AUTOMOBILE COOLING

The cooling system forms an intrinsic part of an automobile engine. It performs

multitude of functions such as removing excess heat from the engine,
maintaining efficient temperature and allowing engine to perform its task within a
short span of time. Ideally, automobile cooling system keeps the engine running
at an optimum temperature whatever the operating conditions are. Automobile
Cooling System consists of components or equipment installed in vehicles for
removing heat from all the moving parts so that they can work suitably without
melting, seizing and overheating. More specifically, automotive cooling system
makes use of coolant, lubricating oil and fan to maintain and regulate the
temperature of other parts of an engine. Basically, there are two types of
automobile cooling systems, which are widely used by the automobiles namely:
liquid cooling and air-cooling. Liquid cooling is one of the sought after system
used by most of the vehicles today while air-cooling is mostly used by airplanes,
motorcycles and lawn mowers. The liquid-cooling system for automobiles offers
the most positive cooling and it maintains an optimum engine temperature. While
air cooling system is feasible for only small vehicles and equipment, as air-cooled
engines do not operate at consistent temperature and command extensive use of
aluminum to disperse heat.
Working of an Automobile Cooling System

Figure illustrated above describes the functioning of cooling system of an

automobile. The key components used in a cooling system are pressure cap,
heater hoses, thermostat, heater core, reserve tank, lower hose, transmission
cooler, water pump, fan, radiator and upper house. The cooling system of a
vehicle operates or functions by directing liquid coolant via passages in the
engine block and heads. After that the liquid coolant which flows through
passages absorb the heat from an engine. Then this fluid passes through a
rubber hose to reach to the radiator. At this stage the hot liquid is cooled by air
stream entering the engine compartment via grills. Once it gets cooled, then it
goes back to engine and same process repeats again.
Components of Automobile Cooling System
Engine Cooling Fluids Water Cooling Systems Valves

A/C Parts Cooling System Gaskets Aluminum Housing

Engine Cooling Fluids:

Engine Cooling Fluids are the liquids or gases which are passed through an
internal combustion engine with the key function of regulating temperature,
stopping overheating and maintaining operating clearances. These are mainly
used for cooling the heated fluid within a thermal system or a machine.
Different types of engine cooling fluids available in the market are: A/C Gas
Engine Coolants
Hydraulic Oil Cooler
Corrosion Inhibitors
Fuel Coolers
Oil Coolers

Water Cooling Systems:

Water Cooling Systems includes various components, equipment and
accessories that are explicitly used for cooling internal combustion engines in
automobiles. An automobile engine cooling system basically need water and
other anti freeze mixtures to lower down the shooting temperature of the engine.
Water Cooling System constitute of various parts which are mentioned
below:
Coolant Hose
Radiator Parts
Radiators
Water Pumps
Air Blower
Cooling Fans
Radiator Pressure Cap
Water Pipes
Valves:
Valves are the mechanical devices, equipment or accessories, which are
inserted into the engine of a vehicle for directing and controlling the flow of a
liquid or gases within an engine. In simpler terms, valves and its different parts
monitor the entry as well as the exit of air and fuel mixture into a combustion
chamber of the engine.
Valves used in automobile engine can be classified into following
categories:

Check Valve
Exhaust Valve
Expansion Valve
Thermostat Valves
Valve Guide
Valve Parts
Valve Stem Seal
Intake Valve
Valve Covers
Valve Locks
Valve Springs
A/C Parts:
A/C Parts consists of whole ensemble of mechanical components or apparatus
used for controlling and lowering the temperature and humidity within an
enclosed space. In other words, air conditioning parts are those, which are used
for cooling and dehumidifying impure air entering the passenger compartment of
a vehicle. The air conditioning system of a vehicle makes use of refrigerant for
cooling the air and taking away the heat from the passenger compartment.
Major components of automobile air conditioning systems are:
A/C Clutch
A/C Hose
A/C Relay
A/C Valves
A/C Compressor
A/C Kits
A/C Sensors

Cooling System Gaskets:

Cooling System Gaskets are seals or packing especially designed for joining or
sealing the matched components or pipe joints in an automobile cooling system
with the main purpose of stopping the escape of a gas or liquid. Usually, cooling
system gaskets are made up of soft sheet metal, which are stamped with ridges
that enclose all leak points. Even steel, copper and asbestos can also be used
for making cooling system gaskets. The main function of cooling system gaskets
is to prevent fluid or gas leaks by offering a close or tight barrier between two
mating surfaces.
Types of cooling system gaskets are:
Exhaust Flange Gasket
Exhaust Manifold Gasket
Exhaust Gaskets
Water Pump Gasket

Aluminum Housing:
Aluminum Housing As its name suggest, aluminum housing are the protective
coverings or fully enclosed cases made of aluminum metal for containing or
supporting mechanical components of a vehicle. In other words, housings are
basically frames, brackets or boxes of varied sizes designed to hold or protect a
mechanical part of a vehicle.
Keeping Your Cool-ant
The no-hassle, drain-and-fill drill
by Phil Coconis/autoMedia.com
Draining and filling your cooling system used to be a whole lot simpler. Back
in the early days of ethylene glycol coolant/antifreeze, all you had to do was
reach for the drain petcock at the bottom of the all-metal radiator and let it
dribble into the drain pan. Then you refilled the radiator with a fresh 50/50
mix of coolant and water until you could see it at the "Full" line embossed
into the radiator tank. After tightening down the radiator cap, off you went,
with nary a need for a second look at your work. Try that procedure on a
modern passenger car or truck today and you will likely end up with an
abbreviated drive and maybe a "cooked" engine to go along with it!

