• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.3
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• pp.291-298
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• 2010

A conventional EGR cooler, which is used in an EGR system of an automobile diesel engine, has a low heat-exchange efficiency. To maximize the heat transfer between the exhaust gas and coolant, dimples are formed on the surface of heat exchange tubes. When designing the dimpled EGR cooler, the net heat transfer areas in the conventional and dimpled tube-type EGR coolers are compared. Structural integrity evaluations are also performed by combining finite element analysis with a homogenization method. Subsequently, the process of manufacturing the dimpled tube, i.e., the formation of dimples, edge bending, center v-notch bending, compression, and plasma welding, is established and carried out. Thus, the dimpled EGR cooler is developed, and its performance is verified.

• Transactions of the Korean Society of Automotive Engineers
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• v.11 no.6
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• pp.44-50
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• 2003

Cooled EGR is an effective method for the reduction of NOx from a diesel engine and an EGR Cooler is the key component of the system. High efficiency, low pressure loss and compactness are required for the EGR Cooler. To meet these requirements, new geometric tube must be developed. In this paper, a full size EGR cooler test bench has been developed to validate the CFD flow and heat transfer models. Fluid temperature and pressure drop measurements are provided. fillet temperature is $200^{\circ}C$ and $300^{\circ}C$, and flow rates vary from 0.008 kg/sec to 0.019 kg/sec. The gas flow and heat transfer in a single tube cooler have been studied using computational fluid dynamics(CFD). Analysis has been carried out in a single tube with a plain tube and six spirally enhanced tubes of varying pitch to depth ratio(p/e).

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.5
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• pp.112-117
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• 2007

With the Euro-4 regulation coming into effect, the domestic car industry is forced to look for newer options to reduce NOX in the exhaust. EGR(Exhaust Gas Recirculation) Cooler is an effective method for the reduction of NOX form a diesel engine. High efficiency, low pressure loss and compactness are desirable features of an EGR Cooler. The cooling performance of EGR depends on the shape of tubes and the location of the entrance and exit. This paper reports the computational work conducted to estimate the performance of EGR cooler with three different cross section tubes and a triangular spiral tube. Three dimensional computation results show that the triangular tube is more effective than circular and rectangular tube. The most effective geometry is a triangular spiral tube with offset inlet and outlet locations.

• Transactions of the Korean Society of Automotive Engineers
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• v.19 no.1
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• pp.101-108
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• 2011

Understanding the exhaust gas recirculation (EGR) cooler fouling in diesel engine is important factor in the durability characteristic of a EGR system. We develope a test rig and PM feeder using carbon black to examine the effect of fouling on EGR cooler devices those were consisted of flat and shell & tube type. The EGR cooler fouling process is a complex interaction involving heat exchanger shape, boundary condition, constitutes, chemistry and operating mode. As the soot deposited to EGR cooler, these formed a thin deposit layer that was less heat exchange than the fresh status of tube enclosing the exhaust gas, resulting in lower heat exchange effectiveness in both type coolers. But these deposits caused different results in pressure drop, it is increased in flat type, but decreased in Shell & tube type of EGR cooler. A cause was estimated from a change of the flow structure and a decrease of contact area as the EGR cooler fouling.

• Transactions of the Korean Society of Automotive Engineers
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• v.19 no.1
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• pp.89-94
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• 2011

The EGR system is one of important components in diesel engine. The regulation on NOx emission has been tightened up. Therefore, it is a significant issue to develop and commercialize the high efficient EGR cooler system that reduces NOx emission in DI diesel engine. Key performance factor of the EGR cooler system is how to properly design both wavy cooling fins and gas tubes. This paper proposes a high efficient EGR cooler that has been upgraded with both the optimized wavy cooling fins and the improved shape of structure. The evaluation of the heat exchange efficiency, outlet temperature, and gas pressure drop of the EGR cooler is performed with the prototype of the proposed EGR cooler. The result shows a good solution and will be implemented to the model of a clean diesel engine being developed for both domestic and overseas market.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.32 no.10
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• pp.769-775
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• 2008

