INTEGRATED ENGINE MANAGEMENT DEVICE AND SYSTEM

Description

1 / 10 INTEGRATED ENGINE MANAGEMENT DEVICE AND SYSTEM

[001] The present invention relates to an integrated engine management device and an integrated engine management system. More particularly, the invention relates to an integrated device, comprising and uniting an ECU (Engine Control Unit) and an ETB (Engine Trothie Body), for the unified management of small internal combustion engines, ICE. State of the Art

[002] The stringency of emission standards has been increasing over the years, and with this, the use of internal combustion engines (ICEs) has to adapt to the new requirements. Global emissions control programs (EURO in particular, which is in its sixth phase and preparing for its seventh phase) are making the standards even more stringent with regard to emissions from mobile sources, whatever the application.

[003] ICEs, operating with gasoline, ethanol, mixtures or any other fuel, regardless of the thermal cycle, emit pollutants. Among the most common gases are carbon monoxide, hydrocarbons, sulfur dioxide, aldehydes, carbon dioxide, nitrogen oxides, particulate matter and vapors from these fuels. It is worth mentioning the EURO 6 standard which, unlike its previous phase, required a 72% reduction in the limit for hydrocarbon emissions and an 80% reduction in nitrogen oxide emissions. EURO 7 discusses the reduction of the NOx emission limit, which in EURO 6 is approximately 80 mg (milligrams), to 60 mg (milligrams), which will require engines to adapt to this new demand regardless of whether they are engines applied to automobiles, trucks or small engines.

[004] Ozone in the upper atmosphere protects the planet from ultraviolet rays, but when it is near the ground (tropospheric ozone) it becomes extremely harmful, forming a noxious atmosphere that compromises human health and agriculture.

[005] The increase in tropospheric ozone comes, among other sources, from gases emitted by motor vehicles and is significantly increased by the evaporation of fuels used. Petition 870250004491, dated 20 / 01 / 2025, page 21 / 38 2 / 10

[006] These evaporative emissions occur with the increase in daytime temperature and consequent increase in fuel temperature in the tank and also at the time of refueling. At refueling, for example, 50 liters of gasoline have 75 g of vapor evaporated, or 100 mL of liquid gasoline.

[007] In order to meet the legal limitations on pollutant emissions into the atmosphere, ICEs have been implementing new devices and methods to constantly reduce these emissions. For example, current vehicles have devices for capturing and recirculating fuel vapors, while combustion management is increasingly improved and controlled by lambda sensors located at the exhaust manifold outlet and downstream of the catalytic converter.

[008] Other components directly linked to the control and management of combustion and, therefore, directly linked to the emissions of pollutants and particulates, are the ECU and the ETB. The throttle body (ETB) and the engine control unit (ECU) are integral parts of the electronic fuel injection system of the ICEs, whose functions are to meter the amount of air demanded by the ICE (via ETB) and manage the electrical and electronic functions of the ICE, a function of the ECU, thus contributing to the reduction of fuel consumption, as well as the reduction of vehicle emissions of gases harmful to health.

[009] While in medium and large-sized ICEs it is possible and relatively easy to incorporate new emission control and reduction devices, the same is not true for small engines. In particular, these ICEs must prioritize simplicity and ensure easy operation because they are not used frequently in the user's daily life, but when required they must provide the expected response for their intended purpose. In addition, these small engines must be simple, occupying the smallest possible space and having the lowest possible weight. Compactness is a fundamental factor.

[0010] Small engines are understood to be any thermal machine applied to equipment intended to assist in human work activities. Examples of such equipment include: lawnmowers, electricity generators, snowplows, augers (machines for drilling soil and ice), recreational vehicles, Petition 870250004491, dated 20 / 01 / 2025, page 22 / 38 3 / 10 karts, motorcycles, jet skis, construction equipment, among others, and whose engine displacement does not exceed 1,000 cm3, usually comprising 1 cylinder, and occasionally 2 cylinders.

[0011] Another characteristic to be highlighted in small motors is the high level of vibration and temperature. Thus, any and all components intended for these applications must be designed to withstand these demands.

