Exhaust gas recirculation pipe alignment system

Abstract

The present disclosure provides "exhaust gas recirculation pipe alignment systems." Systems for aligning and assembling an exhaust gas recirculation (EGR) assembly with an engine intake housing are provided. In one example, an intake system can include an EGR port housing for coupling the EGR assembly on an intake housing. The EGR port housing can include one or more alignment tabs on at least one side of the EGR port housing for aligning and guiding the EGR assembly onto the intake housing during installation.

Description

Technical Field

[0001] This specification generally relates to an engine system with an exhaust gas recirculation system. Background Technology

[0002] Engine systems (including naturally aspirated and turbocharged engines) utilize exhaust gas recirculation (EGR), in which a portion of the exhaust gas is recirculated into the intake air to reduce engine emissions and / or improve fuel economy. In turbocharged engine systems that utilize a compressor in the intake system to provide boost air, EGR can be delivered in either a "high-pressure" (HP) circuit or a "low-pressure" (LP) circuit. In the HP circuit, EGR gas is captured before the turbine and injected after the compressor, and in the LP circuit, EGR gas is captured after the turbine and injected before the compressor. Engine systems with EGR include an EGR port in the intake manifold to allow EGR gas to enter. The intake housing typically includes mounting surfaces for locating the EGR port and mounting the EGR pipe assembly to the intake housing.

[0003] Murphy illustrates an exemplary intake housing configuration in U.S. Patent No. 6,874,487. The intake housing includes an extended boss for receiving an EGR pipe assembly, and the boss further includes a boss extension. An attachment portion of the EGR pipe assembly includes a pair of tabs aligned with the boss extension, and the EGR pipe is coupled to the intake housing via fasteners inserted through openings in the tabs and the boss extension.

[0004] However, the inventors of this paper have recognized the potential problems of such systems. As an example, during the installation of the EGR pipe assembly to the intake manifold, the EGR pipe assembly may be misaligned with the intake housing and connected without detection and correction of the misalignment. Therefore, the EGR pipe assembly may be incorrectly connected, and a tight seal may not be established between the EGR pipe assembly and the intake housing. Consequently, leakage may occur when EGR gas is delivered from the EGR pipe into the intake manifold. Therefore, the assembled intake manifold and EGR pipe unit may fail to pass pipeline testing during development and / or at the end point, potentially leading to delays in final product delivery. In some examples, improper assembly may establish a temporary seal, and therefore may not be detected during testing and development. However, during subsequent vehicle operation, the temporary seal may not remain, leading to gas leakage and thus causing vehicle performance and emissions degradation problems. Furthermore, in some cases, the positioning of the EGR pipe assembly may be incorrect. For example, the EGR pipe assembly may be rotated 180 degrees relative to its correct position. Intake systems (such as Murphy's) do not provide any indication of incorrect EGR pipe assembly orientation. Therefore, the EGR pipe may be installed incorrectly, making the assembled product unsuitable for engine assembly. This causes manufacturing delays. Summary of the Invention

[0005] In one example, the above problem can be solved by an intake system for an engine, the intake system comprising: an intake boost chamber enclosed by an intake boost chamber housing; and an exhaust gas recirculation (EGR) port for allowing exhaust gas recirculated by the EGR system to enter the intake boost chamber; wherein the EGR port is enclosed by an EGR port housing, the EGR port housing including a central boss, one or more housing extensions, and one or more alignment tabs, each alignment tab being positioned on one side of each housing extension.

[0006] In this way, by providing one or more alignment tabs on the EGR port housing, the EGR assembly can be more precisely aligned with the intake housing during assembly. Furthermore, the one or more alignment tabs are configured such that the tabs only allow the EGR assembly to be connected to the intake manifold when the EGR assembly is correctly aligned with the EGR port housing on the intake manifold, thereby preventing the EGR assembly from fastening to the intake manifold if misaligned.

[0007] As an example, the EGR port for delivering EGR gas to the intake manifold is sealed by an EGR port housing. During assembly, the EGR pipe assembly is aligned with and coupled to the EGR port housing via one or more alignment tabs to form an intake-EGR pipe unit. Specifically, the EGR port housing includes a central boss for receiving the EGR pipe portion of the EGR pipe assembly. Furthermore, the EGR port housing includes housing extensions located on opposite sides of the central boss. Each housing extension includes an opening for receiving fasteners. Additionally, the EGR port housing includes one or more alignment tabs, each corresponding to a housing extension on one side of the housing extension, for guiding and aligning the flange of the EGR pipe assembly with the opening on the housing extension. In one example, each alignment tab extends below each housing extension, each housing extension positioned on the opposite side of the central boss. Furthermore, each alignment tab includes a stepped protrusion on the front side of the EGR port housing, which provides a mounting and alignment surface for the EGR pipe assembly. Specifically, during the assembly process, the EGR pipe portion of the EGR pipe assembly is inserted into the central boss, and the flange of the EGR pipe assembly is positioned on the stepped protrusion of the alignment tab and guided to align the fastener holes on the flange with the openings on the housing extension. Fasteners can then be inserted through the fastener holes and the openings on the housing extension to connect the EGR pipe assembly to the EGR port housing on the intake manifold.

[0008] If the EGR tube assembly is correctly positioned relative to the EGR port housing, the alignment tab guides the EGR tube assembly so that the fastener holes on the assembly's flange align with the openings on the housing extension. Once aligned, the EGR tube assembly can be engaged with the EGR port housing. However, if the EGR tube assembly is incorrectly positioned (e.g., rotated 180 degrees), the alignment tab prevents the alignment of the fastener holes and openings. Therefore, it may be impossible to insert fasteners through the fastener holes and housing extensions. This prevents incorrect installation of the EGR tube assembly. Furthermore, when correctly positioned, the fastener holes and openings can be aligned with minimal adjustment by using the alignment tab. Additionally, misalignment is reduced by using the alignment tab for EGR assembly installation, as it significantly reduces the number of potential misalignment locations. In this way, by guiding the alignment of the EGR tube assembly with the EGR port housing and by providing directional guidance for positioning the EGR tube assembly with the EGR port housing, the alignment tab reduces the time required to assemble the EGR tube assembly. Furthermore, by ensuring proper alignment, improper connection between the EGR pipe assembly and the EGR port housing is reduced. Therefore, maintaining a proper seal between the EGR pipe and the intake manifold throughout the vehicle's lifespan is ensured.

[0009] It should be understood that the foregoing summary is intended to present a simplified version of a series of concepts that will be further described in the detailed description section. This does not imply representation of key or essential features of the claimed subject matter, the scope of which is uniquely defined by the claims following the detailed description. Furthermore, the claimed subject matter is not limited to embodiments that address any shortcomings pointed out in the foregoing or any part of this disclosure. Attached Figure Description

[0010] Figure 1 A schematic diagram of an exemplary vehicle including an engine, an intake system, and an exhaust system is shown.

[0011] Figure 2 A perspective view of a portion of the engine intake assembly, including the EGR port housing, is shown.

[0012] Figure 3 It shows Figure 2 A magnified view of the EGR port housing;

[0013] Figure 4 It shows including Figure 2 An exploded view of a portion of the engine intake assembly and the EGR outlet assembly, including the EGR port housing.

[0014] Figure 5 A perspective view of the assembled engine intake assembly and EGR outlet assembly unit is shown;

[0015] Figure 6 It shows Figure 2 Another perspective view of a portion of the engine intake assembly and EGR port housing;

[0016] Figure 7 It shows Figure 5 Another perspective view of the assembled engine intake assembly and EGR outlet assembly unit;

[0017] Figure 8 It shows including Figure 5 An exploded view of the assembled engine intake assembly and EGR outlet assembly unit, including a portion of the engine intake assembly and the EGR inlet assembly; and

[0018] Figure 9 A perspective view of the assembled engine intake assembly, EGR outlet assembly, and EGR inlet assembly unit is shown.

