The Development of an Aftermarket Intercooler Spray for Turbocharged Vehicles Using Ethylene Glycol and Hyaluronic Acid M. I. N. Ma’arof1, Girma T. Chala2, Sathurshan Suresh1, Shaheerthana Suresh1 Email: [email protected]

1INTI International University, Nilai, Malaysia 2International College of Engineering and Management, Muscat, Oman

Introduction Stage 3: Fabricating the Rig and Testing In the automotive industry, turbochargers are used in the internal combustion engine for forced induction. Turbochargers are effectively consisting of two impellers which are attached to the same shaft spinning around together. One of these impellers called turbine sits on the exhaust steam from the cylinder, whilst, the second impeller – known as compressor is located inside the car’s intake. As the cylinders blow out hot gas passes the first impeller rotates, the motion rotates the second impeller as well. Hence, the second impeller (compressor) forces air into the engine’s combustion chamber, therefore, it is called as forced induction.. Spray cooling is the process of spraying small droplets on heated surfaces in order to increase the effective heat transfer to surrounding when cooling media changes phase. One of the method in overcoming the efficiency of the intercooler with respect to air temperature is the utilization of spray cooling. Spray cooling is used in areas such as: cooling of hot surfaces in hot strip mill, fire protection, cooling hot gases, cooling high performance electronic devices and dermatological operations in the medical field. Problem Statements Figure 2. The Test Rig The strength of force induction system is unfortunately its own demise as well. As noted by the ideal gas law, air pressure is directly proportional to its temperature. Henceforth, force induction results in the increment of air temperature. It should be noted that air at higher temperature is in fact less dense, hence, does not provide the best form of combustion. On top of this the Results temperature in the engine bay and also the temperature outdoor affects the temperature of the air that enters the air intake. Therefore, the hot air coming from the compressor is passed through an intercooler. With respect the intercooler, at best, these heat (from various sources) is transferred to Table 2. Experimental Data for Ethylene Glycol Table 3. Experimental Data for Hyaluronic acid the surrounding by convection with the help of intercooler fins, so that the air leaving the intercooler is colder and denser, in other words it has more oxygen molecules per unit volume for thorough combustion. Objectives

The aim of this study was to overcome the aforementioned issues by promoting heat exchange through spray cooling where an automatic spraying mechanism spraying certain liquid with a given concentration at a given pressure generated in order to promote evaporative cooling.

Methods

The system is an automatic plug-and-play turbo intercooler cooling system powered by Arduino Uno microcontroller which receives signal from the temperature and humidity sensor and sprays water or any other liquid with automatically or manually depending on the user’s need. This system was designed to aid the heat exchange process at the intercooler by minimizing the temperature at outlet of the intercooler through spraying, where the hot air flowing through the intercooler from the turbocharger will be more cooled before it reaches the intake of the engine.

Stage 1: Identifying the list of critical parameters involved Table 1. Variables involved in the Experiment Conclusions Controlled Variables Independent Variables Dependent Variable

Inlet Temperature Type of Spray Medium Outlet Temperature This study designed, tested, and optimized aftermarket intercooler cooling spray unit. The

Ambient Temperature Concentration independent variables, type and concentration of spray medium, and the pressure that should be generated to have an optimized prototype with good efficiency was found and utilized for usage. Ambient Humidity Pump Pressure Through this study it was found that, the most efficient spray medium for spray cooling process Speed of Air was 20% Hyaluronic acid with water, followed by 20% Ethylene glycol solution. The efficiency Nozzle Type of the normal Intercooler without the spray cooling unit was improved from 56.52% to 90.72% and also the minimum possible efficiency with the spray cooling unit was 32.38% more Nozzle Diameter efficient, stating the cooling process through spray cooling unit had a vast improvement on the Pipe Diameter efficiency of the intercooling system. Through the study, it was decided that any of the chosen Time of Spray spray medium with the lowest concentration could be used in the Optimized unit as they all needed at most 23psi using 3 pumps, which was replaced by a new single pump in the optimized unit which was readily available in the market. However it all comes down to the basis of cost and efficiency as the chemical compounds need to be bought but medium such as tap water is readily available. Stage 2: Designing and planning the Layout of the System

References

• McKeon C. E., Turney R. E., 1979, Ford Tw- 30 Tractor With Air-To-Air Intercooled Engine, Sae Papers, 790888 • Andersson J., Bengtsson A., Eriksson S., 1984, The Turbocharged and Intercooled 2.3 Liter Engine for the Volvo 760, Sae Papers, 840253 • Thomson G. A., Pratley D. J., Owen D. A., 1987, Intercooling and Regenerating the Modern Marine Gas Turbine Propulsion System, Sae Papers, 871379 • Harry C., 2006, Comparing the Performance and Limitations of a Downsized Formula SAE Engine in Normally Aspirated, Supercharged and Turbocharged Modes. • Watson H. C., Mehrani P., 2010 The Performance and Emissions of the Turbocharged Figure 1. Schematic Diagram of the System Always Lean Burn Spark Ignition (TC-ALSI) Engine, SAE 2010 World Congress & Exhibition, ABD

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