[0012] Thus, the need for compact and highly functional devices remains in the field, capable of being incorporated into equipment with small motors, and fundamentally aimed at reducing emissions of gases harmful to health.

[0013] A specific objective of the invention comprises a compact device capable of integrating the functions of the ECU and the ETB. Another specific objective of the invention is a device that is compact in size and mass, easy to install, and has a reduced volume. Summary of the Invention

[0014] These and other objectives are satisfied from an integrated engine management device, in particular for the management of an internal combustion engine (ICE) of a piece of equipment, the integrated device comprising a throttle body (ETB) and an engine control unit (ECU).

[0015] In particular, the device comprises a base coupled to a cover, the base comprising a shaped seat, preferably cylindrical, for a motor and a valve body fitted with a butterfly valve, and the cover comprising a PCB and a male connector.

[0016] The base of the integrated device houses a motor, at least one reduction gear and an actuator comprising a support shaft and rotary drive of the throttle.

[0017] The motor comprises a drive shaft fitted with a transmission gear, said gear being rotationally coupled with an upper toothed disc of the reduction gear, and the lower toothed disc of the reduction gear being rotationally coupled with a toothed sector of the throttle actuator. Petition 870250004491, dated 20 / 01 / 2025, page 23 / 38 4 / 10

[0018] The actuator comprises a base disc on whose edge is formed the toothed sector or gear sector with an angular amplitude of 90° or other, and the butterfly shaft projecting downwards from the base disc.

[0019] The base disc further comprises a cylindrical projection, coaxial with respect to the butterfly axis, the cylindrical projection defining a seat for a magnetic element.

[0020] The cover supports the PCB, the PCB comprising at least one processor, at least one memory, and on the underside of the PCB is connected a magnetic position sensor, facing the magnetic element of the base disk and capable of identifying the angular position of the butterfly and transmitting such angular position signal to the processor.

[0021] The valve body comprises an intake duct within which the throttle rotates with an angular amplitude of 0 to 90° or another amplitude determined by the ICE.

[0022] Finally, the device is supported and held in position between an intake manifold and an ICE intake nozzle.

[0023] In addition, the objectives are met by means of an integrated engine management system, in particular for the management of an internal combustion engine (ICE) of a piece of equipment, comprising a throttle body (TB) and an engine control unit (ECU) integrated into a single integrated device, wherein the integrated device is able to meter the amount of air demanded by the ICE and manage the electrical and electronic functions of the ICE. Furthermore, the integrated device is able to directly meter the amount of air demanded by the ICE and externally manage the electrical and electronic functions of the ICE. Brief Description of the Figures

[0024] The object of the present invention may be better understood from the detailed description that follows, in a preferred and non-limiting embodiment of the invention, which is made with the support of the attached figures, provided by way of illustration and not limitation, in which: Figure 1 is a top perspective view of an integrated device and Petition 870250004491, dated 20 / 01 / 2025, page 24 / 38 5 / 10 comprising an ECU and an ETB, according to the present invention; Figure 2 is a bottom perspective view of the device of the invention; Figure 3 is a top perspective view of the electromechanical component assembly; Figure 4 is a bottom perspective view of the electromechanical component assembly; Figure 5 is a side elevation view of the electromechanical component assembly; Figure 6 is a perspective view of the components of the butterfly valve actuation mechanisms; Figure 7 is a perspective view of the throttle valve position monitoring system; and Figures 8 and 9 are perspective views of the integrated device of the invention, coupled downstream of the air intake nozzle and upstream of the air / fuel mixture intake manifold for an ICE. Preferred Embodiment of the Invention

[0025] In accordance with the attached figures, 1 is shown in its entirety as an integrated engine management device according to the invention. More specifically, the integrated device 1 incorporates the functions of an ECU and an ETB in a single physical component, resulting in the sharing of components and sensors, the elimination of cables and electrical connection harnesses, and a volumetric reduction of the integrated engine control unit (not shown) of the equipment.