[0019] Figures 2 to 9 Shown roughly to scale. Detailed Implementation

[0020] The following description relates to the connection of the exhaust gas recirculation (EGR) pipe assembly with vehicle systems (such as...) Figure 1 The intake manifold of the EGR pipe assembly is mounted together with the intake manifold housing of the vehicle engine (which may be the intake manifold housing or the intake supercharger housing) to assist in the alignment and installation of the EGR pipe assembly with the intake manifold housing during the assembly process. For example, during the manufacturing / development phase of the vehicle lifecycle, particularly during the installation of the EGR pipe assembly with the intake manifold housing, misalignment of the EGR pipe assembly and the intake manifold housing may result in an improper connection between the EGR pipe assembly and the intake manifold housing. Consequently, a tight seal may not be established between the EGR pipe assembly and the intake manifold housing. As a result, leakage may occur when EGR gas is delivered from the EGR pipe into the intake manifold. Consequently, the assembled intake manifold and EGR pipe unit may fail pipeline testing during the testing phase of the vehicle lifecycle, potentially leading to delays in final product delivery. In some examples, improper sealing may cause vehicle performance and emissions problems due to gas leaks during subsequent vehicle operation. To reduce assembly time of the EGR pipe assembly and maintain proper sealing between the EGR pipe and the intake pipe, an EGR outlet port housing is disposed on the intake housing, wherein one or more alignment tabs adjoin one or more attachment openings. Specifically, the EGR outlet port housing includes one or more EGR pipe alignment tabs for aligning the EGR pipe with the outlet port, and one or more EGR pipe attachment openings for securing the EGR pipe assembly to the EGR outlet port housing. Figure 2 The image shows a portion of an intake manifold including an EGR outlet port housing, the portion comprising one or more alignment tabs and one or more attachment openings. Figure 3 An enlarged view of the EGR outlet port housing with alignment tabs is shown. Furthermore, Figures 4 to 9 The alignment and attachment of the EGR pipe assembly and the EGR outlet port housing via alignment tabs are illustrated. In this way, by implementing an EGR port housing with one or more alignment tabs, the following technical effects are achieved: correct oriented positioning of the EGR pipe assembly and the EGR port housing, and proper alignment of the EGR pipe assembly and the EGR port housing. Additional technical effects include faster assembly of the EGR pipe assembly and the EGR port housing, and a consistently tight seal between the EGR pipe assembly and the EGR port housing.

[0021] refer to Figure 1The diagram illustrates a vehicle 100 including an engine 102, an intake system 104, an exhaust system 106, and an exhaust gas recirculation (EGR) system 108. The intake system 104 is configured to supply intake air to cylinders 110 in the engine 102. The engine is depicted as having four cylinders arranged in an inline configuration. However, it should be understood that the number of cylinders and / or the cylinder configuration may be varied in other embodiments. For example, the engine 102 may include six cylinders arranged in a V-configuration. The intake system 104 is configured to allow intake air to flow into the cylinders, and the exhaust system 106 is configured to receive exhaust gas from the cylinders. Additionally, each cylinder 110 may include an ignition device 112 configured to ignite the air-fuel mixture in the cylinder 110. Alternatively, compression ignition may be used to ignite the air-fuel mixture in the cylinder 110. The engine 102 also includes at least one intake valve and one exhaust valve for each cylinder.

[0022] The intake system includes a compressor 114. The compressor 114 may be included in a turbocharger, which has a turbine 116 in the exhaust system 106. The compressor 114 and the turbine 116 are rotatably coupled. However, in other examples, the compressor 114 may be rotatably coupled to a transmission in the vehicle, thereby providing so-called mechanical supercharging.

[0023] The intake system 104 includes an intake assembly 140 that includes an intake booster chamber 118 (hereinafter referred to as booster chamber 118). The booster chamber 118 may include a boost air cooler (CAC) (not shown) integrated therein. The boost air cooler can be used to cool the intake air, which can be heated via operation of the compressor 114 and EGR gas supplied to the intake system 104 upstream of the booster chamber 118. The booster chamber 118 may include an inlet (not shown) in fluid communication with the compressor 114. The booster chamber 118 also includes a booster chamber housing 121. In this configuration, the cross-sectional area of ​​the booster chamber 121, perpendicular to the overall direction of airflow, increases in the downstream direction. Therefore, the booster chamber housing 121 includes expansion, and the volume of the booster chamber housing expands in the downstream direction. Furthermore, a pressure sensor 127 may be positioned in a pressure sensor port within the booster chamber 118. The pressure sensor 127 can provide an indication of manifold pressure to the engine controller 150, which will be discussed further below.

[0024] The intake assembly 140 also includes an EGR port 178 (alternately referred to as the EGR outlet port 178), which is located downstream of the compressor 114 in the intake airflow direction. EGR gas from the high-pressure (HP) EGR circuit (discussed below) is delivered to the booster chamber housing 121 via the EGR outlet port 178.

[0025] EGR port 178 is enclosed by an EGR port housing, which is integrally connected to the intake boost chamber housing that encloses the intake boost chamber 118 and the housing 121. It can be noted that the EGR port in the intake manifold can alternatively be referred to as the EGR outlet port. Therefore, the terms EGR port and EGR outlet port are used interchangeably. Furthermore, it can be noted that the EGR port housing connected to the intake boost chamber housing can alternatively be referred to as the EGR outlet port housing. Therefore, the terms EGR outlet port housing and EGR port housing are used interchangeably.

[0026] During the vehicle manufacturing phase, an EGR pipe assembly, including EGR pipe 173 for recirculating EGR gas from the high-pressure (HP) EGR circuit (discussed below), is coupled to the EGR outlet port housing via one or more alignment tabs disposed on the EGR outlet port housing. The alignment tabs guide the EGR pipe assembly and align it with the EGR port housing during installation. The alignment tabs also provide directional positioning and reduce misalignment of the EGR pipe assembly during installation. In this way, the alignment tabs reduce installation time while providing alignment and reducing improper installation of the EGR pipe assembly. (Refer to...) Figures 2 to 9 Further discussion includes details of the EGR port housing, including the alignment tabs. Figures 2 to 9 Various perspective views of the intake assembly 140, including the EGR outlet 178 and the EGR outlet port housing, are shown.

[0027] The intake system 104 also includes a plurality of intake passages 134. Each intake passage 134 is in fluid communication with a cylinder 110.

[0028] The exhaust system 106 includes a plurality of exhaust passages 142 and an exhaust manifold 144 in fluid communication with cylinders 110. A turbine 116 is located in the exhaust system 106 downstream of the exhaust manifold 144. Additionally, an emission control device 146 is located downstream of the turbine 116. The turbine 116 is rotatably coupled to a compressor 114. A shaft or other suitable component may be used to connect the turbine 116 and the compressor 114. However, in other examples, the turbine 116 may be omitted from the engine, and rotational energy from the transmission in vehicle 100 may be used to provide rotational energy to the compressor 114. A pressure sensor 147 may be coupled to the exhaust manifold 144. An oxygen sensor 148 may be coupled downstream of the emission control device 146 (in the direction of exhaust flow) to an exhaust passage 149.

[0029] EGR system 108 may include at least one of a high-pressure EGR circuit 170 and a low-pressure EGR circuit 172. A boost air cooler allows for better control of the low-pressure EGR circuit 172 and improved cooling of the high-pressure EGR circuit 170. The high-pressure EGR circuit 170 includes an EGR pipe 173, an EGR inlet port 176 leading to an exhaust manifold 144, and an EGR outlet port 178 leading to a boost chamber 118. Specific geometry of the intake boost chamber 118, including the EGR outlet port 178, is referenced herein. Figures 2 to 9 A more detailed discussion follows. In some examples, EGR outlet 178 may lead to a conduit (not shown) that fluidly connects compressor 114 to pressure chamber 118. High-pressure EGR valve 182 may be included in high-pressure EGR circuit 170. In the open position, valve 182 is configured to allow gas to flow through high-pressure EGR circuit 170. In the closed position, valve 182 is configured to substantially prevent gas from flowing through high-pressure EGR circuit 170.