New-Age Cool
Lots of changes have been made to vehicle cooling and heating systems in
recent years, such as reverse flow (bottom to top of radiator) for more even
cylinder block/head temperatures. This new system allows for a faster warm-
up, thereby reducing exhaust emissions (and complaints from passengers on
those cold winter days). New designs also promote increased engine
durability since aluminum radiator and heater cores are more efficient than
copper and allow for more compact packaging and lighter weight. Moreover,
the use of computer-aided
design, coupled with thermoplastic technology, allows engineers to boldly go
where no slide rule ever allowed them to go before.

Rear heater units are becoming commonplace in minivans and larger SUVs.
Other advancements include dual-stage thermostats for tighter temperature
control, electric fans actuated by the engine management computer (not a
dedicated fan switch circuit), complex climate controls, long-life coolants, and
so on. Many of these technologies have had a negative impact on
serviceability. Radiator drain plugs are less accessible and "air locks" inhibit
easy draining/filling of the system. These new designs may also block visual
inspection of critical components as well as access to routinely replaced
components (thermostats, hoses). With a little time, patience, and know-
how, however, these obstacles can be overcome. Here's a quick checklist of
tips for dealing with your new-age cooling system:
Drain the System

Determine if you can reach the drain plug by

hand. Bear in mind that not all drain plugs are
created equal and take different techniques to
operate correctly. For instance, some plastic GM
types turn 90 degrees, hit a stop and then must be pulled outward, so pay
attention and don't force anything! If the drain isn't easily reached, then
you'll have to remove the lower radiator hose. Fortunately, plastic radiator
tanks make this process easy, as hoses usually don't "weld" themselves to
this material. Direct the coolant into a large collector with at least a two-
gallon capacity (similar to those used in transmission service). To insure
maximum drainage, carefully remove the uppermost heater or bypass hose
(there are special tools for this so damage doesn't occur in case you're
especially heavy-handed) and loosen any "bleeder screws" provided.

Inspect for Sludge

Drain out any coolant in the reservoir (overflow bottle) as well and check
sludge deposits in the bottom. It may be necessary to remove the reservoir
to accomplish both of these tasks. Usually, half-filling the reservoir with clean
water and shaking it (rock 'n roll or bartender-style, take your pick) will
loosen the
 the sludge. Dispose of this funky mixture and the
used coolant in a responsible, legal way (usually outlined on the new coolant
container). Next, inspect the radiator cap for seal damage and sludge packed
in the spring area. Replace it if signs of either are present.

Know Your Stats

If you're changing the thermostat at this time, keep in mind that all
'stats are not created equal, either. Carefully compare your
replacement to the original one. If you're not using the exact original
replacement part, the replacement part you have should exactly
resemble the original, especially in the number of "stages" it has (one
or two—check the center area) and other features like a "jiggle valve."
This valve is essential for quicker and more thorough initial filling of the
system. Its absence will be replaced by your grief during the run-in
procedure.

Picking Coolant
Make sure that you have the correct type of coolant for your vehicle. There
are at least several distinct coolant types commonly used today, and using a
type incompatible with the coolant recommended in the owner's manual (or
on the underhood label) is inviting disaster (no exaggeration here). Whatever
the type, it should be added in a 50/50 coolant/water concentration (well, at
least some things haven't changed!). If the lower radiator hose had to be
removed for drainage, reinstall using the factory "spring-type" clamp.
Hopefully the original one didn't get distorted so you can reuse it. If you
must use a "worm-gear" type clamp, be very careful not to over-tighten (an
easy thing to do with a plastic tank) as the tank fitting can crack, which will
require replacing your radiator!

Refill Procedure
Check for refill instructions printed on any underhood
labels and follow those instructions. Otherwise, slowly
pour the coolant mixture into the radiator. As the

tank fills up, take your hand and repeatedly squeeze the lower radiator hose.
This action activates the "jiggle valve." Continue filling until coolant comes
out of the dislodged heater/bypass hose, its companion fitting or the bleeder
screw(s)—or it reaches the top of the filler neck and stays there. Reinstall the
hose, tighten the bleeder screw and install the radiator cap. Fill the reservoir
to the "Full" mark. You're now ready for the run-in procedure.

Run-in Procedure
Turn interior temperature controls to "hot," or equivalent, and start the
engine. Within about a minute, the heater/bypass hoses should be warming.
After two minutes, there should be some heat noticeable at the heater air
outlets (fan set to slowest speed). Check that the temperature gauge does
not go past the halfway point without heat present at the heater outlets. If
there is no heat present, shut the engine off and wait about ten minutes.
Turn the ignition key on and check the temperature gauge. If it's dropped
significantly, go to the radiator cap and slowly and carefully, preferably with
a padded glove, relieve any built up pressure. Only after that can you then
gingerly remove the cap. Perform the refill procedure again, but this time fill
the radiator extremely slowly, as engine damage may occur otherwise.
Continue with this run-in procedure until the heater functions normally, the
radiator cooling fans (if so equipped) operate normally and the coolant level
remains full in the radiator and reservoir. Certainly, this tedious fill procedure
isn't as easy as in the "old days," but then again, when it comes to servicing
modern vehicles, very little is.

