EGR cooler, engine and motor vehicle

Abstract

The invention provides an EGR cooler, an engine and a motor vehicle, and relates to the technical field of exhaust gas recirculation, and the EGR cooler comprises an air inlet chamber, an air outlet chamber, a circulation valve, an EGR cooler shell and an EGR cooler core body. And the circulation valve is integrated in the air inlet chamber. The flow valve comprises a valve plate and a valve plate controller. The valve plate is arranged in the center area of the installation plane in the air inlet chamber, and a gap exists between the edge of the valve plate and the surface of the inner wall of the EGR cooler shell and is used for enabling EGR gas to pass through the edge area of the installation plane. The valve plate controller adjusts the state of the valve plate based on the EGR flow entering the EGR cooler so as to redistribute distribution of EGR gas entering a core body of the EGR cooler, so that the cooling efficiency of the EGR cooler and the utilization rate of the core body reach set standards. According to the EGR cooler, the utilization rate of the edge area of the EGR cooler core body is improved, the service life of the EGR cooler core body is prolonged, and the performance of an engine is stable.

Description

Technical Field

[0001] The present disclosure belongs to the technical field of exhaust gas recirculation, and particularly relates to an EGR cooler, an engine, and a motor vehicle. Background Art

[0002] With the continuous upgrading of emission standards, engines generally use exhaust gas recirculation (EGR) technology to reduce the generation of nitrogen oxides, thereby improving the engine's original emission performance.

[0003] In the prior art, the intake chamber of an EGR cooler generally utilizes a diffuser structure. This structure results in significant uneven pressure distribution on the outlet plane of the EGR cooler after the EGR gas enters the intake chamber. The EGR gas pressure is primarily concentrated in the center of the outlet plane, failing to effectively and promptly diffuse to the peripheral areas surrounding the center. This uneven pressure distribution significantly reduces the effective utilization of the EGR cooler core. The utilization rate of the EGR cooler core is excessively high, while the utilization rate of the peripheral areas is too low, resulting in suboptimal cooling efficiency. Furthermore, due to the excessive pressure concentration, the center of the EGR cooler core bears greater thermal and mechanical loads, accelerating the aging process of this area. Meanwhile, the peripheral areas surrounding the center of the EGR cooler core are not fully utilized, resulting in a significant waste of resources. This irrational usage not only affects the overall performance of the EGR cooler, but also significantly shortens its service life and increases its maintenance costs and replacement frequency. Summary of the Invention

[0004] The present disclosure provides an EGR cooler, an engine, and a motor vehicle, aiming to at least to some extent solve the technical problem in related technologies that the utilization rate of the edge area of ​​the EGR cooler core is too low, resulting in limited cooling efficiency and service life of the EGR cooler.

[0005] At least one embodiment of the present disclosure provides an EGR cooler applied to an engine, comprising:

[0006] an air intake chamber, the air intake chamber being used to connect to an exhaust pipe of the engine;

[0007] an air outlet chamber, the air outlet chamber being used to connect to an air intake pipe of the engine;

[0008] a circulation valve, the circulation valve being integrated into the interior of the air inlet chamber;

[0009] an EGR cooler housing, one end of the EGR cooler housing being connected to the outlet of the air inlet chamber, and the other end of the EGR cooler housing being connected to the inlet of the air outlet chamber; and

[0010] An EGR cooler core, the EGR cooler core being disposed inside the EGR cooler housing;

[0011] The flow valve includes a valve plate and a valve plate controller; the valve plate is arranged in the central area of ​​a mounting plane perpendicular to the EGR gas intake direction in the intake chamber, and a gap is formed between the edge of the valve plate and the inner wall surface of the EGR cooler housing, the gap is used to allow the EGR gas to pass through the edge area of ​​the mounting plane, the opening of the valve plate is in an adjustable state, and the valve plate is used to control the EGR gas flowing through the central area;

[0012] The valve controller is configured as follows:

[0013] The state of the valve plate is adjusted based on the EGR flow entering the EGR cooler to redistribute the distribution of the EGR gas entering the EGR cooler core and having the EGR flow, so that the cooling efficiency of the EGR cooler and the utilization rate of the EGR cooler core reach their respective set standards.

[0014] At least one embodiment of the present disclosure provides an EGR cooler further comprising:

[0015] An EGR cooler control unit is configured to control the operation of the flow valve after the engine is started, and the EGR cooler control unit is configured to:

[0016] Obtaining an EGR flow rate entering the EGR cooler;

[0017] In response to the EGR flow being less than a preset EGR flow lower limit, issuing a first control instruction for placing the valve plate in a closed state to the valve plate controller;

[0018] In response to the EGR flow being greater than the EGR flow lower limit and the EGR flow being less than a preset EGR flow upper limit, issuing a second control instruction for dynamically adjusting the opening of the valve to the valve controller; and

[0019] In response to the EGR flow rate being greater than the EGR flow rate upper limit, a third control instruction for placing the valve plate in a fully open state is issued to the valve plate controller.