[0030] The low-pressure EGR circuit 172 includes an inlet 184 leading to an exhaust passage 149 and an outlet port 186 leading to an intake passage 188 upstream of the compressor 114 in the intake system 104. The outlet port 186 can be similar to the EGR outlet port 178. Therefore, the outlet port housing that closes the outlet port 186 can be similar to that discussed herein and... Figures 2 to 9 The EGR outlet port housing is shown in the image. Therefore, although... Figures 2 to 9 The outlet port and outlet port housing shown are discussed with respect to outlet port 178 and its corresponding housing; however, it should be understood that all features (including alignment tabs) of EGR outlet port 178 and EGR outlet port housing apply to outlet port 186 and its corresponding outlet port housing. Therefore, in one example, outlet port 186 may be enclosed in an outlet port housing including one or more alignment tabs, which can be used to guide and align the LP EGR assembly, including the LP-EGR pipe 175, with the intake housing.

[0031] A low-pressure EGR valve 190 may be included in the low-pressure EGR circuit 172. In the open position, valve 190 is configured to allow gas to flow through the low-pressure EGR circuit 172. In the closed position, valve 190 is configured to substantially prevent gas from flowing through the low-pressure EGR circuit 172. In this way, gas can flow from the exhaust system 106 to the intake system 104 via both the high-pressure EGR circuit 170 and the low-pressure EGR circuit 172. Coolers 197 and 196 may be included for both the high-pressure EGR circuit 170 and the low-pressure EGR circuit 172 to provide initial EGR cooling before the mixed air and EGR gas pass through the boost air cooler in the boost chamber 118.

[0032] The intake passage 188 includes a throttle valve 192 with a throttle plate 194. In this example, the position of the throttle plate 194 can be changed by a controller 150 via a signal provided to an electric motor or actuator included with the throttle valve 192; this configuration is generally referred to as electronic throttle control (ETC). In this way, the throttle valve 192 can be operated to change the intake air supplied to the engine cylinders 110.

[0033] In some examples, the intake system 104 may also include a plurality of throttle valves (e.g., intake throttle valves) positioned in a plurality of intake passages 134. Specifically, each intake passage 134 may include a single throttle valve positioned therein. Furthermore, each intake passage 134 is in fluid communication with a cylinder 110. In this way, each cylinder has an individual throttle valve configured to regulate airflow through each passage 134. It should be understood that the plurality of throttle valves can be controlled synchronously. For example, the plurality of throttle valves can be controlled via an extended single shaft. However, in other examples, each throttle valve can be controlled individually. A controller 150 included in the engine 102 can be used to control the operation of the plurality of throttle valves.

[0034] Controller 150 in Figure 1 The controller 150, shown as a conventional microcomputer, includes a microprocessor unit 152, an input / output port 154, a read-only memory 156, a random access memory 158, a keep-alive memory 160, and a conventional data bus. The controller 150 is shown receiving various signals from sensors 162 (such as pressure sensors 127, 147, and 148) coupled to the engine 102. The controller 150 can be configured to send signals to actuators 164, such as valves 182, 190, and throttle valve 192. Additionally, instructions for executing various routines, such as one or more routines for operating the engine, can be stored in the memory of the controller 150.

[0035] Now for reference Figures 2 to 9 This illustrates an EGR outlet port (such as one enclosed by an EGR outlet port housing) Figure 1 A schematic diagram of the intake assembly (shown). Specifically, Figures 2 to 9 An exemplary intake assembly (such as) is shown. Figure 1 The diagram shows a three-dimensional schematic of a portion of the intake assembly 140, and the exemplary intake assembly includes an exemplary EGR outlet port, such as... Figure 1 The EGR output port 178 is shown in the figure. Figures 2 to 9 The relative dimensions and locations of components within the intake assembly 140 are shown. Figures 2 to 9 Draw it roughly to scale. In this way, Figures 2 to 9 The components of the intake assembly 140 shown can be connected with Figure 1The components shown are the same. Therefore, the above regarding Figure 1 The components of the intake assembly 140 described below may not be described in detail again.

[0036] refer to Figure 2 This diagram shows a portion of the intake assembly 140, including an EGR outlet port 178. The EGR outlet port 178 is closed by an EGR outlet port housing 210. This allows a portion of the exhaust gas produced by combustion from the engine to exit through the EGR circuit (such as...). Figure 1 The EGR circuit 170 enters the intake boost chamber 118 via the EGR outlet port 178. Therefore, the EGR outlet port 178 is in fluid communication with both the EGR circuit 170 and the intake boost chamber 118, which includes a boost chamber housing, such as a boost chamber housing 121. The EGR assembly is coupled to the intake housing via an EGR outlet port housing 210 at the outlet end portion of the EGR circuit 170. The EGR outlet port housing 210 is adjacent to the intake boost chamber housing 250. Therefore, the EGR outlet port housing and the intake boost chamber housing 250 are directly and integrally coupled. In one example, the EGR port housing may be molded together with the intake boost chamber housing 250 to form a single intake boost chamber unit. In this example, the EGR outlet port housing 210 is positioned upstream of one or more intake air passages 134 in the intake airflow direction, and the EGR outlet port 178 leads to the intake boost chamber housing, such as... Figure 1 The housing 121 in the document. It should be understood that the configuration of the EGR outlet port and EGR outlet port housing (collectively referred to as the EGR outlet port configuration) discussed herein can be used to connect any EGR pipe assembly (such as a low-pressure (LP) EGR pipe assembly) to a manifold housing. Specifically, in one example, the EGR outlet port housing configuration can be used to attach the LP-EGR outlet pipe assembly to the intake passage housing upstream of the compressor in the LP-EGR circuit. In another example, the EGR outlet port configuration can be applied to an EGR inlet port housing that closes a high-pressure EGR inlet port (such as EGR inlet port 176) that communicates with an exhaust manifold (such as exhaust manifold 144). In yet another example, the EGR outlet port configuration can be applied to an LP-EGR inlet port housing that closes an LP-EGR inlet port (such as EGR inlet port 184 in an exhaust passage (such as exhaust passage 149)). Typically, Figures 1 to 9 The EGR outlet port housing configuration discussed herein can be applied to one or more of the HP-EGR inlet port, HP-EGR outlet port, LP-EGR inlet port, and LP-EGR outlet port housings to provide improved alignment and faster installation of the EGR pipe assembly with the corresponding manifold and / or booster chamber. Furthermore, it should be understood that, in addition to Figure 1In addition to the turbocharged engine configurations discussed herein, the EGR outlet port housing configuration can also be used in other engine systems (such as naturally aspirated engines, hybrid engine systems, and supercharged engine systems) for aligning and assembling the EGR system.

[0037] As described above, the EGR outlet port housing 210 is configured to receive the EGR tube assembly. The EGR tube assembly may include an EGR outlet assembly and an EGR inlet assembly. The following describes... Figure 4 and Figure 5 Describe an exemplary EGR outlet pipe assembly, and regarding Figure 8 and Figure 9 Describe an exemplary EGR inlet pipe assembly.

[0038] The EGR outlet port housing 210 includes a central boss 211 extending from the intake booster housing 250. The central boss 211 extends in a direction 203 along the transverse axis (direction 203, also referred to herein as the transverse axis direction) of the intake booster housing 250, with respect to a longitudinal axis direction 201 (direction 201 is also referred to herein as the longitudinal axis direction). The transverse axis is defined as an axis along the length of the central boss. The length of the central boss is defined as the distance between the rear and front sides of the central boss (when viewed relative to the EGR port 178; i.e., relative to an observer facing the opening of the EGR port 178). The transverse axis of the central boss 211 lies in a transverse plane perpendicular to the longitudinal axis of the intake booster housing 250. The central boss 211 closes the EGR outlet port 178, which leads to the intake booster housing 121.

