Engine air inlet module, air inlet system and engine

Abstract

The invention provides an engine air inlet module, an air inlet system and an engine, and the engine air inlet module comprises an air inlet header and an alcohol sprayer. The air inlet header comprises an air inlet pipe section with two open ends and a mixing pipe section; the gas inlet pipe section extends in the first direction, the mixing pipe section extends in the second direction, and the first direction is perpendicular to the second direction. The mixing pipe section comprises an inlet end and an outlet end, the inlet end communicates with the air inlet pipe section body, and the outlet end is used for being in butt joint with an engine cylinder cover. A fuel injection position is arranged on the pipe wall, corresponding to the inlet end of the mixing pipe section, of the air inlet pipe section. The alcohol spraying device is installed in the fuel spraying position of the gas inlet pipe section, and the spraying direction of the alcohol spraying device faces the inlet end of the mixing pipe section. According to the technical scheme, the alcohol spraying device and the air inlet collecting pipe are integrated into an independent unit module, methanol is prevented from directly corroding the cylinder cover, the cylinder cover improvement difficulty is reduced, the methanol and air mixing path is prolonged, and combustion is optimized in cooperation with the mixing uniformity of methanol fuel and air.

Description

Technical Field

[0001] The present application relates to the field of engine air intake technology, and in particular to an engine air intake module, an air intake system and an engine. Background Art

[0002] Methanol-fueled engines are internal combustion engines that use methanol as their primary fuel. Their key advantages include minimal modifications to the original engine and minimal environmental pollution. With the decreasing cost of methanol production, marine methanol inlet injection technology has become a key path toward a low-carbon transition for internal combustion engines.

[0003] Currently, there are two approaches to methanol inlet injection technology. The first involves designing the engine cylinder head and intake manifold into a one-piece cast structure, with the alcohol injector positioned at the bottom of the intake manifold within this integrated structure. This approach has the disadvantages of being suitable only for completely new engines designed from scratch and unsuitable for retrofits (which involve minor structural modifications to an existing marine diesel engine, ultimately converting it to a methanol / diesel dual-fuel engine). Furthermore, the design time and cost are relatively high.

[0004] The second approach involves placing the alcohol injector solely above the cylinder head intake duct. This approach has the following drawbacks: the compact cylinder head structure significantly limits the size and placement of the injector. Furthermore, its placement on the cylinder head results in relatively poor mixing uniformity between methanol and air. Furthermore, because the mixing of methanol and air is a complex process, there's a high probability that the methanol injected by the injector will directly impact the cylinder head structure, causing persistent corrosion. Consequently, if corrosion is severe, maintenance can only be achieved by replacing the cylinder head, significantly increasing maintenance costs. Summary of the Invention

[0005] The purpose of this application is to provide an engine intake module, an intake system and an engine, which integrate the alcohol injector and the intake manifold into an independent unit module, avoid direct corrosion of the cylinder head by methanol, reduce the difficulty of cylinder head improvement, extend the methanol and air mixing path, and coordinate the mixing uniformity of methanol fuel and air to optimize combustion.

[0006] In a first aspect, an engine air intake module is provided, comprising an air intake manifold and an alcohol injector.

[0007] The intake manifold includes an intake pipe section and a mixing pipe section, both open at both ends. The intake pipe section extends in a first direction, while the mixing pipe section extends in a second direction, with the first direction being perpendicular to the second direction. The mixing pipe section includes an inlet end and an outlet end, with the inlet end communicating with the intake pipe section body and the outlet end being adapted to interface with the engine cylinder head. A fuel injection station is provided on the wall of the intake pipe section, corresponding to the mixing pipe section inlet end. An alcohol injector is installed in the fuel injection station of the intake pipe section, with the alcohol injector spraying toward the mixing pipe section inlet end.

[0008] In one feasible solution, the spray range boundary of the alcohol injector does not exceed the inlet end boundary of the mixing pipe section.