[0020] In the EGR cooler provided in at least one embodiment of the disclosure, the EGR cooler control unit is further configured to:

[0021] Obtaining an EGR gas pressure drop between an air inlet end and an air outlet end of the EGR cooler; and

[0022] In response to the EGR gas pressure drop being greater than a preset pressure drop limit, a third control instruction for placing the valve plate in a fully open state is issued to the valve plate controller.

[0023] In the EGR cooler provided by at least one embodiment of the present disclosure, the second control instruction includes a set opening of the flow valve, and the EGR cooler control unit is further configured to:

[0024] Obtaining an EGR air temperature at an intake end of the EGR cooler and an EGR gas pressure drop between an intake end and an outlet end of the EGR cooler;

[0025] generating a set opening of the flow valve based on the current EGR flow rate, the EGR air temperature, and the EGR gas pressure drop; and,

[0026] The second control command is generated based on the set opening of the flow valve.

[0027] In the EGR cooler provided by at least one embodiment of the present disclosure, generating the set opening of the flow valve based on the current EGR flow rate, the EGR air temperature, and the EGR gas pressure drop includes:

[0028] generating a basic opening degree based on the EGR flow rate and the EGR air temperature;

[0029] generating a corrected opening degree based on the EGR gas pressure drop; and

[0030] A set opening degree of the flow valve is generated based on the basic opening degree and the corrected opening degree.

[0031] In the EGR cooler provided by at least one embodiment of the present disclosure, the pressure drop limit is a dynamic value, and the pressure drop limit is configured to be related to the current EGR flow rate and the EGR air temperature at the intake end of the EGR cooler; and the EGR cooler control unit is further configured to:

[0032] In response to the EGR gas pressure drop being continuously greater than the pressure drop limit value within a set time, a warning signal indicating that carbon deposits in the EGR cooler exceed a standard is issued.

[0033] In the EGR cooler provided by at least one embodiment of the present disclosure, the flow valve further includes:

[0034] a circulation valve housing, wherein the circulation valve housing is integrated with the EGR cooler housing, and the valve plate controller is installed on the outer side of the circulation valve housing;

[0035] a valve plate housing, the valve plate housing being arranged in the middle of the circulation valve housing and being used to separate the central area of ​​the mounting plane in the air inlet chamber from the edge area of ​​the mounting plane;

[0036] a valve stem, one end of which is connected to the output shaft of the valve controller, the other end of which passes through the valve housing and is connected to the circulation valve housing, and the valve is fixed to the middle position of the valve stem and is disposed in the valve housing so that the valve rotates around the valve stem in the valve housing; and

[0037] A support frame, one end of the support frame is connected to the circulation valve housing, and the other end of the support frame is connected to the valve plate housing.

[0038] In the EGR cooler provided by at least one embodiment of the present disclosure, the EGR cooler control unit is integrated into the engine controller; and,

[0039] The flow valve controller is provided with an engine harness connector for connecting to the engine controller, so that the engine controller controls the opening of the valve plate.

[0040] In the EGR cooler provided by at least one embodiment of the present disclosure, the center of the valve plate, the center of the valve plate housing, and the center of the inlet of the intake chamber are located on the same straight line; and

[0041] The opening of the valve plate is positively correlated with the EGR flow rate entering the EGR cooler;

[0042] There is no sealing structure between the valve plate and the valve plate housing, and a gap is provided between the valve plate and the valve plate housing.

[0043] At least one embodiment of the present disclosure further provides an engine, comprising the EGR cooler provided in any embodiment of the present disclosure.

[0044] At least one embodiment of the present disclosure further provides a motor vehicle, comprising the EGR cooler provided in any embodiment of the present disclosure.

[0045] Compared to related technologies, the EGR cooler, engine, and motor vehicle provided by the embodiments of the present disclosure are EGR coolers with a flow valve. By embedding the flow valve in the intake chamber, the distribution of EGR gas can be adjusted according to different EGR flow rates, thereby improving the utilization rate of the edge area of ​​the EGR cooler core, thereby achieving the purpose of extending the service life of the EGR cooler and stabilizing engine performance. At the same time, the adaptive control scheme for adjusting the distribution of EGR gas according to different EGR flow rates has good control accuracy and control effect, achieving the performance requirements of uniform carbon deposit distribution and high cooling efficiency of the EGR cooler, thereby stabilizing the power performance and emission levels of the engine in the EGR route, and solving the technical problem of the related technology that the utilization rate of the edge area of ​​the EGR cooler core is too low, resulting in limited cooling efficiency and service life of the EGR cooler.