[0026] In more detail, the integrated device 1 comprises a base 2, preferably obtained by die-casting in aluminum, shaped, on which a cover 3 is disposed, thus defining an isolated and watertight internal volume. The cover 3 is fixed to the base 2 by means of locking springs 4, which engage with the lower edge 6 of the cover 3 and engage with respective reliefs of the base 2, thus fixing (in a watertight manner) and maintaining the cover 3 positioned in relation to the base 2. In one embodiment, a sealing element or gasket (not shown) is provided between the base 2 and the cover 3. Positioning reference as per figures 1 or 5. Petition 870250004491, dated 20 / 01 / 2025, page 25 / 38 6 / 10

[0027] In particular, cover 3 has a parallelepiped shape, from which projects a male connector 5 suitable for receiving a corresponding terminal (not shown) from an ICE harness. This harness, in addition to providing power to the integrated device 1, is also capable of sending and receiving command signals, sensor signals, among others.

[0028] Furthermore, base 2 is defined by a basically flat upper portion and enclosed by an upper edge 7, dimensionally corresponding to the lower edge 6 of the cover 3. From said upper portion of base 2, extending downwards, a shaped seat 8, preferably cylindrical, and a valve body 9 are defined, suitable for receiving, respectively, a DC motor 11 and a throttle body 12, as will be described in more detail below.

[0029] Figures 3 to 5 illustrate more clearly the internal components of the integrated device 1, as well as their respective relative positions in the preferred embodiment. Briefly, the internal volume of the integrated device 1 is divided, in height, by PCB 10, the upper portion of this volume being reserved for electronic components while the lower portion is preferably reserved for mechanical components, but not exclusively, since PCB 10 is a double-sided board. Alternatively, PCB 10 is a multilayer board.

[0030] The upper face of PCB 10 is preferably intended to receive the electronic components, among which are at least one processor 13, at least one memory 14, as well as the terminals of the male connector 5, which are directly soldered onto PCB 10. In addition, a magnetic position sensor 15 is connected to the lower face of PCB 10, the operation of which will be explained later.

[0031] In one embodiment, and in view of fixing the male connector terminals directly to PCB 10, PCB 10 is fixed to cover 3, for example, from pillars (not shown) that project downwards, via snap-fit, by means of screws or other appropriate fastening methods.

[0032] For the purposes of this description, processor 13 may be a general-purpose processor, a special-purpose processor, a conventional processor, a digital signal processor (DSP), a plurality of Petition 870250004491, dated 20 / 01 / 2025, page 26 / 38 7 / 10 microprocessors, one or more microprocessors in association with a DSP core, a controller, a microcontroller, Application Specific Integrated Circuits (ASICs), Field Programmable Gate Array (FPGA) circuits, any other type of integrated circuit (IC) and the like. Furthermore, and for the purposes of this description, memory 14, or generically a data storage medium, may be read-only memory (ROM), random access memory (RAM), solid-state memory, a register, a cache memory, or other semiconductor memory devices.

[0033] In particular, processor 13 receives the power or torque demand from the equipment user and, based on signals received from the various sensors of the equipment to which the integrated device 1 is coupled, acts in controlling fuel injection and, directly, in controlling the intake of fresh air through the position of the throttle 12 of the integrated device 1. In particular, and if the ICE of the equipment is an Otto cycle engine, the integrated device 1 acts mainly in controlling the flow of air intake.

[0034] With regard to the control of the flow of fresh air admitted into the ICE, the lower portion of the internal volume of the integrated device 1 is intended to receive the butterfly valve and the respective means of actuation and control thereof.

[0035] For this purpose, base 2 comprises a shaped seat 8 inside which the DC motor 11 is disposed. The drive shaft 16 of the motor 11 projects into the lower portion of the internal volume of the integrated device 1, receiving a toothed transmission gear 17. In turn, the transmission gear 17 is rotationally coupled with a double reduction gear 18, that is, composed of an upper toothed disc 19 and a lower toothed disc 20, the number of teeth on the upper toothed disc being greater than the number of teeth on the lower toothed disc. Furthermore, the lower toothed disc 20 is rotationally coupled with the toothed sector 22, or gear sector of the butterfly actuator 21.