[0039] The EGR outlet port housing 210 also includes an EGR pipe attachment opening 214 formed on one or more housing extensions 213. The housing extensions 213 are positioned on opposite sides of the central boss 211. This example shows a pair of housing extensions 213, each positioned on opposite sides of the central boss. Each housing extension 213 is configured as a boss, its length extending along a transverse plane parallel to a transverse plane containing the transverse axis of the central boss 211. Thus, the housing extension 213 extends outward from the intake supercharger housing along an axis parallel to the transverse axis of the central boss 211. The housing extension 213, including the attachment opening 214, is adjacent to the central boss 211. In one example, the housing extension 213 may be molded together with the central boss 211 to form a single component having the central boss and the housing extension. In another example, the housing extension 213 may be directly coupled to the central boss 211 via a welding process. Each attachment opening 214 is configured to receive a fastener. During the installation of the EGR pipe assembly and the intake manifold, the attachment opening 214 is aligned with the corresponding hole (not shown) on the flange of the EGR pipe assembly, and fasteners are used to attach the EGR pipe assembly to the EGR outlet port housing 210 via the attachment opening 214.

[0040] This example illustrates two housing extensions 213, each located to the right and left of the central boss (i.e., to the right and left of an observer facing the opening of the central boss 211). However, configurations in which the housing extensions 213 are positioned on the top and bottom sides of the central boss are also within the scope of this disclosure. Some examples may include housing extensions on all four sides of the central boss 211. While this example shows the EGR outlet port on the lower left side of the intake boost chamber when viewed from the downstream side of the intake airflow passage (in the airflow direction), it should be understood that the positioning of the EGR outlet port housing 210 relative to the intake boost chamber housing 250 is based on the desired positioning of the EGR pipe assembly. Therefore, the positioning of the central boss 211 and housing extensions 213 of the EGR outlet port housing 210 relative to the intake boost chamber housing 250 is based on the desired positioning of the EGR pipe assembly.

[0041] The EGR outlet port housing 210 includes one or more alignment tabs 212 positioned on one side of each housing extension 213. The alignment tabs 212 project from the housing extension 213. Typically, the number of alignment tabs 212 is based on the number of housing extensions 213, such that one alignment tab is provided for each housing extension. Thus, each housing extension 213 includes one alignment tab 212 extending from one side of the housing extension 213. In some examples, each housing extension 213 may include at least one alignment tab 212. It should be understood that examples of each housing extension 213 including more than one alignment tab are also within the scope of this disclosure. When each housing extension includes more than one alignment tab, the alignment tabs may be positioned parallel to each alignment tab on the same side or opposite side of the corresponding housing extension.

[0042] Each alignment tab 212 abuts against a corresponding housing extension 213. Therefore, each alignment tab is directly coupled to the corresponding housing extension 213. In one example, each alignment tab 212 may be molded to the corresponding housing extension 213. Thus, the alignment tab 212, the housing extension 213 including the attachment opening 214, and the central boss 211 may be molded together to form an integral EGR port housing. Furthermore, in one example, the integral EGR port housing may be molded together with the intake supercharger housing to form an integral intake supercharger housing with an EGR port. In another example, the alignment tab 212, the housing extension 213 including the attachment opening 214, and the central boss 211 may be machined as a single piece. In yet another example, the alignment tab 212, the housing extension 213 including the attachment opening 214, the central boss 211, and the intake supercharger housing may be machined as a single unit. In some examples, one or more alignment tabs 212, housing extensions 213 including attachment openings 214, central boss 211, and intake booster housing 250 may be manufactured as separate units and joined together (e.g., by welding process) to form the intake booster housing together with the EGR port housing including the alignment tabs.

[0043] When viewed from the EGR outlet port 178 side along the transverse axis of the central boss 211, each alignment tab 212 is positioned on the bottom side of the corresponding housing extension 213. Figure 3 The image shows an enlarged view of a portion of the intake booster housing 250, including the EGR outlet port housing 210. Alignment tab 212 will be referenced below. Figure 3Further description is provided. While this example shows one alignment tab for each housing extension 213, it should be understood that examples of two alignment tabs for each housing extension 213 (e.g., positioned on opposite sides of the housing extension, such as the bottom and top) are also within the scope of this disclosure. When disposed on the top and bottom sides of each housing extension 213, the alignment tabs 212 can provide bidirectional guidance and limit the movement of the EGR tube assembly in the upward and downward directions, thereby improving the alignment of the EGR tube assembly with the EGR port housing.

[0044] refer to Figure 3 Each alignment tab 212 is configured as a flat-walled extension of a housing extension 213 having a desired thickness. The desired thickness is less than the diameter of the housing extension 213. Each alignment tab 212 extends vertically downward from the housing extension 213. Specifically, each alignment tab extends vertically downward from the outer wall of the housing extension 213. Thus, each alignment tab 212 is abutted against its corresponding housing extension 213. In one example, the desired thickness may be based on the thickness of the wall of the housing extension 213. Each alignment tab 212 is coupled to the intake supercharger housing 250 and its corresponding housing extension 213. In one example, each alignment tab 212 is coupled to the intake supercharger housing 250 such that the rear wall of each alignment tab 212 (relative to an observer facing the EGR port 178) abuts against the intake supercharger housing 250. Specifically, each alignment tab 212 can be directly connected to the intake booster housing 250, such that the rear wall of the alignment tab 212 abuts against the outer wall of the intake booster housing 250. In addition, the top wall of each alignment tab 212 (relative to an observer facing the EGR port 178) abuts against the outer wall of the housing extension 213.

[0045] In one example, each alignment tab 212 can be positioned relative to the corresponding housing extension 213 such that the alignment tab 212 extends vertically below the center along the central axis 307 of the corresponding housing extension 213. The central axis 307 is perpendicular to the transverse axis of the central boss 211. In this case, each alignment tab 212 can be directly coupled to the intake supercharger housing 250 such that the top wall of the alignment tab 212 abuts the bottom of the outer wall of the corresponding housing extension 213. In another example, the alignment tab 212 is slightly offset from the central axis 307 of the corresponding housing extension 213. In yet another example, when the alignment tab 212 is offset from the central axis, the top wall of the alignment tab 212 can abut the bottom outer edge of the corresponding housing extension 213. Therefore, the outer wall of the housing extension 213 continues downward to form the sidewall of each alignment tab 212. In some examples, one alignment tab may be configured such that its top wall abuts the bottom portion of the housing extension 213, while the second alignment tab may be configured such that its top wall abuts the outer bottom portion of the housing extension. That is, one alignment tab may be positioned along the central axis 307 of the housing extension 213, while the second alignment tab may be positioned offset from the central axis of the housing extension 213. Furthermore, the positioning of the alignment tab 212 relative to the housing extension 213 may be based on the position of the flange attachment plate mounting tab (see below). Figure 4 (Discussion). For example, the alignment tab can be positioned such that when the flange attachment plate is mounted on the assembled EGR outlet assembly, the alignment tab is located outward relative to the mounting tab on the flange attachment plate.

[0046] Each alignment tab 212 includes a stepped protrusion 303 on its front side. The stepped protrusion 303 extends in front of the outer leading edge of the housing extension 213. In other words, the stepped protrusion 303 extends outward beyond the front of the housing extension 213. The stepped protrusion has a first flat surface 302 and a second flat surface 301. In one example, the first flat surface 302 and the second flat surface are perpendicular to each other. Furthermore, in one example, the first flat surface 302 may be horizontally positioned, parallel to the transverse axis of the central boss 211. In some examples, the first flat surface 302 may not be parallel to the transverse axis. In this case, the first flat surface 302 may be inclined downward from the edge wall of the housing extension 213 (relative to an observer facing the EGR port 178). The first flat surface 302 is configured to properly position and align the flange of the EGR tube assembly such that the hole on the flange of the EGR tube assembly aligns with the attachment opening 214. The length of the first flat surface determines the amount of protrusion of the stepped protrusion. In one example, the length of the first flat surface can be greater than the thickness of the flange plate of the flange and EGR tube assembly.

