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汽车空-空中冷器技术条件
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QCT 828-2010
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标准编号: QC/T 828-2010 (QC/T828-2010)
中文名称: 汽车空-空中冷器技术条件
英文名称: Automobile air-to-air charge air cooler technical specification
行业: 汽车行业标准 (推荐)
中标分类: T35
国际标准分类: 43.040.10
字数估计: 21,284
发布日期: 2010-08-16
实施日期: 2010-12-01
引用标准: GB/T 3821; GB/T 15089; JB/T 10408
起草单位: 东风汽车公司技术中心
归口单位: 全国汽车标准化技术委员会
标准依据: 工科(2010)第113号
范围: 本标准规定了汽车空-空中冷器总成的技术要求、试验方法、检验规则、标志、包装、运输及贮存。
QC/T 828-2010: 汽车空-空中冷器技术条件
QC/T 828-2010 英文名称: Automobile air-to-air charge air cooler technical specification
中华人民共和国汽车行业标准
QC/T 828—2010
中华人民共和国工业和信息化部发布
1范围
本标准规定了汽车空-空中冷器总成（以下简称中冷器）的技术要求、试验方法、检验规则和标 志、包装、运输、储存。
2规范性引用文件
下列文件中的条款通过本标准的引用而成为本标准的条款。凡是注日期的引用文件，
其随后所有的修改单（不包括勘误的内容）或修订版均不适用于本标准，然而，
鼓励根据本标准达成协议的各 方研究是否可使用这些文件的最新版本。
凡是不注日期的引用文件,其最新版本适用于本标准。
3术语和定义
4技术要求
4.1一般技术要求
中冷器应按经规定程序批准的产品图样和技术文件制造，并符合本标准的要求。
4.2外观及尺寸
4.2.1焊缝表面应平整光滑，不得有毛刺，外表面不允许有压伤、碰伤等缺陷。
4.2.2芯子散热带倒伏:中冷器正面积小于或等于0. 3m2,允许2处；中冷器正面积大于0.3m2,允 许3处。
4.2.3每条散热带的波峰数公差为名义波峰数的±2%，波峰节距平均公差为±0.25mmo
4.3性能要求
4.3.1散热性能和压力降：
散热性能和压力降要求按5.1的规定进行试验,满足表1的要求。
4.3.2密封性能:
4.3.2.1湿式检验按5.2.1的规定进行,试验时不得出现肉眼可见的气泡;
4.3.2.2干式检验按5.2.2的规定进行，在15s时间内压力下降不大于用户规定值。
4.3.3静压试验：
静压试验按5.3的规定进行，试验后不允许有破裂和永久性变形,并满足4.3.2密封性试验的要求。
4.3.4振动试验：
振动试验按5.4的规定进行，试验后不允许有破裂和永久性变形,并满足4.3.2密封性试验的要求。
4.3.5压力脉冲试验：
压力脉冲试验按5.5的规定进行，试验后不允许有破裂和永久性变形,并满足4.3.2密封性试 验的要求。
4.3.6热冲击试验：
热冲击试验按5.6的规定进行，试验后不允许有破裂和永久性变形,并满足4.3.2密封性试验的要求。
4.4清洁度
清洁度试验按5.7的规定进行，中冷器热侧清洁度用中冷器热侧表面清洗下来的杂质的质量Wc来表示，其Wc应符合式(3)的规定：
5 试验方法
5.1散热性能、压力降性能试验
5.1.1试验条件：
中冷器散热性能、压力降在规定的试验条件下，试验时热侧进口空气温度应控制在给定温度的
±2℃范围内;热侧进口压力控制在±5%范围内;热侧空气质量流量控制在±1.5%范围内。
5.1.2试验原理:
中冷器试验原理见图1。
5.1.2.1冷侧空气系统:
风机风量必须保证在中冷器冷侧空气流量的50% ~150%范围内提供冷却空气。
5.1.2.2热侧空气系统:
热侧空气回路应能够按照规定的压力和温度,在中冷器额定流量的50% ~ 150%范围内提供高
温压缩空气。
5.1.3测量参数：
测量参数按照附录B。
5.1.4试验程序：
把中冷器安装在试验台上，检查确认各连接处没有泄漏后启动试验设备。调节试验参数到指定 值:
热侧进口空气温度控制在±2℃范围内;热侧进口空气压力控制在± 5%范围内;
热测进口空气流量控制在±1.5%范围内，方可认为系统充分稳定，可以开始测量并记录试验数据。
在试验过程中每 一试验工况点在不小于30s时间内釆集完数据。
5.1.4.1散热性能、压力降试验：
5.1.4.1.1按中冷器正面迎风风速在12m/s±0.4m/s时所对应的风量值为最大风量，在此数值以
下按各自产品的试验大纲选取不少于4个工况点。
5.1.4.1.2先设定热侧其中一个工况点,依次变化冷侧工况,待热侧工况稳定之后,逐次测量,每
一工况点的热侧进口空气温度控制在±2℃范围内，热侧进口空气压力控制在±5%范围内，
热侧进 口空气流量控制在±1.5%范围内，然后更换下一个热侧工况,再依次变化冷侧工况，
以此测得所有 工况下的各参数。在其热平衡误差为±5%时试验结果有效。
5.1.4.2散热量、压力降等参数的计算方法按照附录A。
5.2密封性试验
5.2.1在湿式检验台上，连接中冷器与空气压缩源，并将中冷器浸没于水槽中，
往中冷器热侧通入 250kPa压力的压缩空气,保压时间大于或等于30s。
5.2.2在干式检验台上，往中冷器热侧通入250kPa压力的压缩空气，测量压力下降值。
5.2.3当上述两种方法的检测结论有争议时,优先采用湿式检验。
5.3静压试验
在常温条件下，往中冷器内通入相对压力为500kPa的介质，保压3min。
5.4振动试验
按JB/T 10408的规定的方法进行试验。对中冷器施加上下、左右和前后的正弦波振动，
振动频 率从小到大逐个选取，每个频率依次进行振动,具体要求按表2的规定。
若在上述频率范围内出现共振频率点，跳过该点,增加一个频率点进行试验。
5.5压力脉冲试验
按JB/T 10408的规定的方法进行试验。中冷器在压力脉冲性能试验中使用常温空气,具体要
求按表3的规定，典型的压力脉冲循环见图2所示。
5.6热冲击试验