[0009] In an implementable solution, from a first viewing direction, an overlapping point between an extended axis line of the spraying direction of the alcohol injector and the axis line of the mixing tube section is located within the mixing tube section.

[0010] In an implementable solution, the angle between the axis of the injection direction of the alcohol injector and the axis of the mixing pipe section is β, wherein 90°<β<180°.

[0011] In an implementable solution, the angle β between the axis of the injection direction of the alcohol injector and the axis of the mixing pipe section satisfies 100°≤β≤130°.

[0012] In an implementable solution, there are at least two fuel injection positions provided on the pipe wall of the intake pipe section, and an alcohol injector is installed in each fuel injection position.

[0013] In one feasible solution, a mounting seat is provided at the fuel injection position, and a mounting channel is provided in the mounting seat that penetrates into the interior of the intake pipe section. An alcohol injector is sealed and mounted in the mounting channel. A pressing block is mounted on the mounting seat to compress and seal the alcohol injector.

[0014] The inlet of the alcohol injector is arranged on the side wall, and the mounting seat is laterally provided with a fuel inlet which penetrates into the interior of the mounting channel, and the fuel inlet is docked with and communicated with the inlet of the alcohol injector.

[0015] In one feasible solution, an annular groove is provided on the side wall above the inlet of the alcohol sprayer, and the annular groove and the inner wall of the installation channel form an annular cavity. The mounting seat is provided with a first interface and a second interface communicating with the annular cavity.

[0016] In a second aspect, an engine air intake system is also provided, comprising a plurality of the aforementioned engine air intake modules and a connector; the air intake pipe sections of the air intake manifolds of the plurality of engine air intake modules are connected end to end in sequence through the connector.

[0017] In a third aspect, an engine is provided, comprising a cylinder head and the aforementioned engine intake system, wherein a plurality of intake ports are reserved on the cylinder head, and a mixing pipe section of an intake manifold of the engine intake system is connected to the intake ports on the cylinder head.

[0018] Compared to existing technologies, the present invention offers at least the following advantages: In the engine intake module, the outlet end of the mixing pipe section of the intake manifold is detachably connected to the cylinder head, while the alcohol injector is directly integrated into the intake pipe section. This removes the methanol injection and air mixing functions from the cylinder head, forming a standalone unit. Compared to traditional designs where the cylinder head and intake pipe section are integrally molded, this structure eliminates the need for extensive redesign and significantly reduces the difficulty of casting and machining.

[0019] Because the alcohol injector is no longer installed in the cylinder head but is instead integrated into the intake manifold, even if a trace of methanol leaks, the corrosion risk is limited to the intake manifold itself, preventing damage to the cylinder head. As a separate component, the intake manifold is simple and cost-effective to replace and maintain even if it corrodes. Furthermore, the placement of the alcohol injector in the intake manifold section provides a longer mixing path and larger mixing volume for methanol and air compared to solutions installed in the cylinder head, significantly improving mixing uniformity and resulting in enhanced combustion quality.

[0020] Furthermore, the methanol injector is positioned on the intake manifold, with its injection direction directed toward the inlet of the mixing section. Air flows from the intake section into the mixing section, ensuring that the methanol fuel injection direction and the air intake path remain relatively aligned, creating a mutually guiding effect. Furthermore, the entire mixing section serves as the mixing path for methanol fuel and air, significantly increasing the mixing path length, enhancing mixing quality and effectiveness, and ensuring efficient and stable combustion. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the embodiments. It should be understood that the following drawings only show certain embodiments of the present application and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without creative work.

[0022] Figure 1 This is a three-dimensional diagram of an engine air intake module shown in an embodiment of the present application.

[0023] Figure 2 for Figure 1 Side view of the engine's air intake module.

[0024] Figure 3 for Figure 2 Cross-sectional view along AA.

[0025] Figure 4 for Figure 3 A partial enlarged view of the middle fuel injection position.

[0026] Figure 5 for Figure 1 Bottom view of the engine intake module.

