HEAT EXCHANGER
The invention relates to a heat exchanger, such as in particular an exhaust-gas evaporator, having a housing with a fluid inlet, and with a fluid outlet for a first medium, such as in particular exhaust gas, and having tubes which are arranged in the housing transversely with respect to the flow direction of the first fluid and through which a second medium can flow and which, by way of their ends at the inlet side and at the outlet side are arranged and connected in a fluid tight manner in a tube plate, wherein, to the respective tube plate, there is connected in each case one structure by means of which groups of tubes are connected to one another in such a way that an outlet of at east one tube is fluidically connected to an inlet of at least one other tube.
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The invention relates to a heat exchanger, such as in particular an exhaust gas evaporator, having a housing with a fluid inlet and a fluid outlet for a first medium, such as in particular exhaust gas, and having tubes which are arranged in the housing transversely with respect to the flow direction of the first fluid and through which a second medium can flow and the ends of which are arranged and connected in a fluidtight manner in a tube sheet at the inlet side and at the outlet side.
PRIOR ARTIn the case of motor vehicles, there is a general trend towards reducing fuel consumption. A not inconsiderable proportion of the energy content of the fuel is transferred during combustion in the internal combustion engine to the hot exhaust gas, which often leaves the vehicle unused, and therefore a not inconsiderable proportion of the energy content is not used.
To further reduce the fuel consumption of vehicles, such as commercial vehicles or passenger vehicles, it is therefore expedient to recover some of the energy content of the hot exhaust gas in order to drive the motor vehicle.
There are various methods for this energy recovery currently being tested. Thus, there are attempts to recover the energy content electrically by means of thermoelectric elements. However, this is currently restricted to low powers, and therefore only about 1 kW is achieved by this means in the case of passenger vehicles.
This recovery can be accomplished thermally, i.e. the energy of the exhaust gas is used to heat the passenger compartment or to heat the engine and/or transmission.
In a variant that has been under discussion for some time, thermal energy is indeed taken from the exhaust gas, but the energy is returned to the engine in mechanical form. The method is based on a steam power process, in which a certain suitable medium is evaporated and superheated in an evaporator and expanded in an expander or in a turbine, thus producing mechanical energy.
Evaporation of the medium is accomplished by means of heating using the hot exhaust gas. To achieve as high as possible efficiency, it is expedient here if the medium can be raised to a relatively high pressure. In the case of water as a medium, it is possible here to achieve about 40-50 bar. When using organic refrigerants, pressures of up to about 30 bar are advantageous.
In what is referred to as an evaporator, the medium to be evaporated is heated to boiling temperature in a first step, then evaporated and finally superheated. This can take place at two different locations in a vehicle. Firstly, heat can be removed from the exhaust gas to evaporate the fluid which is to be evaporated in an evaporator, which is used instead of the exhaust gas cooler or in addition thereto. Secondly, the main exhaust gas flow can also be used as a heat source in order likewise to evaporate a fluid in what is referred to as a main exhaust gas evaporator.
In the vehicle air-conditioning sector, “tray evaporators” have been disclosed by WO 2011/051163 A2, wherein ribs are soldered in between pairs of trays and a row of such pairs of trays is connected in parallel with one another. In this case, a fluid flows through the pairs of trays and another fluid flows around these in a conventional manner. The fluid flowing through then evaporates in the trays when the exhaust gas flows around the trays.
Evaporators which consist of trays and ribs have a high power density which makes it possible to provide very compact high-performance evaporators, even for vehicles. However, the disadvantage is that such evaporators are relatively expensive to produce.
DESCRIPTION OF THE INVENTION, OBJECT, SOLUTION AND ADVANTAGESIt is the object of the invention to provide a heat exchanger which is simple and yet inexpensive to produce in comparison with the prior art and which has a good power density.
This object is achieved by means of the features of claim 1.