QS Control - Manufacturer of Plastic Radiator Tanks and

Accessories

QS Control has been in the automotive radiator business for almost

three decades and provides a wide range of plastic radiator
components for the aftermarket industry. Currently, we have over
a large variety of plastic tanks and rubber gaskets available in our
catalog.

QS Control radiator products include:

• Plastic Tanks
• Rubber Gaskets
• Oil Coolers
• Headers
Accessories (Nuts, Washers, Plugs, Brass Fittings, and Filler Necks)
QS Control can open new tooling for any plastic tank orders with 300+
sets. We continue to expand our product offerings by investing in the
development of new models to meet the needs of our clients.
Click here to view our Online Radiator Catalog
A radiator arrangement is disclosed which avoids problems of known
radiator arrangements where it is customary to manufacturer a radiator and
fan unit and to subsequently connect an electric control device with the heat
exchanger and the fan drive and to equip the unit with temperature sensors
during assembly on a vehicle. It is disclosed to fasten the control device and
the temperature sensor directly to the structural unit formed by the heat
exchanger and the fan arrangement. As a result of this construction, the
whole radiator arrangement can still be adjusted in the manufacturing plant
prior to movement of same to a location where the radiator/fan unit is
assembled on a further vehicle part.
What is claimed is:

1. A radiator arrangement, particularly for cooling the engine of commercial

vehicles, comprising:

a fan with a variable speed hydraulic fan drive,

a fan drive control unit for controlling the supply of hydraulic fluid to vary
the speed of the fan drive,
a heat exchanger arranged in front of the fan drive for exchanging heat
between engine coolant and air taken in by the fan,

a temperature sensor for sensing the coolant temperature,

and an electric control device for controlling the fan drive control unit as a
function of the temperature sensed by the temperature sensor,

wherein the heat exchanger, the fan and the fan drive control unit are
combined as a pre-assembled structural unit, and wherein the electric control
device and the temperature sensor and associated connecting lines are
fastened directly to the structural unit.

2. A radiator arrangement according to claim 1, wherein the temperature

sensor is arranged directly at a housing of the control device, and wherein
the housing is fastened to the heat exchanger.

3. A radiator arrangement according to claim 2, wherein the housing is

inserted by means of a thread surrounding the temperature sensor, into an
opening of a radiator tank of the heat exchanger.

4. A radiator arrangement according to claim 3, wherein an outside-

temperature sensor is provided which senses the temperature of the cooling
air entering into the structural unit and is connected with the control device.

5. A radiator according to claim 4, wherein all signal generators are cabled

to the control device.

6. A radiator arrangement according to claim 2, comprising at least one

additional heat exchanger, wherein a temperature sensor signal generator is
provided which is assigned to the additional heat exchanger, said
temperature sensor signal generator being arranged in the flow path of the
charge air and being fixedly cabled to the control device.

7. A radiator arrangement according to claim 2, wherein all signal generators

are cabled to the control device.

8. A radiator arrangement according to claim 1, comprising at least one

additional heat exchanger, wherein a temperature sensor signal generator is
provided which is assigned to the additional heat exchanger, said
temperature sensor signal generator being arranged in the flow path of the
charge air and being fixedly cabled to the control device.

9. A radiator arrangement according to claim 8, wherein an outside-

temperature sensor is provided which senses the temperature of the cooling
air entering into the structural unit and is connected with the control device.

10. A radiator arrangement according to claim 1, wherein an outside-

temperature sensor is provided which senses the temperature of the cooling
air entering into the structural unit and is connected with the control device.

11. A radiator arrangement according to claim 1, wherein a signal generator

is assigned to the fan which measures its rotational speed, said signal
generator being connected with the control device.

12. A radiator arrangement according to claim 11, wherein a pulse counter is

provided as the signal generator which is arranged in the area of a fan shroud
and interacts with a magnetically acting part in one of fan blades.

13. A radiator arrangement, particularly for cooling the engine of

commercial vehicles, comprising:

a fan with a variable speed fan drive,

a heat exchanger arranged in front of the fan drive for exchanging heat
between engine coolant and air taken in by the fan,

a temperature sensor for sensing the coolant temperature,

and an electric control device for controlling the fan drive as a function of
the temperature sensed by the temperature sensor,

wherein the heat exchanger and the fan are combined as a structural unit,
wherein the electric control device and the temperature sensor and
associated connecting lines are fastened directly to the structural unit,

wherein the temperature sensor is arranged directly at a housing of the

control device, and wherein the housing is fastened to the heat exchanger,
and wherein the housing is inserted by means of a thread surrounding the
temperature sensor, into an opening of a radiator tank of the heat exchanger.

14. A radiator arrangement, particularly for cooling the engine of

commercial vehicles, comprising:

a fan with a variable speed fan drive,

a heat exchanger arranged in front of the fan drive for exchanging heat
between engine coolant and air taken in by the fan,

a temperature sensor for sensing the coolant temperature,

and at least one additional heat exchanger,

an electric control device for controlling the fan drive as a function of the
temperature sense by the temperature sensor,

wherein the heat exchangers and the fan are combined as a structural unit,
wherein the electric control device and the temperature sensor and
associated connecting lines are fastened directly to the structural unit,

wherein a temperature sensor signal generator is provided which is assigned

to the additional heat exchanger, said temperature of sensor signal generator
being arranged in the flow path of the charge air and being fixedly cabled to
the control device.