[0027] Figure 6 and Figure 7 for Figure 5 Cross-sectional view along BB.

[0028] Figure 8 for Figure 7 A partial enlarged view of the middle alcohol sprayer.

[0029] Figure 9 for Figure 1 A three-dimensional view of the intake manifold of the engine intake module.

[0030] Figure 10 for Figure 9 Front view of the center intake manifold.

[0031] Figure 11 for Figure 10 Cross-sectional view along CC.

[0032] Figure 12 for Figure 1 A three-dimensional view of the compression block of the engine intake module.

[0033] Figure 13 for Figure 1 Front view of the alcohol injector in the engine intake module.

[0034] Figure 14 for Figure 13 Cross-sectional view along DD.

[0035] In the figure: 100, engine air intake module; 1, air intake manifold; 11, air intake pipe section; 12, mixing pipe section; 121, docking flange; 13, fuel injection position; 131, mounting seat; 1311, fuel inlet; 1312, first interface; 1313, second interface; 132, mounting channel; 133, pressing block; 2, alcohol injector; 21, inlet; 22, annular groove; 221, first sealing structure; 222, second sealing structure; 41, methanol fuel inlet pipe; 42, purge inlet pipe; 43, purge outlet pipe; L1, first direction; L2, second direction. DETAILED DESCRIPTION

[0036] To make the objectives, technical solutions, and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Generally, the components of the embodiments of the present application described and shown in the drawings herein can be arranged and designed in various different configurations.

[0037] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application for protection, but merely represents selected embodiments of the present application. All other embodiments obtained by persons of ordinary skill in the art based on the embodiments in the present application without creative work are within the scope of protection of the present application.

[0038] like Figures 1 to 7 As shown, an embodiment of the present application first provides an engine air intake module, including an air intake manifold 1 and an alcohol injector 2.

[0039] The intake manifold 1 comprises an intake pipe section 11 and a mixing pipe section 12, both open at both ends. The intake pipe section 11 extends in a first direction L1, while the mixing pipe section 12 extends in a second direction L2, with the first direction L1 and the second direction L2 being perpendicular. The mixing pipe section 12 includes an inlet end and an outlet end, with the inlet end communicating with the main body of the intake pipe section 11 and the outlet end being adapted to interface with the engine cylinder head. A fuel injection station 13 is provided on the wall of the intake pipe section 11, corresponding to the inlet end of the mixing pipe section 12. An alcohol injector 2 is mounted in this fuel injection station 13 of the intake pipe section 11, with the injection direction of the alcohol injector 2 directed toward the inlet end of the mixing pipe section 12. In other words, the alcohol injector 2 injects methanol toward the inlet end of the mixing pipe section 12.

[0040] It should be noted that the fuel injection position 13 is the installation position of the alcohol injector 2. The fuel injection position 13 is at least provided with an opening connected to the interior of the intake pipe section 11, so that the alcohol injector 2 can spray methanol into the inlet end of the mixing pipe section 12 and mix it with the air transported by the intake pipe section 11.

[0041] It should also be noted that the mixing tube segment 12 extends along the second direction L2, which can be understood as the axis of the mixing tube segment 12 completely coinciding with the second direction L2; it can also be understood as the axis of the mixing tube segment 12 and the second direction L2 have a certain angle, but its overall extension direction still remains extended in the second direction L2.

[0042] In this embodiment of the engine intake module, the outlet end of the mixing pipe section 12 of the intake manifold 1 is detachably connected to the cylinder head, while the alcohol injector 2 is directly integrated into the intake pipe section 11. This removes the methanol injection and air mixing functions from the cylinder head, forming a standalone unit. Compared to traditional designs where the cylinder head and intake pipe section are integrally molded, this structure eliminates the need for extensive redesign and significantly reduces casting and machining complexity.

