jbj Techniques Limited; exceptional mechanical & fluid power expertise

exceptional mechanical & fluid power expertise

Cooling / Heat Exchange

Satisfy a variety of industrial, offshore and mobile agricultural / heavy plant cooling requirements with a choice of solutions available from these air-oil coolers, off-line coolers, cooler bellhousings and plate heat exchangers.

Interchangeability with existing products available within the current marketplace.

Bespoke design and build to fulfill customers application needs.

Page contents (links)

Cooling-image-cntre
Cooling-image

BASIC HEAT EXCHANGE

Heat; the energy an object has because of the movement of its atoms and molecules.
Waste heat, not a nice term in today’s climate, is unfortunately a fact of life in industry and will necessitate removal or to better describe it, transfer from one object where it is undesirable to another where it is desirable, or at least will not cause damage. Good machinery design will minimise the transfer of energy to heat however mechanical equipment will invariably contain devices that generate heat due to friction of some sort. Consider a gearbox, the bearings will have rolling friction, the gears will have sliding friction, and the lubricating oil will be subject to constant movement, shearing and high pressures, the  oil as well as lubricating the bearings and gears will also readily absorb the heat these components generate by nature of its contact at the various points of friction, which is handy.
Heat transfer; the process of thermal energy moving from one location to another.
Heat transfers from one object to another by conduction, convection and radiation, or by a combination of any of these. Worth noting is the greater the temperature differential (∆ ‘T’) the greater the rate of transfer.

Different substances will conduct heat to a greater of lesser extent, cast iron is a good heat conductor, wood is not. Oil is also good which is very useful for cooling applications.

As an example a gearbox running in a steady loaded state generates heat internally by the processes as described above. This heat is readily conducted into the oil, which in turn conducts the heat to the inner surfaces of the gearbox case. The material of the gearbox case conducts the heat to the outer surfaces of the gearbox where it is radiated into the surrounding air. The hot air will be replaced by cool air due to convection. Providing the combination of these heat transfer processes, components to oil - to surface - to surface - to air, results in cooling the gearbox oil sufficiently to maintain an acceptable steady state working temperature, all is fine.

What if the heat input to the oil is greater than the capability of the combination of transfer processes to maintain an acceptable oil temperature? In this example the causes could be due to high mechanical strength of the gearbox resulting in high input power or a compact unit with a small outer surface area or thick case sections for instance. The resulting situation is a gearbox oil temperature that will continue to increase until it becomes ineffective resulting in damage to the gearbox. This is when the option to add an external cooling system must be considered.

As mentioned, oil is a good conductor of heat plus it can also be pumped. Therefore the oil can be pumped out of the gearbox and into a heat exchanger. In this example the heat exchanger will be oil to air where the oil is passed through channels and air is blown over these channels by a fan. Air-blast cooler matrices are typically manufactured from aluminium which is a very good conductor of heat. The sections are thin which also allows heat to transfer more readily. In order to maximise the heat transfer the oil passageways have turbulators added to the inside surfaces in order to turbulate or stir the oil, known as turbulent flow. This will cause much of the hot oil to contact the sides of the channels and give a better heat transfer rate over the length of the  channel. Without these turbulators the oil will pass through in laminar flow where the outside of the oil column will give up its heat leaving a central core at a higher temperature which in turn will result in less overall heat transfer.
Turbulent Flow diagram
Laminar flow diagram
On the air side of the channels thin fins are added. This has the effect of increasing the surface area subject to the passage of cooling air so the oil conducts its heat into the channels. The channels conduct their heat into the fins, the fins radiate their heat load into the air, the cooler fan speeds up the convection process so allows more heat to be washed away into the air. The cooled oil now returns to the gearbox where the cycle repeats forming a continuous conveyer belt of heat removal.
Cooling channels and fins diagram
With our experience in cooling systems jbj can help in correctly sizing a heat exchanger, oil to air as described or fluid to fluid, for your application. We can look at machine system power input figures, oil flow rates, temperature differentials, required temperatures, heat loads, etc. and provide a solution for the removal of waste heat, or the transfer of heat from a heat source to equipment that requires the addition of heat. After all the process does work in the same way in reverse!

jbj Techniques’ Full Service Cooling

Electric vehicle batteries running too hot?