按JB/T 10408的规定的方法进行试验。
中冷器的热疲劳强度要求按表4的要求，典型的热冲击循环见图3所示。
往中冷器热侧注入其容积60%的试验用清洗液，按照GB/T 3821规定方法进行测试。
试验用清 洗液应符合GB/T 3821的要求。
5.8试验结果的数据处理和评定 5.8.1试验中原始数据、测量参数及计算结果,填入相应中冷器散热性能
与压力降试验记录整理表,见附录B；将试验结果绘制成相应的性能曲线。
5.8.2密封性试验、静压强度试验、压力脉冲强度试验、热冲击强度试验、振动试验中原始数据及测量参数，
填入中冷器可靠性试验记录表,见附录C。
6.1出厂检查
中冷器出厂前，检验部门应按4. 2的规定检验,检验合格并加以标记后方能出厂。
中冷器在装箱前应加以清理，内部不得有任何杂质存在。
有下列情况之一时,除应按4.2的规定检验外,还应按第4章规定对产品进行检验。
a）新产品投产前或老产品转厂生产前的鉴定。
b）产品的结构、工艺或材料发生重大的更改，有可能影响产品性能时。
c）出厂检验结果与上次型式检验有较大差异时。
d）国家质量监督机构提出型式检验要求时。
型式检验是经岀厂检验合格的产品。
6.3检验内容
检验内容按表5的规定进行。
7标志、包装、运输、储存 7.1标志
7.2包装
产品按用户的要求进行包装，进出气口必须用防尘盖密封。
7.3运输
7.4储存
产品应储存在通风、清洁、干燥、无腐蚀性气体的环境中，在正常保管情况下，自岀厂之日起，
制造厂应保证中冷器在12个月内不得有表面腐蚀现象。
ICS 43.040.10
T 35
INDUSTRY STANDARD
OF THE PEOPLE'S REPUBLIC OF CHINA
Automobile Air-to-air Charge
Air Cooler Technical Specification
ISSUED ON. AUGUST 16, 2010
IMPLEMENTED ON. DECEMBER 1, 2010
Issued by. Ministry of Industry and Information Technology of the People's
Republic of China
QC
3. No action is required - Full-copy of this standard will be automatically &
immediately delivered to your EMAIL address in 0~60 minutes.
Contents
Foreword ... I
1 Scope ... 2
2 Normative References ... 2
3 Terms and Definitions ... 2
4 Technical Requirements ... 4
5 Testing Methods ... 5
6 Inspection Rules ... 8
7 Marking, Packing, Transportation, and Storage ... 9
Appendix A (Normative) Calculation Methods for the Heat Release and Pressure Drop Tests on
Air-to-air Charge Air Coolers ... 10
Appendix B (Normative) Test Record Sheet for the Heat Release and Pressure Drop Tests on
Air-to-air Charge Air Coolers ... 14
Appendix C (Normative) CAC Reliability Test Record Sheet ... 16
Appendix D (Normative) Terms and Symbols ... 17
IForeword
This standard is formulated to provide the theoretical basis and technical support for the
design criteria, test method and quality inspection rules of the charge air coolers (CACs), thus
their performance and quality can be improved.
CAC is the important component for which the engine pressurization and intercooling
technology is universally applicable to the finished automobile, its action is to cool the high
pressure & temperature air after the pressurizer is pressurized so as to further increase the air
inflow density and air intake of the engine, reduce the peak value of the combustion
temperature, improve the engine power, reduce the oil consumption and improve the emission.
The formulation of this standard is significant to the energy conservation and emission
reduction of motor vehicles.
This standard is formulated by reference to the relevant standards of foreign countries
such as Japan and France.
This standard is proposed and is under the jurisdiction of the National Technical
Committee of Auto Standardization.