[0036] With particular attention to the butterfly actuator 21, this comprises a base disc 23 from the edge of which the toothed sector 22 is formed. The said sector Petition 870250004491, dated 20 / 01 / 2025, page 27 / 38 The toothed 8 / 10 22 exhibits an angular amplitude of approximately 90°, sufficient to allow the butterfly valve 12 to be angularly displaced from a position of maximum opening to a position of closing of the butterfly valve, or more specifically, of the intake duct 29 of the valve body 9 within which the butterfly valve 12 rotates. To this end, the shaft 24 supports and promotes the rotational actuation of the butterfly valve 12, being fixed at the top to the base disc 23, while the opposite, lower end of the shaft 24 receives a sliding bushing 25 capable of allowing the rotation of the shaft 24 in relation to the base 2, on which the actuator 21 is supported.

[0037] In addition, the actuator 21 also comprises a helical spring 26, the ends of which are connected to the base 2 and the base disc 23 so that, in the event of mechanical failure, the butterfly 12 is automatically moved to the butterfly valve closing position.

[0038] Finally, the base disc 23 also comprises a cylindrical projection 27, coaxial with respect to the axis 24 of the butterfly valve 12, which defines a seat for a magnetic element 28. As particularly illustrated in figures 5 and 7, the aforementioned magnetic position sensor 15 fixed to the lower face of the PCB 10 is positioned close to the magnetic element 28, so as to identify the angular position of the butterfly valve 12 and transmit such angular position signal to the processor 13 through at least one trace of the PCB 10. In this way, the signal sent by the magnetic position sensor 15 to the processor 13 indicates the angular position of the butterfly valve 12 internally located in the intake duct 29, and the angular position of the butterfly valve 12 defines the flow rate of fresh air, or atmospheric air, that enters the combustion chamber of the ICE.

[0039] Figures 8 and 9 represent two perspective views of a possible mounting of the integrated device 1 in relation to the air intake nozzle 31 and the air / fuel mixture intake manifold 30 of the ICE. For this purpose, the valve body 9 comprises a pair of through holes 32 (see specifically figures 1 and 2) through which respective screws 33 (figure 9) securely fix the intake nozzle 31 and the intake manifold 30 on opposite sides of the valve body 9.

[0040] In addition, a support blade 34 is attached to the intake nozzle 31, which can be fixed, at its opposite end, to a housing or chassis of the equipment. From Petition 870250004491, dated 20 / 01 / 2025, page 28 / 38 9 / 10 Similarly, the intake manifold 30 is fixed, at least at one end, to the ICE block. In this way, the integrated device 1 is held indirectly fixed to the equipment, i.e., through the intake nozzle 31 and the intake manifold 30. In any case, its disassembly, if necessary, is simple and quick since it is achieved by removing the two screws 33.

[0041] Just to note, as industry technicians are aware, upstream of the intake nozzle 31 it is possible to provide an air filter (not shown), in order to filter the fresh air, or atmospheric air, before mixing with the fuel and before this mixture is admitted into the combustion chamber of the ICE. On the other hand, the intake manifold 30 may provide one or more fuel injectors, whose injection times are controlled by the integrated device 1, the intake manifold 30 receiving a flow of fresh air and a flow of injected fuel, both proportionally metered by the integrated device 1, the mixture of flows being sent to one or more cylinder(s) of the ICE. Alternatively, the fresh air flow is directed directly to the cylinder(s) through the intake manifold duct(s), while the fuel flow is injected by the fuel injector.

[0042] Furthermore, all internal elements (metallic, plastic and elastomeric) through which intake air and fuel vapors, gasoline, ethanol and mixtures thereof circulate are designed and tested to withstand the entire life of the equipment or device (full Hfé) without compromising its operation. In addition, all mechanical and electro-electronic components are specified and designed to withstand the vibrations and temperatures imposed by the ICE.