A preferred illustrative embodiment discloses a heat exchanger, such as in particular an exhaust gas evaporator, having a housing with a fluid inlet and a fluid outlet for a first medium, such as in particular exhaust gas, and having tubes which are arranged in the housing transversely with respect to the flow direction of the first fluid and through which a second medium can flow and the ends of which are arranged and connected in a fluidtight manner in a tube sheet at the inlet side and at the outlet side, wherein the respective tube sheet has connected to it in each case a structure by means of which groups of tubes are connected to one another in such a way that an outlet of at least one tube is fluidically connected to an inlet of at least one other tube. It is particularly advantageous here if the respective outlet of one group of tubes is connected to the respective inlet of one group of tubes.
It is particularly advantageous if the structure comprises a deflection plate and a cover plate, wherein the deflection plate has openings which connect the outlets of one set of tubes to the inlets of the other set of tubes, and wherein the cover plate covers the deflection plate in a fluidtight manner. Thus, the deflection plate is connected to the tube sheet and has openings within which inlets and outlets of a predeterminable number of tubes are in fluid connection.
It is particularly advantageous if the deflection plate is placed on the respective tube sheet and is connected thereto, wherein the cover plate is placed on the respective deflection plate and connected thereto.
It is also expedient if the deflection plate is formed integrally with the respective tube sheet, wherein the cover plate is placed on the respective deflection plate and connected thereto.
In another illustrative embodiment, it is also advantageous if the deflection plate is formed integrally with the respective cover plate, wherein the deflection plate and the cover plate are placed on the respective tube sheet and connected thereto.
It is particularly advantageous if the tubes are arranged in rows, wherein the deflection plate deflects fluid between tubes in different rows. This means that the deflection plate deflects fluid from a first tube or from a group of first tubes into a second tube or into a group of second tubes, wherein the first tubes and the second tubes are preferably arranged in a different row of tubes.
It is particularly advantageous if the tubes are arranged in rows, wherein the deflection plate deflects fluid between tubes in one row. This means that the deflection plate deflects fluid from a first tube or from a group of first tubes into a second tube or into a group of second tubes, wherein the first tubes and the second tubes are preferably arranged in the same row of tubes.
It is also advantageous if the rows of tubes are arranged in segments, wherein the deflection plate deflects fluid from one segment into another segment.
It is furthermore expedient if a plurality of tubes is connected in parallel, at least in one segment.
It is also advantageous if a plurality of tubes connected in parallel is connected in series with one another, at least in one segment.
Further advantageous embodiments are described by the following description of the figures and by the dependent claims.
The invention is explained in greater detail below on the basis of at least one illustrative embodiment with reference to the drawings, in which:
The heat exchanger is connected to an inlet branch 10 to allow the second fluid to enter and to an outlet branch for discharge. Starting from the inlet, the fluid is distributed between a first number of tubes. The second fluid preferably flows in parallel through these tubes. The fluid is then deflected at the opposite ends of said tubes into a further number of different tubes. The second fluid flows through these, in turn.
To redirect the fluid, the respective tube sheet 8 has connected to it in each case a structure 12 by means of which groups of tubes 5 are connected to one another in such a way that an outlet 15 of at least one tube 5 is fluidically connected to an inlet 16 of at least one other tube 5.
In this case, the structure 12 consists of at least one deflection plate 13 and one cover plate 14, which are formed and arranged one on top of the other. Here, the cover plate 14 covers the deflection plate 13 in a fluidtight manner. The cover plate 14 is preferably welded or soldered or adhesively bonded to the cover plate 13 or even formed integrally therewith.
In this case, the deflection plate 13 has openings which connect the outlets 15 of one set of tubes 5 to the inlets 16 of the other set of tubes 5.
In this case, the tubes 5 are inserted on at least one side in the tube sheet 8, in openings 17, where the tubes are soldered or welded to the plate.
It is possible to use aluminum, but particularly preferably stainless steel, as a material for the tubes and tube sheets. It is also possible for the entire heat exchanger to consist of aluminum or stainless steel.
The deflection plate 13 has openings or channel structures, which are suitable for connecting outlets of tubes to inlets of other tubes.
As an alternative to the separate formation of tube sheet 8, deflection plate 13 and cover plate 14, it may also be advantageous if the deflection plate is designed to give a single part with the tube sheet or if the deflection plate is designed as one part with the cover plate.