[0047] The stepped protrusion serves as a guide for positioning the EGR tube assembly on the alignment tab 212 and moving the EGR tube assembly along the first flat surface 302 until the outer front surfaces of the flange housing extension 213 of the EGR tube assembly are in coplanar contact and the hole on the flange aligns with the attachment opening 214 of the housing extension 213. In this way, during installation, the EGR tube assembly is correctly positioned and aligned with the EGR outlet port housing with the aid of the EGR tube alignment tab 212. Subsequently, the EGR tube assembly is fastened to the intake booster chamber (e.g., with bolts) via the EGR tube connection opening 214 on the EGR outlet port housing and the hole on the flange.

[0048] refer to Figure 4 An exploded view is shown of a portion 400 of the intake boost chamber 118, including an EGR outlet port housing 210, and an EGR outlet assembly 410. The EGR outlet assembly 410 includes an EGR outlet pipe 412 that inserts into an EGR outlet port 178 formed by the EGR outlet port housing 210. The EGR outlet assembly 410 also includes an EGR outlet flange 414 that attaches to one end of the EGR outlet pipe 412. The EGR outlet flange 414 includes a central opening 425, the diameter of which is based on the diameter of the EGR pipe. During assembly, the central opening 425 is aligned with the EGR pipe, allowing unobstructed flow of EGR into the EGR outlet port 178 during operation. The EGR outlet flange 414 also includes a fastener hole 416 for receiving fasteners. The EGR outlet flange 414 also includes grooves 415 on its right and left bottom surfaces. The groove 415 allows the EGR outlet assembly 410 to be positioned and aligned with the alignment tab 212.

[0049] During installation, the EGR outlet assembly 410 is aligned and fitted into the EGR outlet port housing 210 within the intake supercharger housing 250, with alignment tabs 212 on the EGR outlet port housing 210. Specifically, the EGR outlet pipe 412 of the assembly 410 is inserted into the central boss 211 of the EGR outlet port housing 210, and the EGR outlet flange 414 of the assembly 410 is adjusted such that a groove 415 on the bottom surface rests on the corresponding alignment tab 212. Specifically, the groove 415 is positioned on the first flat surface of the stepped protrusion 303 of the alignment tab. Subsequently, the EGR outlet assembly 410 is pushed to fit into the central boss 211 such that the outer surface of the EGR port housing 210 and the rear surface of the flange 414 (when viewed relative to an observer facing the EGR port 178) are in direct coplanar relation. By using the alignment tab 212 to position and assemble the EGR outlet assembly, the attachment opening 214 of the EGR outlet port housing 210 and the fastener hole 416 on the EGR outlet assembly 410 are aligned. Specifically, the alignment tab 212 (independently and in combination with the groove 415) enables directional positioning of the EGR outlet assembly 410. For example, due to the presence of the alignment tab, when attempting to mount the EGR outlet assembly in a 180-degree rotation position (i.e., if the bottom side is incorrectly positioned on top, and vice versa), the attachment opening 214 and the fastener hole 416 are misaligned. That is, since the alignment tab 212 determines the positioning of the flange 414 of the EGR outlet assembly relative to the EGR outlet port housing, if the EGR outlet assembly is incorrectly positioned, a portion of the flange 414 may block the attachment opening 214, thus causing misalignment between the attachment opening 214 on the EGR outlet port housing 210 and the fastener hole 416 on the flange 414 of the EGR outlet assembly. Therefore, the fastener may not fully pass through the fastener hole 416 and the attachment opening 214. Consequently, if the EGR outlet assembly is incorrectly positioned relative to the EGR outlet housing 210, it may not be able to secure the EGR outlet assembly to the intake boost chamber. Therefore, improper installation of the EGR outlet assembly is prevented by using alignment tabs.

[0050] In this way, directional positioning of the EGR outlet assembly is achieved by utilizing the alignment tab 212. This results in faster and more accurate installation of the EGR outlet assembly.

[0051] Subsequently, when the EGR outlet assembly 410 is assembled into the EGR outlet port housing 210, a flange attachment plate 420, including fastener holes 422, is positioned on the front surface of the flange 414 (when viewed relative to an observer facing the EGR port 178) such that the fastener holes 422 align with fastener holes 416 on the flange 414 and attachment openings 214 on the EGR outlet port housing 210. The flange attachment plate 420 also includes a locating tab 423 for aligning the flange attachment plate 420 with the EGR outlet assembly. For example, the locating tab 423 may indicate the underside of the flange attachment plate 420. The flange attachment plate 420 also includes an opening 427 corresponding to the central opening 425 of the EGR outlet assembly 410. The flange attachment plate 420 also includes a pair of mounting tabs 429 located on the top side of the attachment plate 420 for clamping the top side of the flange 414, and may include a second pair of mounting tabs (not shown) located on the bottom side of the attachment plate 420 for clamping the bottom side of the flange 414. During assembly, the front surface of the flange 414 of the EGR outlet assembly 410 and the rear surface of the flange attachment plate are in direct coplanar contact. Figure 5 The image shows an assembled EGR outlet assembly 410 with an EGR outlet port housing 210 and an attachment plate 420. (See image for details.) Figure 5 As shown, when correctly assembled, the fastener holes 422 of plate 420 and the fastener holes 416 of flange 414 are aligned with attachment opening 214. That is, attachment opening 214 is not blocked by flange 414.

[0052] Figure 6 A second perspective view 600 shows a portion of the intake supercharger housing 250, including the EGR outlet port housing 210. As described above, the EGR outlet port housing 210 includes a pair of alignment tabs 212 located on either side of a central boss 211 to achieve directional positioning and proper alignment of the EGR outlet assembly with the EGR outlet port housing 210. As shown, the outer wall of each housing extension 213 extends vertically downward (when viewed relative to the EGR outlet port 178; i.e., facing the EGR outlet port 178) to form the alignment tabs 212. In one example, the alignment tabs 212 are slightly offset from the central axis 307 of the housing extension 213. In another example, the alignment tabs 212 extend below the center along the central axis 307 of the housing extension 213. Furthermore, as described above, regarding Figure 3Each alignment tab 212 includes a stepped protrusion 303 on its front side (when viewed relative to the EGR outlet port 178). The stepped protrusion 303 consists of a first flat surface 302 and a second flat surface 301 forming the step. The step can be positioned in the upper portion of the alignment tab. Thus, the front side of each alignment tab 212 can be configured such that the first upper portion 305 is continuous with the housing extension before the stepped protrusion 303 (the front surface of the housing extension and the front surface of the first upper portion are positioned along the same plane). The first flat surface 302 of the stepped protrusion extends at a right angle in front of the first upper portion. In some examples, the first flat surface 302 can be positioned at an obtuse angle relative to the front surface of the first upper portion. The first flat surface 302 of the stepped protrusion provides guidance for the positioning and alignment of the EGR assembly. The second flat surface 301 extends below the first flat surface 302 and provides additional support to the first flat surface. In one example, the second flat surface 301 can be positioned in a parallel plane relative to the front surface of the first upper portion. In another example, the second flat surface 301 may be inclined at an acute angle relative to the first flat surface 302. The second flat surface 301 and the bottom side of the aligned tab 212 form a stepped base support structure. Although this example shows a rectangular base support structure, in some examples, the base support structure may be triangular. In such an example, one side of the second flat surface 301 may be coupled to the edge of the first flat surface, and a second side of the second flat surface may be coupled to the intake booster housing 250.