15. A radiator arrangement, particularly for cooling the engine of

commercial vehicles, comprising:

a fan with a variable speed fan drive,

a heat exchange arranged in front of the fan drive for exchanging heat
between engine coolant and air taken in by the fan,

a temperature sensor for sensing the coolant temperature,

and an electric control device for controlling the fan drive as a function of
the temperature sensed by the temperature sensor,

wherein the heat exchanger and the fan are combined as a structural unit,
wherein the electric control device and the temperature sensor and
associated connecting lines are fastened directly to the structural unit,

and wherein a signal generator is assigned to the fan which measures its
rotational speed, signal generator being connected with the control device.

16. A radiator arrangement, particularly for cooling the engine of

commercial vehicles, comprising:

a fan with a variable speed fan drive,

a heat exchanger arranged in front of the fan drive for exchanging heat
between engine coolant and air taken in by the fan,

a temperature sensor for sensing the coolant temperature,

and an electric control device for controlling the fan drive as a function of
the temperature sensed by the temperature sensor,

wherein the heat exchanger and the fan are combined as a structural unit,
wherein the electric control device and the temperature sensor and
associated connecting lines are fastened directly to the structural unit,

wherein the temperature sensor is arranged directly at a housing of the

control device, and wherein the housing is fastened to the heat exchanger,

and wherein all signal generators are cabled to the control device.

17. A method of manufacturing a radiator arrangement, particularly a

radiator arrangement for cooling the engine of commercial vehicles of the
type including:

a fan with a variable speed hydraulic fan drive,

a fan drive control unit for controlling the supply of hydraulic fluid to vary
the speed of the fan drive,

a heat exchanger arranged in front of the fan drive for exchanging heat
between engine coolant and air taken in by the fan,

a temperature sensor for sensing the coolant temperature,

and an electric control device for controlling the fan drive control unit as a
function of the temperature sensed by the temperature sensor,

said method comprising combining the heat exchanger, the fan, and the fan
drive control unit into a pre-assembled structural unit, and subsequently
installing the pre-assembled structural unit in a commercial vehicle with the
electrical control device and the temperature sensor and associated
connecting lines being fastened directly to the pre-assembled structural unit.

18. A method according to claim 17, wherein the temperature sensor is

arranged directly at a housing of the control device, and wherein the housing
is fastened to the heat exchanger.

19. A method according to Claim 18, wherein the housing is inserted by

means of a thread surrounding the temperature sensor, into an opening of a
radiator tank of the heat exchanger.

20. A method according to claim 17, further comprising installing at least

one additional heat exchanger and providing a temperature sensor signal
generator assigned to the additional heat exchanger such that said
temperature sensor signal generator is arranged in the flow path of charge air
and is fixedly cabled to the control device.

21. A method according to claim 17, wherein a signal generator is assigned

to the fan which measures its rotational speed, said signal generator being
connected with the control device.

22. A method according to claim 21, wherein a pulse counter is provided as

the signal generator which is arranged in the area of a fan shroud and
interacts with a magnetically acting part in one of fan blades.
Description:

BACKGROUND AND SUMMARY OF THE INVENTION

The invention relates to a radiator arrangement of the type having a fan with
a variable fan drive, at least one heat exchanger arranged in front of the fan
for exchanging heat between engine coolant and air taken in by the fan, a
temperature sensor for the engine coolant, and an electric control device
which controls the fan drive as a function of the temperature sensed by the
temperature sensor.

Radiator arrangements of this type are known (DE-37 14 842 Al-P 80 01). In
the known constructions, the electric control device, which is part of the
vehicle, is always connected with the heat exchanger and the fan drive
subsequently, the corresponding temperature sensors also not being installed
before the control device is connected. In the case of vehicles which are
equipped with a radiator arrangement of the type referred to above, the
control device is generally located in an area situated outside the engine
compartment, such as the driver's cab. In constructions of this type, it is
therefore a disadvantage that the coordination of the desired control
characteristics and the adjusting of the control device required for this
purpose and possibly of other existing components of the control system can
only be carried out at the customer's after the installation of the radiator.
This is relatively expensive and, more importantly, does not always result in
the adjustment of the desired control characteristics of the radiator.

An object of the invention is to develop a radiator arrangement of the

initially mentioned type in such a manner that also the future operating
method of the radiator can also be determined by the radiator manufacturer.
For achieving this object, the radiator arrangement is constructed with the
heat exchanger and fan combined as a structural unit, wherein the electric
control device and the temperature sensor and associated connecting lines
are fastened directly to the structural unit. By means of this development, the
control device with all its connecting lines and temperature sensors becomes
part of the structural unit which can be preassembled and which comprises
the fan and the heat exchanger. Therefore, the whole radiator arrangement
can be adjusted before its delivery. The only measure that is still required is
the electrical connection of the control device or its connection with
additional sensors which, however, can be achieved in a simple manner and
advantageously with respect to the assembling by means of the arrangement
of plug elements.

Advantageous further developments are provided in preferred embodiments

of the invention, including deposition of the temperature sensor directly at
the housing for the control device, which housing is threadably attachable in
an opening in the radiator tank of the heat exchanger. This arrangement
provides the advantage that no connecting lines exist between the control
device and the temperature sensor assigned to the cooling circulating system
of the heat exchanger which may be subjected to outside influences. The
control device and the temperature sensor constitute a structural unit which
can be screwed in and which, in a simple manner, by means of connecting
cables, may lead to additional signal generators and to the power connection.