In this case, the common part 18 or 19 is in each case placed on the other part 14 or 8 and connected in a fluidtight manner thereto.
In this case, the tube sheet can also be designed in such a way, being milled for example, that the tube sheet modified in this way so as to be multifunctional also additionally assumes the task of fluid distribution and acts as a combination of a tube sheet and a deflection plate. In that case, only one cover plate is mounted on and connected to the tube sheet. In a corresponding manner, part 19 can likewise act as a milled component which integrates the deflection plate and the cover plate.
It is furthermore also possible for the tube sheet and/or the deflection plate and/or the cover plate to be designed as a casting which has a corresponding structure with recessed integrated openings for distributing the medium.
The connection between the two or three elements, the tube sheet, the deflection plate and the cover plate, is advantageously accomplished by means of welding, soldering or screwing, and it is also possible to employ a combination of these connection options. For this purpose, it is also possible for the upper plate to have holes in order to connect the plates to one another by a welding method at particular points distributed over the surface.
Particularly to achieve a good soldered joint, the 3 plates can be fixed relative to one another and pressed against one another by means of riveting or tack welds, alternative means being spot welds, stamped features or screwed joints.
The deflection plate contains openings as structures in order to collect the medium from at least one tube and redistribute it to at least one other tube. The fluid to be evaporated is preferably collected in the openings from up to 4 or more tubes and is then redistributed to 4 or more tubes. During each collection and distribution of the fluid, thermal instabilities leading to nonuniform mass flow distribution in the tubes and hence to different temperatures and/or vapor contents are very largely compensated. It is thereby possible to compensate for instability effects that lead to considerable losses of performance.
This is also a significant advantage of the 2 sandwich sheets over the solution with tube bends and just one sandwich sheet. As a result, the mixing processes take place in both sheets.
As viewed in the exhaust gas flow direction 23, the distributor plates 21, 22 are divided into individual segments 24, 25, 26, 27, 28 and 29. A number of tube rows 30, 31 are in turn provided within a segment 24 to 29. In the example in
In the illustrative embodiment of
As can be seen in
Thus, the fluid flows through the first segment in alternating passes and finally emerges from the segment in zone 39 and is diverted into the second segment 28 at crossover 40 from the first segment 29.
The corresponding pass through the second segment 28 then takes place, until the fluid flows into the third segment 27 at crossover 41. The corresponding pass through the third segment 27 then takes place, until the fluid flows into the fourth segment 26 at crossover 42. The corresponding pass through the fourth segment 26 then takes place, until the fluid flows into the fifth segment 25 at crossover 43. The corresponding pass through the fifth segment 25 then takes place, until the fluid flows into the sixth segment 24 at crossover 44. The corresponding pass through the sixth segment 24 then takes place, until the fluid flows out of the sixth segment 24 at the outlet 4.
The flow through the heat exchanger in
Moreover, three tubes in each case are combined and connected in parallel to form a passage 78. In the case of passage 78, the fluid flows in and flows through the tubes to the rear deflection zone. There, the fluid is deflected from one tube row to the adjacent tube row through openings 79 in the deflection plate. The fluid then flows through the next three tubes and is deflected in the front deflection zone into three further tubes in the same row of tubes through the opening 80 in the front deflection plate. After this, the fluid flows through the tubes to the rear deflection zone. There, the fluid is again deflected from one tube row to the adjacent tube row. The fluid then flows through the next three tubes and is deflected in the front deflection zone into three further tubes in the same row of tubes. This continues until the fluid flows out of the tubes in zone 81 and is transferred into the next segment 71, 72 through crossover 82. Crossover 82 can preferably be integrated into the deflection plate or can be implemented by means of an external crossover for each tube.