[0053] As mentioned above Figure 4 As discussed, during the assembly process, the alignment tab 212 provides a surface for positioning the EGR outlet assembly (specifically, the flange of the EGR assembly) and guides the EGR outlet assembly into the correct position such that the fastener holes on the EGR outlet assembly are aligned with the attachment openings on the EGR outlet port housing, and the EGR outlet assembly is mounted flush with the EGR outlet port housing. Figure 7 The image shows a second perspective view 700 of an assembled EGR outlet assembly 410 with an EGR outlet port housing 210. In this way, a pair of alignment tabs on the EGR outlet port housing provide positioning and alignment for faster and more accurate installation of the EGR assembly into the EGR outlet port. Additionally, the alignment tabs prevent incorrect installation of the EGR assembly. For example, if the EGR outlet assembly is rotated and in the wrong position, the alignment tabs will not allow the EGR outlet assembly to be installed flush with the surface of the EGR outlet port housing. Therefore, the fastener holes on the EGR outlet assembly are not aligned with the attachment openings on the EGR outlet port housing, which prevents incorrect installation of the EGR outlet assembly.

[0054] In addition, such as Figure 4As discussed, when the EGR outlet assembly is assembled with the EGR outlet port housing, the flange attachment plate 420 is mounted on the EGR outlet flange. Subsequently, the EGR inlet assembly is installed to assemble the EGR outlet assembly 410 and the flange attachment plate 420. Figure 8 An exploded view 800 shows the assembled EGR outlet assembly 410, flange attachment plate 420, and EGR inlet assembly 810. Figure 9 The image shows an assembled EGR assembly including the EGR outlet assembly 410 and the EGR inlet assembly.

[0055] refer to Figure 8 The EGR inlet assembly 810 includes an EGR inlet tube 812 and an EGR inlet tube flange 816. During the EGR tube assembly process, the EGR inlet assembly 810 is positioned on and adjusted over the assembled EGR outlet assembly 410 and flange attachment plate 420 unit such that the fastener hole 816 on the EGR inlet flange 814 is aligned with the aligned fastener hole 416 and attachment opening 214. In one example, an alignment tab 212 on the EGR outlet port housing 210 provides positioning guidance and alignment for the EGR inlet assembly. For example, a stepped protrusion on the alignment tab 212 extends beyond the assembled EGR outlet assembly and flange attachment plate 420 unit to allow the EGR inlet tube flange 814 to be positioned on the stepped protrusion on the alignment tab on either side of the EGR. Once positioned on the alignment tab 212, the EGR inlet assembly 810 is guided via the alignment tab 212 to align with the respective holes 816, 416, and 214 on the EGR inlet assembly 810, the EGR outlet assembly 410, and the EGR outlet port housing 210. When correctly aligned and positioned, the central transverse axes of holes 816, 416, and 214 are aligned, and the rear surface of the EGR inlet flange 814 is in direct coplanar contact with the flange attachment plate 420. Fasteners 850 can be used to connect the EGR inlet assembly 810, the EGR outlet assembly 410, and the EGR outlet port housing 210 during alignment and positioning via the alignment tab 212. When the EGR inlet assembly is mispositioned (e.g., rotated 180 degrees from the desired position), the hole 816 is not aligned with the hole 416 of the EGR outlet assembly and the opening 214 of the EGR outlet port housing, and the flange 816 partially blocks the hole 416 and the opening 214. Therefore, the fastener 850 cannot pass through the hole and the opening to engage the inlet assembly.

[0056] In this way, the alignment tab 212 on the EGR outlet port housing 210 provides positioning and alignment guidance for faster and more accurate installation of one or more EGR assemblies, including the EGR outlet assembly and the EGR inlet assembly. Additionally, the alignment tab 212 prevents the installation of the one or more EGR assemblies if misaligned.

[0057] Figures 2 to 9 Exemplary configurations with the relative positioning of various components are shown. If shown as being in direct contact or directly connected to each other, then in at least one example such components may be referred to as being in direct contact or directly connected, respectively. Similarly, components shown as being connected or adjacent to each other may be connected or adjacent to each other, respectively, in at least one example. For example, components in coplanar contact with each other may be referred to as being in coplanar contact. As another example, in at least one example, components positioned apart from each other and having only a gap between them without other components may be referred to as being in coplanar contact. As yet another example, components shown above / below each other, on opposite sides of each other, or on the left / right side of each other may be referred to as being in coplanar contact relative to each other. Furthermore, as shown, in at least one example, the topmost component or the highest vertex of the component may be referred to as the “top” of the component, while the bottommost component or the lowest point of the component may be referred to as the “bottom” of the component. As used herein, top / bottom, upper / lower, above / below may be relative to the vertical axis of the figures and are used to describe the positioning of the components in the figures relative to each other. Thus, in one example, an component shown above other components is located above other components in the vertical direction. As yet another example, the shapes of the elements depicted in the figure can be described as having these shapes (e.g., circular, straight, planar, curved, rounded, chamfered, angled, etc.). Furthermore, in at least one example, elements shown intersecting each other can be described as intersecting elements or intersecting each other. Additionally, in one example, an element shown as being inside another element or an element shown as being outside another element can be described as such.

[0058] As one embodiment, an intake system for an engine includes: an intake booster chamber enclosed by an intake booster chamber housing; and an exhaust gas recirculation (EGR) port for allowing exhaust gas recirculated by an EGR system to enter the intake booster chamber; wherein the EGR port is enclosed by an EGR port housing, the EGR port housing including a central boss, one or more housing extensions, and one or more alignment tabs, each alignment tab positioned on one side of each housing extension. In a first example, the intake system includes: wherein the EGR port housing is adjacent to the intake booster chamber housing and extends outwardly from the intake booster chamber housing; and wherein each alignment tab includes a stepped protrusion on a front side of the alignment tab. A second example of the intake system optionally includes the first example and further includes: wherein the stepped protrusion extends outwardly beyond the front of the corresponding housing extension, and wherein the stepped protrusion includes a first flat surface and a second flat surface. A third example of the intake system optionally includes one or more of the first and second examples and further includes: wherein the first flat surface is parallel to the transverse axis of the central boss and perpendicular to the second flat surface. A fourth example of the intake system may optionally include one or more of the first to third examples, and further includes: wherein each alignment tab is coupled to the intake housing and the corresponding housing extension on its rear and top sides, respectively, such that the rear side is adjacent to the intake housing and the top side is adjacent to the bottom portion of the corresponding housing extension; and wherein the left and right surfaces of each alignment tab are flat and perpendicular to the intake booster housing. A fifth example of the intake system may optionally include one or more of the first to fourth examples, and further includes: wherein each housing extension is configured as a boss having an opening and positioned on the opposite side of the central boss; and wherein the thickness of the alignment tab is less than the diameter of the opening. A sixth example of the intake system may optionally include one or more of the first to fifth examples, and further includes: wherein one or more of the alignment tabs are positioned along the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss. The seventh example of the intake system may optionally include one or more of the first to sixth examples, and further includes: wherein one or more of the alignment tabs are positioned offset from the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss.An eighth example of the intake system may optionally include one or more of the first to seventh examples, and further includes an EGR assembly coupled to an EGR port housing, wherein the EGR assembly includes an EGR outlet pipe disposed within the EGR port, and an EGR pipe flange coplanarly contacting and positioned above the one or more alignment protrusions of the front surface of the EGR port housing; and wherein the EGR pipe flange includes one or more mounting grooves on its underside, each of the mounting grooves being aligned with a corresponding alignment protrusion. A ninth example of the intake system may optionally include one or more of the first to eighth examples, and further includes: wherein the EGR port is a high-pressure EGR port located downstream of a compressor located upstream of the intake boost chamber in the intake passage, the compressor delivering compressed air to the engine via the intake boost chamber.