[0043] Since the alcohol injector 2 is no longer installed in the cylinder head but is instead integrated into the intake manifold 1, even if a trace of methanol leaks, the corrosion risk is limited to the intake manifold 1 itself, preventing damage to the cylinder head. As an independent component, the intake manifold 1 is simple and cost-effective to replace and maintain even if corroded. Furthermore, the placement of the alcohol injector 2 in the intake manifold section 11 of the intake manifold 1 provides a longer mixing path and a larger mixing volume for methanol and air compared to designs installed in the cylinder head. This significantly improves mixing uniformity and combustion quality.

[0044] Furthermore, the alcohol injector 2 is positioned on the intake manifold 1's intake section 11, with its injection direction directed toward the inlet of the mixing section 12. Air is transported from the intake section 11 into the mixing section 12. This means that the methanol fuel injection direction and the air intake path remain relatively consistent, creating a mutually guiding effect. Furthermore, the entire path of the mixing section 12 serves as the mixing path for the methanol fuel and air, significantly increasing the mixing path length, enhancing mixing quality and performance, and ensuring efficient and stable combustion.

[0045] Furthermore, this design is compatible with both retrofits and new builds. A retrofit involves modifying the existing marine diesel engine structure to create a methanol / diesel dual-fuel engine. A new build refers to a completely newly designed and manufactured methanol-fueled engine, rather than a minor modification of an existing diesel engine.

[0046] In one embodiment, if Figure 6 As shown, it is preferred to set the injection range boundary of the alcohol injector 2 not to exceed the inlet end boundary of the mixing pipe section 12, thereby reducing the obstruction effect of the pipe wall of the intake pipe section 11 on the injected fuel, so as to ensure that the methanol fuel sprayed by the current alcohol injector 2 directly enters the corresponding mixing pipe section 12 as much as possible, so as to ensure the working efficiency of the engine cylinder connected to the current mixing pipe section 12. Among them, the injection range of the alcohol injector 2 can be determined by designing the nozzle opening shape of the alcohol injector 2 to ensure that the injection range boundary of the alcohol injector 2 is located within the opening boundary of the inlet end of the mixing pipe section 12.

[0047] In one embodiment, if Figure 7 As shown, from the perspective of the first direction L1, the overlapping point P of the extended line of the axis of the injection direction of the alcohol injector 2 and the axis of the mixing pipe section 12 is inside the mixing pipe section 12, so as to ensure as much as possible that all the injected fuel of the alcohol injector 2 enters the mixing pipe section 12, and to a certain extent, the injection path of the fuel avoids most areas of the intake pipe section 11 as much as possible, so as to ensure the smooth transfer of air along the current intake pipe section 11 to the next intake pipe section 11.

[0048] In one embodiment, if Figure 7As shown, the angle β between the injection axis of the alcohol injector 2 and the axis of the mixing pipe section 12 is 90° < β < 180°. Within this angle range, the fuel injection direction and the direction of air entering the mixing pipe section 12 can intersect at a certain angle, thereby enhancing the uniformity of the fuel-air mixing. Furthermore, this angle setting allows the fuel injection path to avoid most of the intake pipe section 11 as much as possible, ensuring smooth air transfer from one intake pipe section 11 to the next.

[0049] In one embodiment, the angle β between the axis of the injection direction of the alcohol injector 2 and the axis of the mixing pipe section 12 preferably satisfies 100°≤β≤130°. For example, β can be set to 110°, 115°, 120°, etc.

[0050] In one embodiment, if Figure 6 or Figure 7 As shown, the injection end of the alcohol injector 2 does not extend into the air intake pipe section 11 or the length of the injection end into the air intake pipe section 11 does not exceed 10 mm, which reduces the interference of the alcohol injector 2 on the air intake process and is also conducive to improving mixing uniformity.

[0051] In one embodiment, if Figure 1 、 Figure 3 and Figure 4 As shown, there may be at least two fuel injection positions 13 provided on the pipe wall of the intake pipe section 11 , and an alcohol injector 2 is installed in each fuel injection position 13 .