Hydraulic system running too hot?

Need to cool your diesel/petrol engine, intercooler or gearbox oil?

Have a hydraulically driven cooling fan requirement?

Need for ATEX certified coolers, stainless steel coolers or coolers to C5M corrosion protection?
Is your electric vehicle battery running too hot?jbj Techniques has the solution.
We design and deliver complete autonomous cooling systems tailored to your EV battery requirements. Our systems integrate seamlessly with vehicle air conditioning circuits and feature energy-efficient fan drives that minimise power draw from the battery pack. From initial concept to fully packaged solutions - we’ve got you covered.

Overheating hydraulic system? jbj Techniques has the solution.
Choose from our extensive range of in-line or offline coolers to suit your specific application.

Need to cool a diesel or petrol engine, intercooler, or gearbox oil? jbj Techniques has the solution.
Whether you're a machine manufacturer seeking enhanced performance or need compact, multi-media cooling in a unique footprint - we provide efficient and reliable cooling components.
Components of hybrid vehicle cooling system.
Have a hydraulically driven cooling fan requirement?
jbj Techniques have the answer. Proportional fan drive systems having CAN Bus compatibility.

Looking for specialist coolers?
We offer ATEX-certified, stainless steel, and C5M-protected coolers to meet the most demanding requirements.

Contact jbj Techniques Limited for thoughtfully engineered cooling systems designed for performance and efficiency.
If it needs cooling, we’ll make it happen!
Cooling system for hybrid vehicle.
jbj Techniques Ltd in partnership with IRA Engineering are pleased to announce an exciting new addition to their product portfolio. This new addition being the IRA Engineering, Italian manufactured, range of air blast coolers. The range of air blast coolers is extensive, consisting of the RAL, aluminium, series of inline coolers, having a heat dissipation range of 1.6 kW to 200 kW (based on a ∆T of 40°C) and an oil flow capacity of 5 to 800 lpm. All standard AC and DC motor voltages are available for the fan drive, as well as AC motors to ATEX certification. In addition, hydraulic fan drives are available as standard fixed speed or as a proportional motor drive system, enabling you to tune the fan speed to the heat dissipation requirement. In addition to the RAL series is the GA series of offline (autonomous) coolers, the RO copper and steel air blast coolers and the RS series suitable for closed loop hydraulic systems.
industrial vehicle cooling
Coolers are available to ATEX certification, marine specification C5M and of stainless steel manufacture. IRA Engineering in conjunction with jbj Techniques Ltd, have the ability to design and manufacture bespoke cooling to suit your specific applications. Taking your cooling concept from design to completion. A most recent example of this being a battery cooling system for electric vehicles. In addition, and in this application, the electric cooling fan motor fitted to the air blast cooler can have CAN bus integration ability, enabling the speed of the fan to be tuned to the required heat dissipation from the air blast cooler, saving power and extending the vehicle range. For those of you wanting a complete engine cooling solution, taking into account engine water cooling, oil cooling and intercooler cooling, details provided on request.
GA series (Offline Coolers)

GA series (Offline Coolers)

For use where pressure spikes occur within the main circuit.
Dissipation 0.12 to 3.7 kW / °C or 4.8 kw to 148.8 kW when DT = 40°C for oil flows from 9 to 440 lpm.
Material: High resistance a aluminium alloy matrix, steel housing.
Link to: GA series technical detail
RA series (Water / Air coolers)

RA series (Water / Air coolers)