[0059] As another embodiment, an exhaust gas recirculation (EGR) port for a manifold includes: an EGR port housing, the EGR port housing including a central boss, a pair of housing extensions, and a pair of alignment tabs, each housing extension including an opening and positioned on opposite sides of the central boss, wherein each alignment tab is positioned on at least one side of each housing extension. In a first example, the EGR port includes: wherein the EGR port housing is integrally coupled to a manifold housing; and wherein each alignment tab extends from an outer wall of the manifold housing along the length of the corresponding housing extension and beyond the front of the corresponding housing extension. A second example of the EGR port optionally includes the first example and further includes: wherein each alignment tab is positioned below the corresponding housing extension; and wherein each alignment tab includes a stepped protrusion on the front side of the alignment tab. A third example of the EGR port may optionally include one or more of the first and second examples, and further includes: wherein the stepped protrusion extends outward beyond the front of the corresponding housing extension and includes a first flat surface and a second flat surface; and wherein the rear side of each alignment tab abuts the intake housing, and the top side abuts the bottom portion of the corresponding housing extension. A fourth example of the EGR port may optionally include one or more of the first to third examples, and further includes: wherein the EGR port housing is coupled to an EGR assembly; wherein the EGR assembly includes an EGR tube disposed within the EGR port, and an EGR tube flange coplanarly contacting and positioned above the pair of alignment tabs on the front surface of the EGR port housing; and wherein the EGR tube flange includes a pair of mounting grooves on its bottom side, each of the mounting grooves being aligned with the corresponding alignment tab. A fifth example of the EGR port may optionally include one or more of the first to fourth examples, and further includes: wherein one or more of the pair of alignment tabs are positioned along a central axis of the corresponding housing extension, the central axis being perpendicular to a transverse axis along the length of the central boss. A sixth example of the EGR port may optionally include one or more of the first to fifth examples, and further includes: wherein one or more of the pair of alignment tabs are positioned offset from the central axis of the corresponding housing extension, the central axis being perpendicular to a transverse axis along the length of the central boss. A seventh example of the EGR port may optionally include one or more of the first to third examples, and further includes: wherein the manifold housing closes the engine's intake manifold, and the EGR port housing closes the EGR outlet port to allow exhaust gas from the engine to recirculate into the intake manifold.

[0060] As another embodiment, an engine system includes: an engine comprising a plurality of cylinders; an intake manifold on the intake side of the engine for delivering intake air to the engine, the intake manifold being enclosed by an intake manifold housing; and an exhaust gas recirculation (EGR) system including an EGR pipe assembly for recirculating a portion of exhaust gas into the intake manifold; wherein the intake manifold housing includes an EGR outlet port housing for connecting the EGR pipe assembly to the intake manifold; and wherein the EGR outlet port housing includes one or more alignment tabs for aligning the EGR pipe assembly with the EGR outlet port housing. In the first example, the engine system includes: the EGR outlet port housing further includes a central boss and a pair of housing extensions, each located on opposite sides of the central boss; wherein each alignment tab is positioned below each housing extension; wherein each alignment tab is configured as a flat wall having a stepped protrusion on its front side, the stepped protrusion extending outward beyond the front of the corresponding housing extension; and wherein the rear side of each alignment tab is adjacent to the intake manifold housing, and the top side is adjacent to the bottom portion of the corresponding housing extension.

[0061] As another representation, a method for assembling an engine includes: aligning an exhaust gas recirculation (EGR) pipe assembly to the EGR outlet port housing via one or more alignment tabs on the EGR outlet port housing; and connecting the EGR pipe assembly to the EGR outlet port housing; wherein the engine includes: a plurality of cylinders; an intake manifold on the intake side of the engine for delivering intake air to the engine, the intake manifold being closed by an intake manifold housing; and an exhaust gas recirculation (EGR) system including the EGR pipe assembly for recirculating a portion of exhaust gas into the intake manifold; and wherein the intake manifold housing includes the EGR outlet port housing for connecting the EGR pipe assembly to the intake manifold. In a first example, the method includes: the EGR outlet port housing further includes a central boss and a pair of housing extensions, each located on an opposite side of the central boss; wherein each alignment tab is positioned below each housing extension; wherein each alignment tab is configured as a flat wall with a stepped protrusion on its front side, the stepped protrusion extending outward beyond the front of the corresponding housing extension; and wherein the rear side of each alignment tab is adjacent to the intake manifold housing, and its top side is adjacent to the bottom portion of the corresponding housing extension. A second example of the method optionally includes the first example and further includes: wherein the EGR outlet port is a high-pressure EGR port located downstream of a compressor located upstream of the intake manifold in the intake passage, the compressor delivering compressed air to the engine via the intake manifold. A third example of the method optionally includes one or more of the first and second examples and further includes: wherein the one or more alignment tabs are positioned along a central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss. A fourth example of the method may optionally include one or more of the first to third examples, wherein the one or more alignment tabs are positioned offset from the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss.

[0062] Note that the exemplary control and estimation programs included herein can be used in conjunction with various engine and / or vehicle system configurations. The control methods and programs disclosed herein can be stored as executable instructions in non-transitory memory and can be executed by a control system including a controller in conjunction with various sensors, actuators, and other engine hardware. The specific programs described herein can represent one or more of any number of processing strategies, such as event-driven, interrupt-driven, multi-tasking, multi-threaded processing strategies, etc. Therefore, the various actions, operations, or functions shown can be executed in the order shown, in parallel, or in some cases omitted. Similarly, the processing order is not necessarily required to achieve the features and advantages of the exemplary embodiments described herein, but is provided for ease of illustration and description. One or more of the shown actions, operations, and / or functions can be repeatedly executed according to the specific strategy used. Furthermore, the described actions, operations, and / or functions can be graphically represented as code to be programmed into the non-transitory memory of a computer-readable storage medium in the engine control system, wherein the described actions are implemented by executing instructions in conjunction with an electronic controller in a system including various engine hardware components.

[0063] It will be understood that the configurations and procedures disclosed herein are exemplary in nature, and these specific embodiments should not be considered limiting, as many variations are possible. For example, the above-described techniques can be applied to V-6, I-4, I-6, V-12, opposed 4-cylinder, and other engine types. The subject matter of this disclosure includes all novel and non-obvious combinations and sub-combinations of various systems and configurations, as well as other features, functions, and / or properties disclosed herein.

[0064] The following claims specifically point to certain combinations and sub-combinations considered novel and non-obvious. These claims may relate to an “a” element or a “first” element or its equivalents. These claims should be understood to include combinations of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and / or properties may be claimed by amendments to these claims or by setting new claims in this application or related applications. Such claims, whether broader, narrower, identical, or different in scope than the original claims, are considered to be included within the subject matter of this disclosure.

[0065] According to the present invention, an intake system for an engine is provided, comprising: an intake boost chamber enclosed by an intake boost chamber housing; and an exhaust gas recirculation (EGR) port for allowing exhaust gas recirculated by an EGR system to enter the intake boost chamber, the EGR port being enclosed by an EGR port housing, the EGR port housing including a central boss, one or more housing extensions, and one or more alignment tabs, each alignment tab being positioned on one side of each housing extension.

[0066] According to an embodiment, the EGR port housing is adjacent to the intake boost chamber housing and extends outward from the intake boost chamber housing; and each alignment tab includes a stepped protrusion on the front side of the alignment tab.

[0067] According to an embodiment, the stepped protrusion extends outward beyond the front of the corresponding housing extension, and the stepped protrusion includes a first flat surface and a second flat surface.

[0068] According to an embodiment, the first flat surface is parallel to the transverse axis of the central boss and perpendicular to the second flat surface.

[0069] According to an embodiment, each alignment tab is connected to the intake housing and the corresponding housing extension on the rear and top sides of the alignment tab, respectively, such that the rear side is adjacent to the intake housing and the top side is adjacent to the bottom portion of the corresponding housing extension; and wherein the left and right surfaces of each alignment tab are flat and perpendicular to the intake booster housing.

[0070] According to an embodiment, each housing extension is configured as a boss having an opening and positioned on the opposite side of the central boss; and the thickness of the alignment tab is less than the diameter of the opening.