[0052] In one embodiment, if Figure 3 、 Figure 4 and Figure 8 As shown, and Figure 9 、 Figure 10 and Figure 11 As shown, a mounting base 131 is provided at the fuel injection position 13, and a mounting channel 132 is provided in the mounting base 131, which extends into the interior of the intake pipe section 11. The alcohol injector 2 is sealed and mounted in the mounting channel 132. A pressing block 133 is mounted on the mounting base 131 to compress the alcohol injector 2 and seal it. The pressing block 133 can be connected and fixed to the mounting base 131 by fasteners such as bolts and nuts. Figure 4 、 Figure 13 and Figure 14 As shown, the inlet 21 of the alcohol injector 2 is provided on the side wall, and the mounting base 131 is laterally provided with a fuel inlet 1311 extending through the interior of the mounting channel 132. The fuel inlet 1311 is docked and connected to the inlet 21 of the alcohol injector 2. In addition, the fuel inlet 1311 is connected to a methanol fuel inlet pipe 41 for delivering methanol.

[0053] In one embodiment, if Figure 8As shown, a first sealing structure 221 is provided on the upper side of the inlet 21 of the alcohol sprayer 2, and a second sealing structure 222 is provided on the lower side. Both the first sealing structure 221 and the second sealing structure 222 can achieve a sealing effect by providing multiple O-rings.

[0054] In some cases, methanol fuel may leak from the first sealing structure 221 or the second sealing structure 222. Methanol leaking from the second sealing structure 222 on the lower side of the inlet 21 of the alcohol injector 2 can directly enter the intake pipe section 11 and will not cause significant corrosion problems. However, methanol leaking from the first sealing structure 221 on the upper side of the inlet 21 of the alcohol injector 2 will accumulate in the installation gap and cause corrosion problems.

[0055] Therefore, in one embodiment, if Figure 8 As shown, an annular groove 22 is provided on the side wall above the inlet 21 of the alcohol injector 2. The annular groove 22 and the inner wall of the mounting channel 132 form an annular cavity, which can temporarily accommodate the leaked methanol fuel. Figure 4 and Figure 8 As shown, the mounting seat 131 is provided with a first interface 1312 and a second interface 1313 communicating with the annular cavity. The first interface 1312 is connected to the purge air inlet pipe 42 , and the second interface 1313 is connected to the purge air outlet pipe 43 .

[0056] Furthermore, a purge device (not shown in the figure) and a detection device (not shown in the figure) can also be provided. The purge device is connected to the purge inlet pipe 42, and the purge outlet pipe 43 is connected to the detection device. If the first sealing structure 221 fails to a certain extent, resulting in methanol leakage at the air inlet end of the alcohol injector 2, the leaked methanol will enter the annular cavity. The purge device is started from time to time (the purge gas can be nitrogen), see Figure 8 and Figure 4 In the direction of the arrow in FIG, the purge gas enters the annular cavity through the purge inlet pipe 42, and is then blown out through the purge outlet pipe 43 and delivered to the detection device to detect the methanol concentration and thus determine whether a leak has occurred. Thus, it can be seen that this embodiment, through the provision of the annular cavity, the first interface 1312, and the second interface 1313, can conveniently detect whether a leak has occurred at the air inlet end of the alcohol injector 2 through the purge action, thereby facilitating timely troubleshooting and maintenance, and can also promptly purge out leaked methanol to prevent the leaked methanol from remaining for a long time and corroding the structure.

[0057] In one embodiment, if Figures 1 to 3 As shown, the end of the mixing pipe section 12 away from the intake pipe section 11 is provided with a docking flange 121 for sealing connection with the engine cylinder head, and a corresponding flange structure is also provided on the engine cylinder head side, through which a convenient connection with the cylinder head structure is achieved.

[0058] The present application also provides an engine air intake system comprising a plurality of the aforementioned engine air intake modules 100 and a connector (not shown). The air intake pipe sections 11 of the air intake manifolds 1 of the plurality of engine air intake modules 100 are sequentially connected end-to-end via the connector. The connector may be a flanged expansion joint or a clamp.

