Abstract: A heat exchanger having: an inlet header having inlet tubes stacked against the first side of the heat exchanger; an outlet header having outlet tubes stacked against the second side of the heat exchanger, first inlet and outlet tubes have a same length as each other, second inlet and outlet tubes have the same length as each other and are longer than the first inlet and outlet tubes, and third inlet and outlet tubes have a same length as each other and are longer than the second inlet and outlet tubes; core channels extend from the first side to the second side of the heat exchanger, the core channels connect the inlet tubes to the outlet tubes such that: the first inlet tube and third outlet tube are connected; the second inlet tube and second outlet tube are connected; and the third inlet tube and first outlet tube are connected.

Abstract: A method for controlling an internal combustion engine cooling system includes pumping coolant in an engine cooling loop with a coolant pump, pumping the coolant in an air cooler loop that includes a liquid-to-liquid heat exchanger with the coolant pump, and receiving a condition signal indicative of at least one condition associated with the internal combustion engine. The method also includes, based on the condition signal, adjusting a position of a flow control valve to modify a flow of coolant to the liquid-to-liquid heat exchanger.

Abstract: Systems and techniques for identifying abnormal exhaust valve performance of an internal combustion engine may include receiving exhaust passage temperature signals from a plurality of exhaust passage temperature sensors, each exhaust passage being fluidly connected to one or more exhaust valves of the internal combustion engine, the exhaust passage temperature signals being indicative of respective exhaust passage temperatures. The method may further include comparing one or more of the exhaust passage temperatures, identifying a caution exhaust passage temperature, from one or more of the exhaust passage temperatures, that deviates from one or more of the other one or more exhaust passage temperatures, and outputting an abnormal exhaust valve performance indication based on identifying the caution exhaust passage temperature.

Abstract: Fuel leak detection systems and methods are disclosed. A method for detecting a fuel leak for a fuel system of an engine includes detecting a ramp up of the engine. The method includes measuring rail pressure of a fuel rail during the ramp up. The method also includes determining a fuel leak exists in the fuel system based on the measured rail pressure during the ramp up. In accordance with a determination that a fuel leak exists, the method includes outputting an indication of the fuel leak in the fuel system.

Abstract: Lubricant dilution detection systems and methods are disclosed. A method for detecting lubricant dilution for a lubrication system includes detecting a shutdown event of the lubrication system. The method includes measuring lubricant pressure during the shutdown event. The method further includes determining lubricant dilution based on the measured lubricant pressure during the shutdown event. In accordance with a determination that there is lubricant dilution, the method includes outputting an indication of the lubricant dilution.

Abstract: Lubricant dilution detection systems and methods are disclosed. A method for detecting lubricant dilution for a lubrication system includes detecting a shutdown event of the lubrication system. The method includes measuring lubricant pressure during the shutdown event. The method further includes determining lubricant dilution based on the measured lubricant pressure during the shutdown event. In accordance with a determination that there is lubricant dilution, the method includes outputting an indication of the lubricant dilution.

Abstract: Fuel leak detection systems and methods are disclosed. A method for detecting a fuel leak for a fuel system of an engine includes detecting a ramp up of the engine. The method includes measuring rail pressure of a fuel rail during the ramp up. The method also includes determining a fuel leak exists in the fuel system based on the measured rail pressure during the ramp up. In accordance with a determination that a fuel leak exists, the method includes outputting an indication of the fuel leak in the fuel system.

Abstract: An exhaust assembly includes an exhaust tube and a coolant passage. The exhaust tube is oriented about an axis and an exhaust gas is configured to flow through the exhaust tube in a direction away from an end of the exhaust tube. The coolant passage is oriented about the axis radially outward of the exhaust tube, the coolant passage having an inner shell and an outer shell. The end of the exhaust tube includes one or more holes permitting exhaust gas to flow around the end of the exhaust tube between an outer wall of the exhaust tube and the inner shell of the coolant passage to regulate a temperature of the inner shell of the coolant passage.

Abstract: An exhaust assembly includes an exhaust tube and a coolant passage. The exhaust tube is oriented about an axis and an exhaust gas is configured to flow through the exhaust tube in a direction away from an end of the exhaust tube. The coolant passage is oriented about the axis radially outward of the exhaust tube, the coolant passage having an inner shell and an outer shell. The end of the exhaust tube includes one or more holes permitting exhaust gas to flow around the end of the exhaust tube between an outer wall of the exhaust tube and the inner shell of the coolant passage to regulate a temperature of the inner shell of the coolant passage.

Abstract: An air-to-air aftercooler (ATAAC) configured to cool compressed air from an air compressor is disclosed. The ATAAC may comprise a header at a cold end, and a plurality of core tubes. Each of the core tubes may have a first end and a second end. The ATAAC may further comprise a plurality of grommets each connecting the second end of one of the core tubes to a slot of the header. Each of the grommets may include an inner surface contacting the core tube and an outer surface contacting the slot of the header. The inner surface of the grommet may include radially-inwardly projecting regions contacting the core tube, and depressed regions providing clearance between the grommet and the core tube.

Abstract: The invention relates to an ATAAC having a header, a plurality of slots defined in the header, a plurality of core tubes coupled to the header, and a plurality of joint assemblies to couple the header with the plurality of core tubes. Each of the plurality of joint assemblies includes an adapter, a sleeve, and a nut. The adapter further includes a first section threadedly engaged with one of the plurality of slots. The adapter further includes a tapered section inserted inside a flared end portion of one of the plurality of core tubes. Furthermore, the adapter includes a second section defined between the tapered section and the first section. The sleeve disposed around the one of the plurality of core tubes, the sleeve is engaged with the flared end portion of the one of the plurality of core tubes. The nut is engaged with the sleeve and the second section of the adapter.

