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> Air/Air Systems
>
Liquid/Air Systems
> Miscellaneous
Shown below are examples of just a few
of the wide variety of intercooler designs
available from Bell Intercoolers. Each
of these units was designed specifically
for one of our customers and designed
specifically for their application.
At Bell Intercoolers we can offer this
level of custom design and manufacturing
at prices you would expect to pay for
an off-the-shelf unit. Our Design Services
team of engineers is here to assist
you with any intercooling project, at
no cost. That is part of our commitment
at Bell Intercoolers. We want to be
sure you have the best intercooler,
regardless of complexity or requirements.
Whether you are designing a single intercooler
for your next project or you need to
spec a model for your next production
run we can help. Call or email us today
to get a price quote on your next intercooler.
Please note, these examples are presented
to provide a view into the wide variety
intercooler shapes, configurations and
type that are available to you. Please
note, the power ratings listed are for
these specific models only. Intercooler
size and placement will determine the
power rating, performance and efficiency
of your specific intercooler design.
Contact our Design Services team with
any questions regarding the correct
sizing and placement of your intercooler
system.
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Twin
Inlet/Twin Outlet
An example of a popular solution to twin turbo intercooling,
the twin inlet/twin outlet design allows for a single
intercooler assembly to be used, as opposed to two,
separate intercooler assemblies. This can simplify
installation and allow for the location of the intercooler
in the primary air stream opening(s), ahead of the
radiator, providing optimal exposure to cooling
air. The model shown here utilizes curved tanks
(end caps), instead of the standard angled design.
Core Dimensions: 4 x 24 x 12
Horsepower Rating: 450 hp (max) (for core shown) |
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Single
Inlet/Single Outlet
This is an example of the most common intercooler
assembly design, the single inlet/single outlet
system. Designed for use with single turbocharger
or supercharger systems, this intercooler can dramatically
vary in size and shape to meet any horsepower, space
and mounting requirements. Size of the intercooler
will core can have a dramatic effect on the efficiency
and performance of the forced induction system.
As with any Air/Air intercooler, optimal placement
in the ambient airflow path is a key factor to a
successful design.
Core Dimensions: 3 x 30 x 12
Horsepower Rating: 550 hp (max) (for core shown) |
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Twin
Single Inlet/Single Outlet
Many twin turbocharger applications will require
the use to two, separate intercooler assemblies,
as opposed to a large, shared assembly. In this
case, the twin intercoolers are designed for the
twin turbocharged Ferrari F40. This may be a requirement
do to limited space in the vehicle primary cooling
air opening(s) or may be due to limitations in space
required to properly route the turbo/intercooler/throttle
tubing system. Regardless of the reason, the use
of two intercoolers is can be as, or more efficient
than a single intercooler if the assemblies are
properly designed and are located with sufficient
ambient cooling airflow.
Core Dimensions: x x x x x (x2)
Horsepower Rating: xxx hp (max) (for core shown) |
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Twin
Single Inlet/Single Outlet
Another example of the twin intercooler design,
although in this case the design is actually used
as an aircraft cabin air/ventilation system heat
exchanger, rather than an engine intercooler. These
two, small heat exchangers cool the pressurized
air for the cabin.
Core Dimensions: 3 x 8 x 6 (x2)
Horsepower Rating: 230 hp (max) (for core shown) |
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Single
Inlet/Single Outlet
Another version of the Single Inlet/Single Outlet
design, but with a variation on the tank configurations.
This unit, built for a turbocharged Porsche features
machined inlet and outlet fittings to allow fitting
to the OEM intercooler plumbing connections. The
design also incorporates OEM specific mounting bosses
to allow easy installation.
Core Dimensions: x x x x x
Horsepower Rating: xxx hp (max) (for core shown) |
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Single
Inlet/Single Outlet
When compared to an Air/Air intercooler, a Liquid/Air
system can handle more heat transfer and, therefore,
more power for a given core size. This is due to
the use of liquid as the charge cooling medium,
which provides better heat transfer properties than
air. The trade off for this increase in cooling
capacity is the need for additional components not
required with an Air/Air system (coolant reservoir,
pump and heat exchanger). Liquid/Air systems are
well suited for applications where there may not
be direct access to a cooling air stream, for instance
in a rear or mid engine vehicle. Liquid/Air systems
are also able to increase intercooler efficiencies
beyond 100% through the use of chilled or ice water
as a cooling medium.
Core Dimensions: 12 x 6 x 6
Horsepower Rating: 400 hp (max) (for core shown) |
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Single
Inlet/Single Outlet - 2000+ HP
There are applications in which a Liquid/Air system
far outperforms an Air/Air system. Two such case
are drag racing and tractor pulling, both competition
environments where maximum power is applied for
short durations, under 30 seconds. The unit shown
is designed to accommodate power ranges from 2000-5000
horsepower. Large coolant reservoirs and pumps are
used in these applications, with the coolant being
ice water. This allows for efficiencies in the range
of 105 - 115 %, much higher than available with
an Air/Air system. Boost pressures for the diesel
based tractor pullers can exceed 200 psi.
Core Dimensions: 18 x 10 x 8 (x2)
Horsepower Rating: 3000 hp (max) (for core shown) |
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Single
Inlet/Single Outlet - Industrial Stationary System
Other applications for Liquid/Air systems include
stationary industrial gas cooling and separator
systems. When the size and weight of the system
is not a limiting factor the assembly can be designed
to accommodate very high pressures (100 - 200 psi)
and/or very high efficiencies (100 - 120%) over
extended periods through the use of very low temperature
coolants and high volume coolant transfer.
Core Dimensions: X x X x X
Horsepower Rating: N/A (for core shown) |
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