[0043] In operation, once the equipment is switched on, at least through the ICE start-up, the user transmits a power demand to the integrated device 1 through electrical signals transferred from a control via the electrical connection harness and male connector 5. Thus, the integrated device 1 calculates the necessary flows of fresh air and fuel for the requested power and torque demand, altering the position of its throttle 12 and controlling the fuel injection times via electrical signals through the aforementioned male connector 5 and electrical connection harness. The actuation of the throttle 12 is performed by the DC motor 11, while its position Petition 870250004491, dated 20 / 01 / 2025, pp. 29 / 38 The 10 / 10 angular rotation is controlled by the magnetic position sensor assembly 15 of PCB 10 and magnetic element 28, of the throttle shaft 24 12. In time, the integrated device 1 keeps the fuel injection times and throttle position 12 under control, always according to the power and torque demand and, if provided, by a lambda sensor (not shown) that informs the integrated device 1 about the composition of the exhaust gases in order to adjust the fuel injection times (or fuel mixture) to improve combustion and reduce emissions of pollutants and particulates.

[0044] As can be seen, the integrated device 1, according to the invention, has a very compact layout in size and mass and is particularly suitable for use in small equipment, equipped with ICEs that are also small in size and small in displacement, resulting from the functional integration operated by the integrated device 1.

[0045] Moreover, such functional integration, according to the characteristics of the invention, also innovates in the reduction of components, sensors, harnesses and others, contributing to the reduction of the dead weight of the equipment and, therefore, increasing its energy efficiency. Petition 870250004491, dated 20 / 01 / 2025, pages 30 / 38

Claims

1 / 2 Claims 1. Integrated engine management device, in particular for the management of an internal combustion engine ICE of a piece of equipment, the integrated device (1) characterized by comprising a throttle body ETB and an engine control unit ECU.

2. Device according to claim 1, characterized by comprising a base (2) coupled to a cover (3), wherein the base (2) comprises a shaped seat (8), preferably cylindrical, for a motor (11) and a valve body (9) fitted with a butterfly valve (12), and wherein the cover (3) comprises a PCB (10) and a male connector (5).

3. Device according to claim 1 or 2, characterized in that the base (2) of the integrated device (1) houses a motor (11), at least one reduction gear (18) and an actuator (21) comprising a shaft (24) supporting and rotating the butterfly (12).

4. Device according to claim 3, characterized in that the motor (11) comprises a drive shaft (16) fitted with a transmission gear (17), said gear (17) being rotatably coupled with an upper toothed disc (19) of the reduction gear (18), and the lower toothed disc (20) of the reduction gear (18) being rotatably coupled with a toothed sector (22) of the butterfly actuator (21) (12).

5. Device according to claim 3, characterized in that the actuator (21) comprises a base disc (23) on whose edge is formed the toothed sector (22) with an angular amplitude of 90°, and in that the axis (24) of the butterfly (12) projects downwards from the base disc (23).

6. Device according to claim 5, characterized in that the base disc (23) further comprises a cylindrical projection (27), coaxial with respect to the axis (24) of the butterfly (12), the cylindrical projection (27) defining a seat for a magnetic element (28).

7. Device, according to claim 1 or 2, characterized in that the cover (3) supports the PCB (10), the PCB comprising at least one processor (13), at least one memory (14) and in that on the underside of the PCB (10) is connected a magnetic position sensor (15), facing the magnetic element (28) of the base disk (23) and able to identify the angular position of the butterfly (12) and transmit such angular position signal to the processor (13).

8. Device according to claim 1 or 2, characterized in that the valve body (9) comprises an intake duct (29) within which the butterfly valve (12) rotates.

9. Device according to claim 1 or 2, characterized by being supported and held in position between an intake manifold (30) and an intake nozzle (31) of the ICE.

10. Integrated engine management system, in particular for the management of an internal combustion engine (ICE) of a piece of equipment, characterized by comprising a throttle body (TB) and an engine control unit (ECU) integrated into an integrated device (1), wherein the integrated device (1) is able to meter the amount of air demanded by the ICE and manage the electrical and electronic functions of the ICE.

11. System, according to claim 10, characterized in that the integrated device (1) is able to directly dose the amount of air demanded by the ICE and externally manage the electrical and electronic functions of the ICE. Petition 870250004491, dated 20 / 01 / 2025, pp. 32 / 38

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