[0071] According to an embodiment, one or more of the alignment tabs are positioned along the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss.

[0072] According to an embodiment, one or more of the alignment tabs are positioned offset from the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss.

[0073] According to an embodiment, the invention is further characterized by an EGR assembly connected to an EGR port housing, wherein the EGR assembly includes an EGR outlet pipe disposed within the EGR port, and an EGR pipe flange that is coplanarly contacted with the front surface of the EGR port housing and positioned above one or more alignment tabs; and wherein the EGR pipe flange includes one or more mounting grooves on its bottom side, each of the mounting grooves being aligned with a corresponding alignment tab.

[0074] According to an embodiment, the EGR port is a high-pressure EGR port located downstream of the compressor, the compressor being located upstream of the intake boost chamber in the intake passage, and the compressor delivering compressed air to the engine via the intake boost chamber.

[0075] According to the present invention, an exhaust gas recirculation (EGR) port for a manifold is provided, comprising: an EGR port housing including a central boss, a pair of housing extensions and a pair of alignment tabs, each housing extension including an opening and positioned on opposite sides of the central boss, wherein each alignment tab is positioned on at least one side of each housing extension.

[0076] According to an embodiment, the EGR port housing is integrally connected to the manifold housing; and each alignment tab extends from the outer wall of the manifold housing along the length of the corresponding housing extension and beyond the front of the corresponding housing extension.

[0077] According to an embodiment, each alignment tab is positioned below the corresponding housing extension; and each alignment tab includes a stepped protrusion on the front side of the alignment tab.

[0078] According to an embodiment, the stepped protrusion extends outward beyond the front of the corresponding housing extension and includes a first flat surface and a second flat surface; and wherein the rear side of each alignment tab is adjacent to the air intake housing, and the top side is adjacent to the bottom portion of the corresponding housing extension.

[0079] According to an embodiment, the EGR port housing is coupled to an EGR assembly; wherein the EGR assembly includes an EGR outlet pipe disposed within the EGR port, and an EGR pipe flange that is coplanarly contacted with the front surface of the EGR port housing and positioned above the pair of alignment tabs; and wherein the EGR pipe flange includes a pair of mounting grooves on its bottom side, each of the mounting grooves being aligned with the corresponding alignment tab.

[0080] According to an embodiment, one or more of the pair of alignment tabs are positioned along the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis along the length of the central boss.

[0081] According to an embodiment, one or more of the alignment tabs are positioned offset from the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis along the length of the central boss.

[0082] According to an embodiment, the manifold housing seals the engine's intake manifold, and the EGR port housing seals the EGR outlet port to allow exhaust gas from the engine to recirculate back into the intake manifold.

[0083] According to the present invention, an engine system is provided, comprising: an engine including a plurality of cylinders; an intake manifold on the intake side of the engine for delivering intake air to the engine, the intake manifold being closed by an intake manifold housing; and an exhaust gas recirculation (EGR) system including an EGR pipe assembly for recirculating a portion of exhaust gas into the intake manifold; wherein the intake manifold housing includes an EGR outlet port housing for connecting the EGR pipe assembly to the intake manifold; and wherein the EGR outlet port housing includes one or more alignment tabs for aligning the EGR pipe assembly with the EGR outlet port housing.

[0084] According to an embodiment, the EGR outlet port housing further includes a central boss and a pair of housing extensions, each located on opposite sides of the central boss; wherein each alignment tab is positioned below each housing extension; wherein each alignment tab is configured as a flat wall with a stepped protrusion on its front side, the stepped protrusion extending outward beyond the front of the corresponding housing extension; and wherein the rear side of each alignment tab is adjacent to the intake manifold housing, and the top side is adjacent to the bottom portion of the corresponding housing extension.

Claims

1. An intake system for an engine, comprising: The intake booster chamber is enclosed by the intake booster chamber shell; An exhaust gas recirculation (EGR) port is provided for allowing exhaust gas recirculated by the EGR system to enter the intake boost chamber. The EGR port is closed by an EGR port housing, which includes a central boss, one or more housing extensions, and one or more alignment tabs, each alignment tab being positioned on one side of each housing extension. and An EGR assembly is connected to the EGR port housing, wherein the EGR assembly includes an EGR outlet pipe disposed within the EGR port, and an EGR pipe flange that is coplanarly contacted with the front surface of the EGR port housing and positioned above one or more alignment tabs; and wherein the EGR pipe flange includes one or more mounting grooves on its bottom side, each of the mounting grooves being aligned with a corresponding alignment tab.

2. The intake system of claim 1, wherein the EGR port housing is adjacent to the intake boost chamber housing and extends outward from the intake boost chamber housing; and wherein each alignment tab includes a stepped protrusion on the front side of the alignment tab.

3. The intake system of claim 2, wherein the stepped protrusion extends outward beyond the front of the corresponding housing extension, and wherein the stepped protrusion includes a first flat surface and a second flat surface.

4. The intake system of claim 3, wherein the first flat surface is parallel to the transverse axis of the central boss and perpendicular to the second flat surface.

5. The intake system of claim 1, wherein each alignment tab is connected to the intake booster housing and the corresponding housing extension on the rear and top sides of the alignment tab, respectively, such that the rear side is adjacent to the intake booster housing and the top side is adjacent to the bottom portion of the corresponding housing extension; and wherein the left and right surfaces of each alignment tab are flat and perpendicular to the intake booster housing.

6. The intake system of claim 1, wherein each housing extension is configured as a boss having an opening and positioned on the opposite side of the central boss; and wherein the thickness of the alignment tab is less than the diameter of the opening.

7. The intake system of claim 1, wherein one or more of the alignment tabs are positioned along the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss.

8. The intake system of claim 1, wherein one or more of the alignment tabs are positioned offset from the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss.

9. The intake system of claim 1, wherein the EGR port is a high-pressure EGR port located downstream of the compressor, the compressor being located upstream of the intake boost chamber in the intake passage, and the compressor delivering compressed air to the engine via the intake boost chamber.

10. A method for assembling an engine, comprising: The exhaust gas recirculation EGR pipe assembly is aligned with the EGR outlet port housing via one or more alignment tabs on the EGR outlet port housing; as well as Connect the EGR pipe assembly to the EGR outlet port housing; The engine includes: a plurality of cylinders; an intake manifold on the intake side of the engine for delivering intake air to the engine, the intake manifold being sealed by an intake manifold housing; and an exhaust gas recirculation (EGR) system including the EGR pipe assembly for recirculating a portion of the exhaust gas into the intake manifold; and The intake manifold housing includes the EGR outlet port housing, which is used to connect the EGR pipe assembly to the intake manifold. The EGR tube assembly includes an EGR outlet tube disposed within the EGR outlet port, and an EGR tube flange that is coplanarly contacted with the front surface of the EGR outlet port housing and positioned above one or more alignment tabs; and the EGR tube flange includes one or more mounting grooves on its bottom side, each of the mounting grooves being aligned with the corresponding alignment tab.

11. The method of claim 10, wherein the EGR outlet port housing further comprises a central boss and a pair of housing extensions, each located on an opposite side of the central boss; wherein each alignment tab is positioned below each housing extension; wherein each alignment tab is configured as a flat wall having a stepped protrusion on its front side, the stepped protrusion extending outward beyond the front of the corresponding housing extension; and wherein the rear side of each alignment tab is adjacent to the intake manifold housing, and the top side is adjacent to the bottom portion of the corresponding housing extension.

12. The method of claim 10, wherein the EGR outlet port is a high-pressure EGR port located downstream of the compressor, the compressor being located upstream of the intake manifold in the intake passage, the compressor delivering compressed air to the engine via the intake manifold.

13. The method of claim 11, wherein the one or more alignment tabs are positioned along the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss.

14. The method of claim 11, wherein the one or more alignment tabs are positioned offset from the central axis of the corresponding housing extension, the central axis being perpendicular to the transverse axis of the central boss.

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