The flow through segments 71, 72 takes place in the same way as in segment 70, although these segments are connected in parallel and the entry of fluid into zones 83 and 84 takes place in parallel. The fluid then flows through the tubes of segments 71 and 72 in the same way as through the tubes of segment 70, before the fluid is discharged from the segment again in zones 85 and 86 and is transferred by means of crossover 87 into segments 73 and 74, which are connected in parallel. In segments 73 and 74, the fluid flows through as in segments 71 and 72. The fluid is then collected from segments 73 and 74 and directed into the final segment 75, where it flows through segment 75 as in the inlet-side segment 70 before it is discharged from the heat exchanger.
In segments 90 and 91 and in segments 92 to 94, the fluid in each case flows through just one tube 98 parallel to one tube 99 of the other segment. Within the segment, the flow through the tubes 98 is exclusively serial. This continues as far as the center of the segment. There, the fluid flows out of the tubes 101, 102 of both segments. There, there is a mixing zone 100, allowing the fluid from the first segment 90 to mix with the fluid from the second segment 91 before it is again distributed between tubes 103, 104 of the segments.
In the case of passage 98, the fluid flows in and flows through a tube to the rear deflection zone. There, the fluid is deflected from one tube row to the adjacent tube row through an opening 105 in the deflection plate.
The fluid then flows through the next tube and is deflected in the front deflection zone into another tube in the same row of tubes through the opening 106 in the front deflection plate. After this, the fluid flows through the tubes to the rear deflection zone. There, the fluid is again deflected from one tube row to the adjacent tube row. The fluid then flows through the next tube and is deflected in the front deflection zone into another tube in the same row of tubes. This continues until the fluid flows out in the mixing zone 100. In the second zone after the mixing zone there is a corresponding flow through the tubes. The fluid is then transferred to the next segment 92, 93, 94 through crossover 107. Crossover 107 can preferably be integrated into the deflection plate or can be implemented by means of an external crossover for each tube.
The flow through segments 92, 93, 94 takes place in the same way as in segment 90, 91, although all three of these segments are connected in parallel. The fluid then flows through the tubes of segments 92 to 94, before the fluid is discharged from the segment again and is transferred to segment 95 by means of crossover 108. In segment 95, the fluid flows through as in segment 70 in
In segments 110 to 112 and in segments 113 to 115, the fluid in each case flows through just one tube 116 parallel to one tube 117, 118 of the other segment. Within the segment, the flow through the tubes 116, 117 or 118 is exclusively serial. This continues as far as the center of the segment. There, the fluid flows out of the tubes 119, 120, 121 of the three segments. There, there is a mixing zone 122, allowing the fluid from the first segment 110 to mix with the fluid from the second and third segment 111, 112 before it is again distributed between tubes 123, 124 and 125 of segments 110, 111, 112.
In the case of passage 116, the fluid flows in and flows through a tube to the rear deflection zone. There, the fluid is deflected from one tube row to the adjacent tube row through an opening in the deflection plate. The fluid then flows through the next tube and is deflected in the front deflection zone into another tube in the same row of tubes through the opening in the front deflection plate. After this, the fluid flows through the tubes to the rear deflection zone. There, the fluid is again deflected from one tube row to the adjacent tube row. The fluid then flows through the next tube and is deflected in the front deflection zone into another tube in the same row of tubes. This continues until the fluid flows out in mixing zone 122. In the second zone after the mixing zone there is a corresponding flow through the tubes. The fluid is then transferred to the next segment 113, 114, 115 through crossover 126. Crossover 126 can preferably be integrated into the deflection plate or can be implemented by means of an external crossover for each tube.
In segments 113, 114 and 115, the fluid flows through as in segments 110, 111 and 112. The fluid is then discharged from the heat exchanger.
In the figures, the configuration envisaged for the deflection plate is rectangular. It can also be round, allowing it to be installed in a round cylindrical aperture in a housing or in a muffler.
To improve performance, gas-side ribs can be mounted on the tubes, see ribs 6 in
A better bond between the ribs and the tubes, with or without solder, can be achieved through a combination of austenitic tubes and ferritic ribs. Ferrites expand less at high temperatures than austenites, with the result that the tubes are pressed against the ribs at the soldering temperature. In order to avoid the ribs coming away from the tubes during cooling, the rib can have small slots around the tubes.