In especially preferred embodiments, the preassembled radiator arrangement

can also be used for the control of the cooling water temperature as well as
for the control of other quantities, such as the air temperature of the charge
air. For this purpose, the control device can implement corresponding
characteristic curves for water and air temperatures. Finally, the advantage is
also achieved in certain preferred embodiments, of the direct and
determinable assignment of the rotational fan speed to certain cooling water
temperatures or outside temperatures with the rotational speed of the fan
monitored directly. A relatively expensive control device can therefore be
integrated originally into the structural radiator unit. This radiator unit can
be laid out correspondingly at the manufacturer's so that during the
assembly, a cumbersome adjustment of the control system becomes
superfluous.

Other objects, advantages and novel features of the present invention will
become apparent from the following detailed description of the invention
when considered in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front schematic view of a radiator of a commercial vehicle which

is equipped according to a preferred embodiment of the invention;

FIG. 2 is a top view of the radiator of FIG. 1;

FIG. 3 is a lateral view of the radiator of FIGS. 1 and 2;

FIG. 4 is an enlarged partial representation in top view of the control device
used in the case of the radiator of FIGS. 1 to 3; and

FIG. 5 is a lateral view of the control device of FIG. 4.

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 1 to 3 show a radiator arrangement in the form of a structural unit 1

which comprises a known heat exchanger 4 having a gilled-tube block 21
with a radiator tank 10 and a collector tank 22 as well as of a fan
arrangement 2 which is connected behind this heat exchanger 4 in the
direction 23 of the flowing air. The fan arrangement 2 with respect to its
details is also constructed in a known manner. A fan 2 is provided which is
equipped with fan blades 16 and which can be controlled in its rotational
speed by means of a hydraulic fan drive 3. In this case, the driving speed is
determined by means of a control element 7 in the form of a control valve
which controls the supply of hydraulic medium to the fan drive 3 as a
function of the temperature of the cooling water in the heat exchanger 4.

By means of a fan cowl 14, the fan arrangement 2 is fixedly connected with
a frame of the heat exchanger 4. The fan drive 3 is also held at the frame of
the heat exchanger 4 by means of supporting arms 25. By way of hydraulic
pipes 26, which are connected with the storage device for the hydraulic
medium and with a pump in a manner which is not shown in detail, and
otherwise also lead to an oil cooler 27, the fan drive 3 is connected with a
hydraulic circulating system. As mentioned, the supply of the hydraulic
medium is determined by way of a control element 7 constructed as a control
valve.

A control device 6, which is shown in detail in FIGS. 4 and 5, is fixedly

connected with the radiator tank 10 of the heat exchanger 4. The electric
control device 6 has a housing 6a in which the required electric control
circuits are contained, for example, in the form of insert cards or the like. By
means of a hexagon 28 and a thread 9, the housing can be inserted into a
corresponding opening in the radiator tank 10 so that the control device 6 is
fixedly connected with the radiator tank 10 and with the heat exchanger 4. In
the embodiment shown, a temperature sensor 5 is integrated into the control
device 6, this temperature sensor 5 being surrounded by the thread 9 and
therefore, when the control device housing 6a is screwed into the radiator
tank 6, dipping into the water circulating system of the heat exchanger 4.
The temperature of the cooling water in the heat exchanger 4 is therefore
measured directly by the screwed-in control device 6 which, by means of
electric connecting lines 8, which are mounted directly at the housing 6a,
can also be connected with other signal generators. In the case of the
embodiment in which other heat exchangers 11 are connected in front of the
heat exchanger 4 in the form of a charge air cooler, a temperature sensor 20
is provided which projects into the outlet tube of the charge air cooler,
measures the temperature of the charge air and which, by means of a
connecting part 18, is connected directly with the assigned line 8 and with
the control device 6. Other connecting lines 8 lead to a plug 17 for the power
connection of the control device and to a plug 19 which leads to a
connecting line 8' to the control element 7. Embodiments are also
contemplated where the control element 7 is directly connected with the
control device 6 by way of a connecting line 8.

FIGS. 4 and 5 do not show another connecting line to the control device 6.
The reason is that the control device 6, by means of an electric connecting
line 8", is connected with a signal generator 13 in the form of a pulse counter
which is fixedly arranged at the shroud 14 of the fan 2 in the area of the
rotating ventilator. A magnetically acting part 15 is also assigned to one of
the fan blades 16, such as a small permanent magnet or an iron plate which,
when the fan 2 is rotated moves past the pulse counter 13 at certain intervals,
and thus permits an exact determination of the rotational speed of the fan 2
which in the control device, in turn, can be utilized for a coordination of the
desired control characteristics. Also in a known manner, the fan blades 16
move inside the cowl 14 serving as the fan shroud, in the area of which the
pulse counter 13 is mounted.

As a result of the use of the pulse counter 13 and its connection to the
control device, data exist concerning the actual rotational speed of the fan.
Nevertheless, the control device 6, as mentioned, with all its connecting
lines 8, 8', 8" and other signal generators in the form of temperature sensors
20 or of an additional outside-temperature sensor 12 as well as the pulse
generator 13 is part of the constructional unit 1 of the overall radiator
aggregate which only has to be installed into the vehicle. The electric
connection of the control device 6 can take place by means of the plug 17.
Other mounting or adjusting work is not required.