Abstract: A system for determining a remaining useful life of a cooling component operatively connected to a prime mover. A controller performs a thermal strain analysis that includes determining the power output of the prime mover based upon sensor signals, determining a temperature output of the prime mover based upon the power output, determining a temperature at each of the plurality of analysis locations based upon the temperature output, determining a temperature difference based upon the temperature at each respective one of the plurality of analysis locations, and determining a thermal strain based upon the temperature difference. The controller repeats the thermal strain analysis at time intervals over a period of time, determines an accumulated damage for the cooling component based upon the thermal strain from each thermal strain analysis, and determines a remaining useful life of the cooling component based upon the material characteristics and the accumulated damage.

Abstract: A work machine heat exchanger is provided. The work machine heat exchanger includes an upstream tank having an inlet and a downstream tank having an outlet. The work machine heat exchanger also includes a first core and a second core, both coupled between the upstream and the downstream tank, and including a first inner side sheet and a second inner side sheet, respectively. The first and the second inner side sheet define an air gap between the first and the second core. A pair of supporting bars are stacked between the first and the second inner side sheet, and configured to retain the first and the second inner side sheet parallel to each other. A first supporting bar of the pair of supporting bars is attached to the upstream tank and a second supporting bar of the pair of supporting bars is attached to the downstream tank.

Abstract: The invention relates to an ATAAC having a header, a plurality of slots defined in the header, a plurality of core tubes coupled to the header, and a plurality of joint assemblies to couple the header with the plurality of core tubes. Each of the plurality of joint assemblies includes an adapter, a sleeve, and a nut. The adapter further includes a first section threadedly engaged with one of the plurality of slots. The adapter further includes a tapered section inserted inside a flared end portion of one of the plurality of core tubes. Furthermore, the adapter includes a second section defined between the tapered section and the first section. The sleeve disposed around the one of the plurality of core tubes, the sleeve is engaged with the flared end portion of the one of the plurality of core tubes. The nut is engaged with the sleeve and the second section of the adapter.

Abstract: A shunt tank assembly for a cooling system is provided. The shunt tank assembly includes a vent tube, a shunt tank, and an inlet port provided on the shunt tank. The inlet port is in fluid communication with the vent tube. The shunt tank assembly also includes an insert disposed in the inlet port. The shunt tank assembly further includes a drop tube. The drop tube includes a plug portion having a first length and received within the insert. The drop tube includes a transition portion tapered with respect to the plug portion. The drop tube includes a tube portion extending from the transition portion and terminating with a chamfered end. The tube portion has a second length greater than the first length of the plug portion. The tube portion is bent such that the chamfered end is disposed below an average coolant level of the shunt tank.

Abstract: An air-to-air aftercooler (ATAAC) configured to cool compressed air from an air compressor is disclosed. The ATAAC may comprise a first header. The first header may include a plurality of slots each having a recessed groove. The ATAAC may further comprise a plurality of core tubes each including a first end inserted in a respective one of the slots of the first header. The ATAAC may further comprise a plurality of mechanical joints each connecting the first end of one of the core tubes to the first header. Each of the mechanical joints may include a C-ring inserted in the recessed groove of one of the slots, and a clamp clamping the core tube to the first header. The C-ring and the clamp may both be formed from a metallic material.

Abstract: An air-to-air aftercooler (ATAAC) configured to cool compressed air from an air compressor is disclosed. The ATAAC may comprise a header at a cold end, and a plurality of core tubes. Each of the core tubes may have a first end and a second end. The ATAAC may further comprise a plurality of grommets each connecting the second end of one of the core tubes to a slot of the header. Each of the grommets may include an inner surface contacting the core tube and an outer surface contacting the slot of the header. The inner surface of the grommet may include radially-inwardly projecting regions contacting the core tube, and depressed regions providing clearance between the grommet and the core tube.

Abstract: A system for determining a remaining useful life of a cooling component operatively connected to a prime mover. A controller performs a thermal strain analysis that includes determining the power output of the prime mover based upon sensor signals, determining a temperature output of the prime mover based upon the power output, determining a temperature at each of the plurality of analysis locations based upon the temperature output, determining a temperature difference based upon the temperature at each respective one of the plurality of analysis locations, and determining a thermal strain based upon the temperature difference. The controller repeats the thermal strain analysis at time intervals over a period of time, determines an accumulated damage for the cooling component based upon the thermal strain from each thermal strain analysis, and determines a remaining useful life of the cooling component based upon the material characteristics and the accumulated damage.

Abstract: A work machine heat exchanger is provided. The work machine heat exchanger includes an upstream tank having an inlet and a downstream tank having an outlet. The work machine heat exchanger also includes a first core and a second core, both coupled between the upstream and the downstream tank, and including a first inner side sheet and a second inner side sheet, respectively. The first and the second inner side sheet define an air gap between the first and the second core. A pair of supporting bars are stacked between the first and the second inner side sheet, and configured to retain the first and the second inner side sheet parallel to each other. A first supporting bar of the pair of supporting bars is attached to the upstream tank and a second supporting bar of the pair of supporting bars is attached to the downstream tank.