The ribs have rim holes for the tubes, said holes having what are referred to as collars, which ensure the spacing between the ribs. As an alternative, it is also possible for the rib spacing to be ensured by raising spacers in the rib. The rib density here can be between 30 Ri/dm and 80 Ri/dm. The ribs can be punched and have cut and raised fins or can also have merely stamped-in structures, such as winglets, dimples or bosses, to improve performance. In particular, it is expedient to stamp structures into the ribs which guide the flow to the tubes in a controlled manner and thus enable greater heat transfer to be achieved at the
In this case, the rib thickness is 0.1 mm to 0.5 mm or preferably between 0.25 and 0.4 mm, this being advantageous for stainless steel as the rib material.
It is furthermore possible to make slots at the top and/or bottom in the plate assembly, allowing differential thermal expansion on the basis of different temperatures from the gas inlet to the gas outlet and ensuring that this does not lead to any damage.
The tube diameter of the tubes is preferably in a range of 3-20 mm, ideally in a range of 5-15 mm and preferably in a range of 6-10 mm.
Turbulence-generating structures can be introduced into the tubes, e.g. swirl generators, in order to promote heat transfer, particularly in the region where the fluid is superheated.
The tube can also be embodied as a rifled tube but in that case preferably has no external ribs. In particular, it is also possible to use tubes with very deep grooves which are of similar design to a bellows with relatively large tubing diameters in order to increase heat transfer on the gas side and, at the same time, to enable the differential thermal expansion between the tubes to be accommodated. In principle, different performance classes can be achieved if an evaporator consists of individual modules in the exhaust gas flow direction.
Claims
1. A heat exchanger, such as in particular an exhaust gas evaporator, having a housing with a fluid inlet and a fluid outlet for a first medium, such as in particular exhaust gas, and having tubes which are arranged in the housing transversely with respect to the flow direction of the first fluid and through which a second medium can flow and the ends of which are arranged and connected in a fluidtight manner in a tube sheet at the inlet side and at the outlet side, wherein the respective tube sheet has connected to it in each case a structure by means of which groups of tubes are connected to one another in such a way that an outlet of at least one tube is fluidically connected to an inlet of at least one other tube.
2. The heat exchanger as claimed in claim 1, wherein the structure comprises a deflection plate and a cover plate, wherein the deflection plate has openings which connect the outlets of one set of tubes to the inlets of the other set of tubes, and wherein the cover plate covers the deflection plate in a fluidtight manner.
3. The heat exchanger as claimed in claim 1, wherein the deflection plate is placed on the respective tube sheet and is connected thereto, wherein the cover plate is placed on the respective deflection plate and connected thereto.
4. The heat exchanger as claimed in claim 1, wherein the deflection plate is of one-piece design with the respective tube sheet, wherein the cover plate is placed on the respective deflection plate and connected thereto.
5. The heat exchanger as claimed in claim 1, wherein the deflection plate is of one-piece design with the respective cover plate, wherein the deflection plate and the cover plate are placed on the respective tube sheet and connected thereto.
6. The heat exchanger as claimed in claim 1, wherein the tubes are arranged in rows, wherein the deflection plate deflects fluid between tubes in different rows.
7. The heat exchanger as claimed in claim 1, wherein the tubes are arranged in rows, wherein the deflection plate deflects fluid between tubes in the same row.
8. The heat exchanger as claimed in claim 1, wherein the rows of tubes are arranged in segments, wherein the deflection plate deflects fluid from one segment into another segment.
9. The heat exchanger as claimed in claim 1, wherein a plurality of tubes is connected in parallel, at least in one segment.
10. The heat exchanger as claimed in claim 1, wherein a plurality of tubes connected in parallel is connected in series with one another, at least in one segment.
Type: Application
Filed: Mar 14, 2013
Publication Date: Mar 5, 2015
Applicant: BEHR GMBH & CO. KG (Stuttgart)
Inventors: Klaus Irmler (Tubingen), Peter Geskes (Ostfildern)
Application Number: 14/385,661
International Classification: F28D 7/16 (20060101);