Although the present invention has been described and illustrated in detail, it
is to be clearly understood that the same is by way of illustration and
example only, and is not to be taken by way of limitation. The spirit and
scope of the present invention are to be limited only by the terms of the
appended claims.

Radiators are classified according to the direction that the coolant flows
through them. The two types of radiators are the downflow and crossflow.
The downflow radiator has the coolant tanks on the top and bottom and
the core tubes run vertically. Hot coolant from the engine enters the top
tank. The coolant flows downward through the core tubes. After cooling,
coolant flows out the bottom tank and back into the engine. The crossflow
radiator is a design that has the tanks on the sides of the core. The core tubes
are arranged for horizontal coolant flow. The tank with the radiator cap is
normally the outer tank. A crossflow radiator can be shorter, allowing
for a lower vehicle hood. The operation of a radiator is as follows: The
upper tank collects incoming coolant and, through the use of an internal
baffle, distributes it across the top of the core. The core is made up of
numerous rows of small vertical tubes that connect the upper tank and the
lower tank. Sandwiched between the rows of tubes are thin sheet metal
fins. As the coolant passes through the tubes to the lower tank, the fins
conduct the heat away from it and dissipate this heat into the atmosphere.
The dissipation of the heat from the fins is aided by directing a constant air
flow between the tube and over the fins. The lower tank collects the coolant
from the core and discharges it to the engine through the outlet pipe. The
overflow tube provides an opening from the radiator for escape of
coolant if the pressure in the system exceeds the regulated maximum. This
will prevent rupture of cooling system components. A transmission oil
cooler is often placed in the radiator on vehicles with automatic
transmissions. It is a small tank enclosed in one of the main radiator tanks.
Since the transmission fluid is hotter than engine coolant, heat is removed
from the fluid as it passes through the radiator and cooler. In downflow
radiators, the transmission oil cooler is located in the lower tank. In a
crossflow radiator, it is located in the tank having the radiator cap. Both
tanks are coolant outlet tanks. Line fittings from the cooler extend through
the radiator tank to the outside. Metal lines from the automatic transmission
connect to these fittings. The transmission oil pump forces the fluid through
the lines and cooler. Radiator Hoses Radiator hoses carry coolant between
the engine water jackets and the radiator. Being flexible, hoses can
withstand the vibration and rocking of the engine without breaking. The
upper radiator hose normally connects to the thermostat housing on the
intake manifold or cylinder head. The other end of the hose fits on the
radiator. The lower hose connects the water pump inlet and the radiator. A
molded hose is manufactured into a special shape with bends to clean the
parts especially the cooling fan. It must be purchased to fit the exact year
and make of the vehicle. A flexible hose has an accordion shape and can be
bent to different angles. The pleated construction allows the hose to bend
without collapsing and blocking coolant flow. It is also known as a universal
type radiator hose. A hose spring is used in the lower radiator hose to
prevent its collapse. The lower hose is exposed to suction from the water
pump. The spring assures that the inner lining of the hose does NOT tear
away, close up, and stop circulation. Radiator Pressure Cap The radiator
pressure cap (fig. 6-6) is used on nearly all of the modern engines. The
radiator cap locks onto the radiator tank filler neck Rubber or metal seals
make the cap-to-neck joint airtight. The functions of the pressure cap are as
follows: 1. Seals the top of the radiator tiller neck to prevent leakage. 2.
Pressurizes system to raise boiling point of coolant. 3. Relieves excess
pressure to protect against system damage. 4. In a closed system, it allows
coolant flow into and from the coolant reservoir. The radiator cap pressure
valve consists of a spring- loaded disc that contacts the filler neck. The
spring pushes the valve into the neck to form a seal. Under 6-6

Radiator plates are contoured to fit the rims of radiator tanks where the
tanks are bolted to the radiator core, and the radiator plates have bolt holes
therein which align with the bolt holes in the radiator tanks and the radiator
core, whereby the radiator plates may be bolted along with the tanks to the
radiator core to prevent deformation and failure of the tanks and leaking of
the radiato
What is claimed is:

1. Apparatus for use with a radiator tank having a surface with a plurality of
spaced bolt holes therein whereby said tank may be bolted to a radiator core,
said apparatus comprising: Four (4) plates, each having two ends, shaped to
be superposable on said surface and having a plurality of bolt holes therein
congruent with said bolt holes in said surface, whereby said tank and said
plates may be bolted to said core in superposed position such that ends of
adjacent plates abut; and Four (4) washers positioned at bolt holes nearest
where the ends of said plates abut whereby said washers overlap the edges of
adjacent plates to maintain said plates coplanar.

2. The apparatus of claim 1 wherein said surface forms a perimeter

substantially rectangular in shape, having two (2) straight sides and two (2)
rounded ends, and said plates comprise four (4) plates, two (2) of which are
substantially straight and two (2) of which are rounded to be superposable
on said surface.

3. The apparatus of claim 1 wherein said plates are made of steel having a
thickness of approximately one-eighth inch (1/8").

Description:

BACKGROUND OF THE INVENTION

This invention relates to truck radiators, and more particularly to contoured

metal plates for use with tanks of truck radiators to reinforce same by
providing a stronger surface on which the bolts may be tightened sufficiently
to prevent leaking without deforming the tanks.