Drafting organizations of this standard. Dongfeng Motor Corporation Technical Center,
Zhejiang Yinlun Machinery Co., Ltd.
Chief drafting staffs of this standard. Meng Jianjun, Fan Zhengyin, Yin Shjengdai, Xia
Lifeng, Cui Jingming.
This standard is issued for the first time.
2PROFESSIONAL STANDARD
OF THE PEOPLE'S REPUBLIC OF CHINA
Automobile Air-to-air Charge Air
Cooler Technical Specification
1 Scope
This standard specifies the technical requirements, test methods and inspection rules,
marking, packing, transportation and storage of the automobile air-to-air charge air cooler
assembly (hereinafter referred to as CAC).
2 Normative References
The following documents contain provisions which, through reference in this standard,
constitute provisions of this standard. For dated reference, subsequent amendments to
(excluding corrections to), or revisions of, any of these publications do not apply. However,
the parties to agreements based on this standard are encouraged to investigate the possibility
of applying the most recent editions of the standards. For undated references, the latest edition
of the normative document referred to applies.
CB/T 3821 "Small and Medium Power Internal Combustion Engines - Cleanliness
Measurement"
GB/T 15089 "Classification of Power-driven Vehicles and Trailers"
JB/T 10408 "Internal Combustion Engines - Test Method for Reliability of Exchangers"
3 Terms and Definitions
3.1
Air-to-air charge air cooler (CAC)
manifold and reduces the pressurized air temperature through air cooling.
3.2
Hot side
It refers to the side at which the pressurized air passes through.
3.3
Cold side
It refers to the side at which the cooling air passes through.
3.4
CAC effectiveness
the same condition, which is expressed by the ratio of the difference of temperature at the
inlet & outlet on the CAC hot side to the difference between the temperature at the inlet in the
CAC hot/cold side, in % and of which the formula is as Formula (1).
%100
aciahi
ahoahi
a TT
TTE (1)
Ea——the CAC effectiveness, %;
Tahi——the inlet temperature at the hot side of CAC,℃;
Taho——the outlet temperature at the hot side of CAC, ℃;
Taci——the inlet temperature at the cold side of CAC, ℃.
3.5
Temperature rise
It refers to the difference between the outlet temperature at the hot side of CAC and the
inlet temperature at the cold side of CAC, of which the formula is as Formula (2).
ΔT=Taho-Taci (2)
Pressure drop of hot side (Δρah)
It refers to the pressure drop which is caused due to the pressurized air passes through
the CAC under test conditions.
3.7
Pressure drop of cold side (Δρac)
It refers to the pressure drop which is caused due to the cooling air passes through the
CAC under test conditions.
3.8
CAC frontal area (Af)
3.9
CAC heat radiating area
It refers to the surface area of the cooling tube and heat radiating belt of the CAC which
are exposed in the cooling air.
3.10
Heat release coefficient
It refers to the heat quantity which is transferred by the unit heat radiating area of CAC if
the temperature changes by 1℃.
3.11
The air circuit on the hot side shall be able to supply the high-temperature compressed
air within 50%~150% of the rated flow for the CAC according to the specified pressure and
temperature.
5.1.3 Measurement parameters.
Measurement parameters shall be as those in Appendix B.
5.1.4 Test procedures.
The CAC is installed at the test bench; start up the test equipment after the connections
are confirmed by inspection to be without any leakage. Regulate the test parameters to the
designated values; control the temperature of inlet air of the hot side within ±2℃. Control the
side within ±1.5%. It is regarded that the system is sufficiently stable, then begin to measure
and record the test data. In the test, data of points in each test condition are collected within
the time greater than or equal to 30s.
5.1.4.1 Tests on heat radiating performance and pressure drop.
5.1.4.1.1 The air volume is the maximum air volume which is corresponding to the
windward air velocity on the CAC fromt of 12m/s±0.4m/s, if the air volume is less than the
above one, 4 (at least) operating points shall be selected in accordance with the test outline for
each product.
5.1.4.1.2 Firstly, set the operating point of the hot side, and then change operating
measure them; the temperature of the inlet air for the hot side in each operating point is within
±2℃, the pressure of the inlet air for the hot side is controlled within ±5% and the inlet air
flow of the hot side is controlled within ±1.5%. Then change to another operating condition
of the hot side and successively change the operating conditions of the cold side, at last,
measure all the parameters under all the operating conditions. The test result is valid if the
measurement error of its thermal balance is within ±5%.
5.1.4.2 The parameters such as the heat release capacity and pressure drop shall be
calculated in accordance with Appendix A.
5.2 Sealing test
and the CAC is immersed in the water channel; then the compressed air with the pressure of
250kPa is lead to the hot side of the CAC, and the time for pressure maintaining is greater
than or equal to 30s.
5.2.2 The compressed air with the pressure of 250kPa is lead to the CAC on the dry
inspection platform and the pressure drop value is measured.
5.2.3 If the test conclusions obtained through the two methods above are inconsistent, the
method of wet inspection shall preferably adopted.
5.3 Static pressure test
Under the normal temperature, the media with the relative pressure of 500kPa is lead to
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