Generally, for use on low pressure mobile / agricultural applications.
Designed for your application and can be positioned directly in front of the engine or fitted with fans driven by electric or hydraulic motors.
Material: Brass and copper or high resistance aluminium alloy.
ATEX certification for suitable units on request.
Technical details on request due to bespoke nature of this series.
RAL Series (Return line coolers)

RAL Series (Return line coolers)

For use in cooling hydraulic circuits.
Dissipation 0.038 to 4.9 kW / °C or 2.2 kW to 196 kW when DT = 40°C for oil flows up to 800 lpm.
DP from 0.3 to 1.8 bar.Material: high resistance aluminium alloy.
Link to: RAL series technical detail (pages 1 to 77)
RO Series (Return Line coolers)

RO Series (Return Line coolers)

For use in cooling hydraulic circuits.
Dissipation 0.06 to 2.2 kW / °C or 2.4 to 88 kW when DT = 40°C for oil flows up to 500 lpm.
DP from 0.1 to 1.6 bar.
Material: copper and steel.
Link to: RO series technical detail (pages 85 to 135)
RS Series (Heat exchangers)

RS Series (Heat exchangers)

For use in closed loop circuit hydraulic applications.
Dissipation 0.15 to 0.31 kW °C or 7.5 to 12.5 kW when DT = 40°C for oil flows up to 140 lpm.
Complete with integrated surge tank and suction filter.
Materials: Steel and copper, high resistance aluminium alloy.
Link to: RS series technical detail
RC Series (Combination coolers)

RC Series (Combination coolers)

For machine manufacturers requiring cooling of multiple media.
Standard product or designed to suit your application requirements.
Cool water, oil or air through one assembly.
Positioned in front of the engine or supplied with fan driven by electric or hydraulic motor.
Materials: Steel and copper or brass and aluminium.
Technical details on request due to bespoke nature of this series.
RP series (Stand-alone coolers)

RP series (Stand-alone coolers)

For use in cooling hydraulic circuits.
Designed for your application with special consideration to thermal performances increasing whilst pressure drops reduce.
Material: Aluminium. Working pressure: 12 bar. Test pressure: 18 bar.
Max working temperature: 120°C.
Link to: RP series technical detail
RF Series (water / oil coolers)

RF Series (water / oil coolers)

For use in return line or low-pressure applications.
Dissipation: 1.5 kW to 231 kW.
Maximum continuous working pressure 10 bar.
Shell and tube design with steel plates and copper tubes.
Link to: RF series technical detail
KPV Series Cooler Bellhousings

KPV Series Cooler Bellhousings

Bellhousing coolers for drain line or full flow cooling.
Dimensions according to the VDMA Standard.
Rigid and noise damping versions with identical lengths.
Will replace existing bellhousing mounted in systems.
Optional foot bracket allows horizontal mounting.
To connect metric frame electric motors to a wide variety of pumps.
Link to: KPV series technical detail
Brazed Plate Heat Exchangers

Brazed Plate Heat Exchangers

Compact alternatives to conventional Shell & Tube coolers.
Vacuum brazed units ensure system integrity.
High efficiency means reduced coolant requirement.
Small size allows for reduce pipe and space requirements.
Optimised performance delivers exact system requirements.
Reduced size and weight improves shipping costs.
Plates pressed in either AISI 316L with SMO 254 available on request.
Copper or Nickel braze suits all environments and applications.
Various pipe connections and accessories available.
Accept temperatures up to 200°C and pressure of up to 31 bar.
ASME code certified and UL listed designs available on request.
Link to: brazed plate heat exchanger technical detail
Gasketed Plate Heat Exchangers

Gasketed Plate Heat Exchangers

Gasketed versions for ease of assembly and cleaning.
Designed to suit individual customers requirements.
Fail safe design eliminates cross fluid contamination.
Modular design provides maximum efficiency of fluid heat transfer.
Unit performance adjusted by adding or reducing plate numbers when requirements change.
A variety of channel arrangements offer different solutions within the same footprint.
Maximum flows up to 4,600 cubic metres per hour.
Maximum pressures up to 25 bar.
Temperature range from -40 to 180°C.
Various pipe connections from DN 25 to DN500, weld neck flanges or threaded.
Plate materials in AISI 304, 316L and Titanium combat the most arduous conditions.
Optimised performance meets exact system requirements.
Link to: gasketed plate heat exchanger technical detail

External gear motors for fan drives

This fan drive motor is a range for vehicle cooling systems. These types of motors are widely used in modern hydraulics thanks to their performance, long service life and low maintenance costs.