In recent years, truck manufacturers have attempted to economize on the

weight and cost of the trucks by making radiator tanks with thinner metal.
But while the redesigned truck radiators are lighter and less expensive, a
problem has arisen due to the thin metal of the tank. The top and bottom
radiator tanks must be bolted to the radiator core with bolts which fit
through a plurality of holes located in a channel which surrounds the tanks.
In order to withstand the high pressures in the radiator and prevent leaking,
the bolts must be tightened with a substantial amount of force. Due to the
thin construction of the tanks, the metal adjacent the bolts has a tendency to
bend and split when subjected to the forces required to adequately tighten
the bolts. This bending and splitting has the effect of providing weakened
spots for leaks. Moreover, while these weakened spots may be repaired, such
repairs are required more frequently and there comes a point at which the
radiator may no longer be repaired and must be replaced at a substantial
expense.
Therefore, an object of the invention is to provide a means for preventing
radiator tanks from bending and splitting adjacent the bolts used to secure
the tanks to the radiator core.

Another object of the invention is t provide reinforcing means which allow

the radiator bolts to be tightened without bending and splitting the radiator
tank metal.

Another object of the invention is to provide radiator plates which prevent

the bending and splitting of the radiator tanks, greatly decreasing the
necessity and frequency of repairs to radiator tanks, prolonging the life of
radiator tanks, and decreasing the cost of operating the vehicle.

SUMMARY OF THE INVENTION

The radiator tank plates of this invention comprise metal plates contoured to
fit around the edge of the upper and lower tanks and having bolt holes
therein positioned to align with the bolt holes in the tanks whereby the bolts
which secure the tanks to the radiator core also secure the tank plates to the
core and the tanks, whereby the radiator tank plates reinforce the tank metal
to prevent the tanks from bending and splitting in the spaces adjacent the
bolt holes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a conventional truck radiator, partially

broken away, showing the radiator tank plates of the present invention and
one of the radiator tanks in exploded format.

FIG. 2 is a perspective view of a conventional truck radiator showing upper

and lower tank radiators in relation to the radiator core, with the radiator
tank plates of the present invention mounted thereon.

FIG. 3 is a sectional view taken along the lines 3-3 of FIG. 2.

FIG. 4 is a sectional view taken along the lines 4--4 of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, a conventional truck radiator is illustrated in

schematic form to comprise upper 12 and a lower 14 radiator tanks mounted
at the opposite ends of a radiator core 16 which has a frame 18. The
customary drains, hoses, and auxiliary tanks usually found on truck
radiators, but which form no part of this invention, are not illustrated.

Since the radiator tank plates which fit on either one of the radiator tanks
will be positioned and will function identically to the tank plates used on the
other tank, only a single set of such plates will be described in this
specification, with the understanding that an identical set may be mounted
with the other tank and will function in an identical manner.

The frame 18 of the radiator core 16 has a mounting surface 20 having a

plurality of bolt holes 22 therein. A gasket 24 fits on the flange 20 and has a
plurality of bolt holes 26 therein which are congruent with the bolt holes 22
in flange 20.

A conventional truck radiator tank 12 is designed to fit on top of flange 20

and gasket 24. The tank 12 has a circumferential mounting surface or rim 28
which has a plurality of bolt holes 30 therein. Prior to this invention, the tank
12 was bolted directly to the radiator core flange 20 by a plurality of nuts 46
and bolts 44 tightened with great force to prevent leaking. However, because
of an effort to economize, the metal of the radiator tank 12, particularly at
spaces 32 between the bolt holes 30 in the circumferential mounting rim 28,
is relatively thin and subject t bending and splitting under the forces which
must be used to tighten the bolts and nuts.

The present invention overcomes this problem by providing radiator tank

plates 34, 36, 38 and 40. The tank plates are designed and contoured to fit
within the tank rim 28, and have a plurality of bolt holes 42 therein which
are congruent with the bolt holes in tank rim 28, gasket 24 and flange 20.

When the radiator plates are mounted in the tank rim 28, they may be
secured to the radiator core by a plurality of bolts 44 and nuts 46.

In order to maintain the radiator plates in a single plane, oversized washers

56, 58, 60, and 62, are used at bolt holes 48, 50, 52, and 54, which are
nearest the plate interfaces, to level the four tank plates.

The radiator tank plates of the present invention function to reinforce and
strengthen the relatively weak metal in the spaces 32 between the bolt holes
in the tank mounting rim 28. The radiator tank plates permit the substantial
forces which are necessary to secure the tanks to the radiator core in order to
prevent leaking to be applied without bending or splitting the tank metal in
the spaces 32 between the bolt holes, and causing damage which either
necessitates frequent repairs or greatly shortens the life of the radiator tanks.

Radiator tank plates made according to the present invention of one-eighth

inch (1/8") steel have been found to function satisfactorily to significantly
decrease the frequency of repairs necessary to tank plates and to
significantly decrease the failure rate of such tanks. While the radiator tank
plates of the present invention illustrated in the drawings have a somewhat
circular or rounded end, some conventional truck radiators have tanks with a
rectangular or square shape. It will be apparent to those skilled in the art that
the radiator tank plates of the present invention may be round or square as
required by the design of the particular radiator tank to be reinforced.