[0059] The present application also provides an engine comprising a cylinder head and the aforementioned engine intake system, wherein the cylinder head has multiple intake ports reserved thereon, and the mixing pipe section 12 of the intake manifold 1 of the engine intake system is connected to the intake ports on the cylinder head.

[0060] The foregoing description is merely a partial embodiment of the present application and is not intended to limit the present application. Persons skilled in the art will readily appreciate that various modifications and variations are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.

Claims

1. An engine air intake module, characterized in that: include: An intake manifold (1) comprises an intake pipe section (11) and a mixing pipe section (12) with openings at both ends; the intake pipe section (11) extends along a first direction, and the mixing pipe section (12) extends along a second direction, the first direction being perpendicular to the second direction; the mixing pipe section (12) comprises an inlet end and an outlet end, the inlet end being in communication with the main body of the intake pipe section (11), and the outlet end being used for docking with an engine cylinder head; a fuel injection position (13) is provided on a pipe wall of the intake pipe section (11) corresponding to the inlet end of the mixing pipe section (12); An alcohol injector (2) is installed in the fuel injection position (13) of the intake pipe section (11), and the injection direction of the alcohol injector (2) is toward the inlet end of the mixing pipe section (12).

2. The engine air intake module according to claim 1, characterized in that: The spray range boundary of the alcohol sprayer (2) does not exceed the inlet end boundary of the mixing pipe section (12).

3. The engine air intake module according to claim 2, characterized in that: From a first direction perspective, the overlapping point between the extended axis of the spraying direction of the alcohol sprayer (2) and the axis of the mixing pipe section (12) is located within the mixing pipe section (12).

4. The engine air intake module according to claim 2, characterized in that: The included angle between the axis of the spray direction of the alcohol sprayer (2) and the axis of the mixing pipe section (12) is β, wherein 90°<β<180°.

5. The engine air intake module according to claim 4, characterized in that: The included angle β between the axis of the injection direction of the alcohol sprayer (2) and the axis of the mixing pipe section (12) satisfies 100°≤β≤130°.

6. The engine air intake module according to claim 1, characterized in that: There are at least two fuel injection positions (13) arranged on the pipe wall of the air intake pipe section (11), and an alcohol injector (2) is installed in each of the fuel injection positions (13).

7. The engine air intake module according to claim 1 or 6, characterized in that: A mounting seat (131) is provided at the fuel injection position (13), and a mounting channel (132) is provided in the mounting seat (131) and extends through the interior of the intake pipe section (11). The alcohol sprayer (2) is sealed and mounted in the mounting channel (132). A pressing block (133) is mounted on the mounting seat (131) to compress and seal the alcohol sprayer (2). The inlet (21) of the alcohol sprayer (2) is arranged on the side wall, and the mounting seat (131) is laterally provided with a fuel inlet (1311) that penetrates into the interior of the mounting channel (132), and the fuel inlet (1311) is docked with and communicated with the inlet (21) of the alcohol sprayer (2).

8. The engine air intake module according to claim 7, characterized in that: An annular groove (22) is provided on the side wall above the inlet (21) of the alcohol sprayer (2), and the annular groove (22) and the inner wall of the mounting channel (132) form an annular cavity. The mounting seat (131) is provided with a first interface (1312) and a second interface (1313) that are in communication with the annular cavity.

9. An engine air intake system, characterized in that: comprising a plurality of engine air intake modules according to any one of claims 1 to 8, further comprising a connecting member; The air intake pipe sections (11) of the air intake manifolds (1) of the plurality of engine air intake modules are connected end to end in sequence through the connecting piece.

10. An engine, characterized in that: include: a cylinder head, wherein a plurality of air inlets are reserved on the cylinder head; The engine air intake system according to claim 9, wherein the mixing pipe section (12) of the air intake manifold (1) of the engine air intake system is connected to the air intake port on the cylinder head.

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