In this study, the investigations on the dimpled type Exhaust Gas Recirculation (EGR) cooler have been focused on the high heat exchanger efficiency. To overcome low heat exchanger efficiency of general EGR cooler, the dimpled type EGR cooler was developed. It was ensured the improvement of the performance of the dimpled type EGR cooler related to the heat exchange based on a series of the experiment. These results were caused by the increase of thermal surface area in accordance with the dimple's one. The estimation model of the heat exchanger efficiency using the Effectiveness-NTU method was also developed in order to verify the validity of experimental result. Also, the program for the estimation of the heat exchanger efficiency on the EGR cooler with regard to the dimpled tube shape was developed. Resultantly, it was confirmed that the dimpled type EGR cooler could be served better performance than the conventional one in view of the heat exchanger efficiency.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.3
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• pp.183-188
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• 2007

Recently, diesel engine has been frequently applied to RV, SUV and light duty truck due to the good fuel economy and high thermal efficiency. $NO_x$ and PM, environmental pollution materials are basically produced in diesel combustion process. The most important target in diesel engine research is the development of system to reduce the emissions of $NO_x$ and PM. Cooled EGR system is an effective method for the reduction of $NO_x$ emission and PM emission from a diesel engine and EGR cooler is the key component of the system. This study investigates the EGR cooler of oval gas tubes compared with the EGR cooler of shell & tubes to verify the heat exchange efficiency of cooler by means of engine dynamometer tests, rig performance tests and numerical analyses.

• Transactions of the Korean Society of Automotive Engineers
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• v.20 no.4
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• pp.25-32
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• 2012

Cold start driving cycles exhibit an increases in friction losses due to the low temperatures of metal components and media compared to the normal operating engine conditions. These friction losses are adversely affected to fuel economy. Therefore, in recent years, various techniques for the improvement of fuel economy at cold start driving cycles have been introduced. The main techniques are the upward control of coolant temperature and the fast warm-up techniques. In particular, the fast warm-up techniques are implemented with the coolant flow-controlled water pump and the WHRS (waste heat recovery system). This paper deals with an effect of fast ATF (automatic transmission fluid) warm-up on fuel economy using a recovery system of EGR gas waste heat in a diesel engine. On a conventional diesel engine, two ATF coolers have been connected in series, i.e., an air-cooled ATF cooler is placed in front of the condenser of air conditioning system and a water-cooled one is embedded into the radiator header. However, the new system consists of only a water-cooled heat exchanger that has been changed into the integrated structure with an EGR cooler to have the engine coolant directly from the EGR cooler. The ATF cooler becomes the ATF warmer and cooler, i.e., it plays a role of an ATF warmer if the temperature of ATF is lower than that of coolant, and plays a role of an ATF cooler otherwise. Chassis dynamometer experiments demonstrated the fuel economy improvement of over 2.5% with rapid increase in the ATF temperature.

• Proceedings of the Korean Society of Marine Engineers Conference
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• 2002.05a
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• pp.75-82
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• 2002

The effects of intake mixture temperature on performance and exhaust emissions under four kinds of engine loads were experimentally investigated by using a four-cycle four-cylinder, swirl chamber type, water-cooled diesel engine with scrubber EGR system operating at three kinds of engine speeds. The purpose of this study is to develop the scrubber exhaust gas recirculation(EGR) control system for reducing $NO_x$ and soot emissions simultaneously in diesel engines. The EGR system is used to reduce NOx emissions. And a novel diesel soot-removal device with a cylinder-type scrubber which has five water injection nozzles is specially designed and manufactured to reduce soot contents in the recirculated exhaust gas to the intake system of the engine. The influences of cooled EGR and water injection, however, would be included within those of scrubber EGR system. In order to study the effect of intake mixture temperature, a intake mixture heating device which has five heating coils is made of a steel drum. It is found that the specific fuel consumption rate is considerably elevated by the increase of intake mixture temperature, and that NOx emissions are markedly decreased as EGR rates are increased and intake mixture temperature is dropped, while soot emissions are increased with increasing EGR rates and intake mixture temperature.

• Transactions of the Korean Society of Automotive Engineers
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• v.17 no.2
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• pp.159-164
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• 2009

Cooled EGR system is an effective method for the reduction of $NO_x$ emission and PM emission from a diesel engine. Proper choice of wavy cooling fins and gas tubes is a key factor of cooled EGR system. As a part of solutions for energy crisis and environmental problems, hybrid vehicles mounted with diesel engines are under development globally. This study investigates the cooled EGR systems for hybrid diesel engine with the specifications of both optimized wavy cooling fins and improved shape of structure to verify the heat exchange efficiency, outlet temperature and gas pressure drop of cooler by means of numerical analyses and rig performance tests. The output of this study will be applied to a 2.0L hybrid diesel engine which is being developed for domestic and overseas market.