An electro-hydraulic fan drive offers significant advantages if compared with traditional solutions with electric or belt drives. Maximum performance is achieved by combining the fan drive system with a fully-programmable electronic control unit.

The fan drive system consists of:
» Reverisible fixed displacement hydraulic gear motor.

Fan drive for external gear motors
Fan-drive-operated manifold which consists of:
» Special NG6 directional valve for smooth controlled rotation change.

» Non-return valve to avoid cavitation during reversing.

» Proportional valve – which allows rotational changes by over riding the settings. The valve is actuated by an signal from an electronic circuit board designed for the “fan drive” function. It controls the rotation speed of the hydraulic motor by means of on-board sensors.

» Circuit relief valve to control the operating pressure of the hydraulic motor.

» Motor displacement: Group 2 from 4 to 31.5 cm³/rev. (from 0.24 to 1.92 in³/rev).

» Maximum pressure: up to 250 bar (3600 psi).

» Speed rotation: up to 4000 rpm.

» NG6 solenoid operated directional valve allows the reversing functiuon: technical data flow max 80 l/min, P max 350 bar.

» Coil data: 12 or 24 dc with plug DEUTSCH DT04-2P for male connector type DEUTSCH DT06-2S.

» Pressure control valve: Q max 120 l/min, P max 210 bar.

» Proportional pressure control: Q max 80 l/min, P max 250 bar.

In a fan drive system, the electronic circuit board controls the rotation speed of the hydraulic motor based on the actual heat dissipation through the cooling system. The signals from the temperature sensors or CAN network are processed by the electronic card which, depending on its settings, controls the rotational speed of the hydraulic motor proportionally and cleans the cooler matrix by automatically reversing the direction of rotation of the motor. The software developed and designed for the fan drive function improves the vehicle fuel economy in compliance with eco-sustainability regulations. Resulting in advantages for both the client and the community. The electronic card is plug and play and reduces the vehicle start-up time and costs.

Cooling solution for internal combustion engines

For machine manufacturers requiring improved performance or combined cooling of multiple media in a compact design or different cooler shape.

Following an accurate design, verification and operational validation of the prototype directly on the engine, we develop a complete product for cooling the water / intercooler / oil with side by side or overlapping masses.
The complete package can have the configurations chosen by the customer and can include, in addition to the heat exchanger, the fan suitable for the application and relative protections, supports and brackets for connection to the motor, aluminum, stainless steel or rubber pipes, aluminum expansion tanks, integrated or independent.

Analysis of engine data sheet and customer cooling and sizing requirements, followed by design of cooling system.

CAD drawings produced to enable full component set up including all parts in 3D model.
Cooling solution for internal combustion engines

Further analysis of component package.

Either the engine is supplied by the customer for full build up of package to the engine or components supplied to customer to build the package.

Bespoke design and build to fulfill customers application needs.
There are existing design packages for Cummins, Perkins, Volvo, Caterpillar, Kubota, Hatz, Yanmar, Doosan, Fpt, VM, Kohler and Deutz.

Contact jbj Techniques technical office to discuss your requirements, telephone: +44 (0)1737 767493 or email: info@jbj.co.uk
Specification of all heat exchangers found in this on-line » catalogue « link
Questions?

Contact
jbj Techniques Limited
for friendly help and advice
telephone: +44 (0)1737 767493
email:
happy to help at jbj Techniques Limited, quality products for mechanical and fluid power