It can be seen that the radiator tank plates of the present invention function
to solve the problem of the relatively thin metal of truck radiator tanks. The
present invention extends the life of radiator tanks by preventing the damage
caused by the large forces which must be used to tighten the nuts and bolts
in order to avoid leaking. The present invention minimizes the repairs
necessary to such radiator tanks, extends the life of radiator tanks, and
decreases the operational cost of vehicles which must use such tanks.

Preventative Cooling System Maintenance Program

A vehicle's cooling system is designed

to protect the engine from the
destructive forces of too much heat. If
the system isn't in good repair, simple
tasks such as sitting idle in rush-hour
traffic can cause a vehicle to overheat
even when temperature
Cooling the Big Rigs

Heat, sometimes expressed as Btus or British thermal units, is the

one item that every diesel engine has in abundance. One Btu is the
amount of thermal energy necessary to raise the temperature of one
pound of water by one degree Fahrenheit.

Preventing Cylinder Head Gasket and Cooling System Failures

A cylinder head gasket is required to effect a seal

between the cylinder head and block of a gasoline or
diesel engine. It is an integral component of the engine and
is requires to perform many functions at the same time
during engine operation

Overheating: Causes and Cures

Internal combustion engines run on heat. Chemical energy

in the fuel is transformed into thermal energy when the fuel
burns, which produces mechanical energy to push the
pistons, spin the crankshaft and drive the vehicle down the road.

Cavitation, SCAs and the Proper Maintenance of Diesel

Engine Cooling Systems

Would you believe me if I were to tell you that the presence of a few tiny
bubbles, some so small that you need a microscope to see them, could
destroy a diesel engine? One problem that has been plaguing the owners of
diesel rigs for years is cavitation.

Heavy-Duty Workhorses, Cooling the HD Heatwave

In the world of HD trucks, off-road equipment and stationary power
sources, the emphasis is always on more - more horse-power, more
digging power, more break-out force, more hauling capacity and more
generated power.

Why is my Car Overheating?

Reader Question: My car is overheating, what

causes this to happen?

To properly diagnose your overheating complaint

we need to rule out a few basic things.

First: Is there enough coolant/antifreeze in the radiator? Don't just look

inside the plastic overflow bottle, but remove the radiator cap (when the
engine is cold) and look inside the radiator.

Flushing your Radiator and Cooling

System

Reader Question: I want to flush the radiator in

my car, how do I do it?

The first question that comes to mind is WHY do

you want to do this? Red flags go up in my head when customers ask me a
"how do I..." question.

Radiator and Coolant (Antifreeze) Service

Did you know that up to a third of the heat energy

produced by an internal combustion engine ends
up as waste heat in the cooling system? A gallon
of gasoline produces about 19,000 to 20,000
BTUs of heat energy when it is burned, which is enough to boil over 120
gallons of water!
 Head Gasket Failure

The head gasket is one of the most critical gaskets in an engine because it
has to seal all of the combustion chambers as well as the coolant and oil
passages between the head and block. The gasket has to provide a leak-free
seal from the moment it is first installed, and maintain that seal for the life of
the engine - which might well be 150,000 miles or more on many of today’s
vehicles.

Radiator Diagnosis, Repair, & Replacement Tips

Ordinary leaks are easy enough to diagnose because they're hard to miss. A
leak of any size at all will weep, drip or spray coolant. The resulting loss of
coolant usually leads to engine overheating, which can cause more damage
if the leak isn't found and fixed. Leak inhibiting additives can usually seal
small leaks. But sealers are a temporary fix and more of a do-it-yourself
product.

Does Your Radiator Pass Inspection?

Today’s plastic-tank, aluminum core design radiators are

more dependable than ever, but when there is a problem, the
problem generally makes itself quite apparent.

Ordinary leaks are easy enough to diagnose because they’re hard to miss. A
leak of any size will weep, drip or spray coolant. The resulting loss of
coolant usually leads to engine overheating, which can cause more damage
if the leak isn’t found and fixed.

Preventing Overheating

The last thing any motorist wants to see is a TEMP warning light flashing in
his/her face, or worse yet, steam billowing out from under the hood of the
vehicle. Yet it happens all too often. The hotter the weather, the greater the
load on the cooling system and the greater the chance of the engine
overheating if the cooling system can’t handle the heat.

Coping with Summer Heat-Cooling Systems Checks

Extreme cooling performance. That’s what August typically demands from a
vehicle’s cooling system. The thermal loads created by the hottest ambient
temperatures of the year, maximum air conditioning and city traffic can push
many cooling systems to the max and give a vehicle a bad case of the BTU
blues. As cooling demands climb, the system has to work harder and harder
to dump the extra heat. Eventually the point may be reached where the
cooling system can’t keep up with the load and the engine starts to overheat.
What happens next depends on the driver, the driving conditions and the
vehicle itself.

Head Gasket or Combustion Leak Test Procedure

One method is to use a block tester, also known as a

combustion leak tester, to determine if you have exhaust
gases in your cooling system. A combustion test kit can
be found at your local NAPA, auto parts store. The part
number is 700-1006. The price for this part is less than
$50.00. Exhaust gases in your cooling system can suggest a head gasket
leak, a cracked block, or a warped head, etc.

14 Rules for Improving Engine Cooling System Capability in

High-Performance Automobiles

It’s not unusual for automobile enthusiasts to want to increase the power of the engine in
their automobiles and many aftermarket options are available to them to accomplish this.
Increasing the engine horsepower then presents the problem of making sure that other
components of the vehicle, such as the drive train and the cooling system, can handle the
increased engine power.