out, which, by the way, can be repaired. In addition, a similar problem can arise due to the fact that at high engine speeds, even in a new turbine, the engine can pass oil into the intake duct. During the operation of the oil in the intercooler can get very much, but this problem is easily solved - you just need to clean the unit.

Each car - its intercooler

Today it is very common to create a cooler for a particular engine. For example, the intercooler "Nissan" for each model of this brand fits different. Therefore, when choosing a cooler, it is necessary to take into account a lot of details: the frontal area of the heat exchanger and its thickness, the direction of the flow, the internal passage section and many other things. At the same time, the new Nissan cars are equipped with "clean" engines, which are not equipped with an intercooler or a turbo.

Intercooler "Mercedes" is a heat exchanger, which reduces the temperature of air passing through it. In most models of this brand, the heat exchanger is located in the front of the engine compartment and is blown naturally during the movement of the vehicle.

Why do I need an intercooler?

What is it, many will ask - the next navorot in the car or really necessary thing? And is it worth it to install? Most experts agree that for engines with a turbocharger, it is necessary. In addition, today you can choose the most different configurations of this device, which, however, in no way affect the efficiency of its operation. That is, any aesthetic delights, say, some original form or design of intercooler receivers, the role is more decorative than functional.

Specialists also advise choosing aggregates made of thin sheet metal, as it will contribute to maximum heat preservation. The choice of type of intercooler follows, depending on what are the specific features of the existing turbine.