[0046] It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In order to more clearly illustrate the technical solutions in the embodiments of the present disclosure, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present disclosure. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0048] Figure 1 A schematic structural diagram of an EGR cooler provided by at least one embodiment of the present disclosure;

[0049] Figure 2 A schematic diagram of the appearance of an EGR cooler provided by at least one embodiment of the present disclosure;

[0050] Figure 3 A schematic structural diagram of a flow valve provided by at least one embodiment of the present disclosure;

[0051] Figure 4 A schematic structural diagram of another flow valve provided by at least one embodiment of the present disclosure;

[0052] Figure 5 A schematic structural diagram of another EGR cooler provided by at least one embodiment of the present disclosure;

[0053] Figure 6 A schematic diagram of the appearance of another EGR cooler provided by at least one embodiment of the present disclosure;

[0054] Figure 7 A control diagram of an EGR cooler control logic example provided by at least one embodiment of the present disclosure;

[0055] Figure 8 A structural block diagram of an engine provided by at least one embodiment of the present disclosure;

[0056] Figure 9 A structural block diagram of a motor vehicle provided in at least one embodiment of the present disclosure.

[0057] Reference numerals

[0058] 1-inlet chamber; 2-outlet chamber; 3-circulation valve; 4-EGR cooler housing; 5-EGR cooler core; 6-inlet flange; 7-outlet flange; 8-water pipe; 31-valve plate; 32-valve plate controller; 33-circulation valve housing; 34-valve plate housing; 35-valve stem; 36-support frame; D-partition. DETAILED DESCRIPTION

[0059] The present disclosure will be further described in detail below in conjunction with the accompanying drawings and examples. It is particularly noted that the following examples are only used to illustrate the present disclosure and do not limit the scope of the present disclosure. Similarly, the following examples are only some embodiments of the present disclosure and not all embodiments. All other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present disclosure.

[0060] The terms "first," "second," and "third" in the embodiments of the present disclosure are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of technical features indicated. Therefore, features defined as "first," "second," and "third" may explicitly or implicitly include at least one of such features.

[0061] In the description of the present disclosure, “a plurality of” means at least two, such as two or three, etc., unless otherwise clearly and specifically defined.

[0062] In the present disclosure, the terms "one embodiment", "some embodiments", "examples", "specific examples" or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present disclosure. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples without contradiction.

[0063] The terms "including," "having," and any variations thereof, in the embodiments of the present disclosure are intended to cover non-exclusive inclusions. For example, a process, EGR cooler, system, product, or apparatus comprising a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or components inherent to the process, EGR cooler, product, or apparatus.

[0064] The term "engine controller" in the embodiments of the present disclosure, abbreviated as ECU, refers to an electronic controller with calculation and control functions applied to the engine. When the engine is running, it collects signals from various sensors, performs calculations, and converts the results of the calculations into control signals to control the operation of the controlled object.

[0065] The term "exhaust gas recirculation", abbreviated as EGR, in the embodiments of the present disclosure refers to a technology that directs a portion of the engine's EGR gas back into the engine cylinder and mixes it with the fresh gas entering the engine to improve the engine's operating efficiency, improve the combustion environment, reduce engine load, reduce NOx compound emissions, reduce knock, and extend the service life of various components.

[0066] The term "EGR cooler" in the embodiments of the present disclosure refers to a device that uses an EGR cooler core to cool the EGR gas to reduce its temperature before it enters the intake manifold. Multiple gas pipes can be configured inside the EGR cooler, and the outside of these gas pipes surrounds a coolant circulation path. When the EGR gas enters the EGR cooler, it flows through these relatively independent gas pipes. During this process, the coolant absorbs the heat of the EGR gas, thereby reducing the temperature of the EGR gas.

[0067] Related technologies underutilize the edge area of ​​the EGR cooler core, limiting the cooling efficiency and service life of the EGR cooler. Furthermore, under low EGR flow conditions, the EGR cooler often exhibits overcapacity, making it impossible to flexibly adjust the cooling effect based on varying EGR flow rates.

[0068] Figure 1 A schematic diagram of the structure of an EGR cooler provided by at least one embodiment of the present disclosure. Figure 1 As shown, the EGR cooler may include an intake chamber 1, an outlet chamber 2, a flow valve 3, an EGR cooler housing 4, and an EGR cooler core 5. The intake chamber 1 is used to connect to the exhaust pipe of the engine. The outlet chamber 2 is used to connect to the intake pipe of the engine. The flow valve 3 is integrated into the interior of the intake chamber 1. One end of the EGR cooler housing 4 is connected to the outlet of the intake chamber 1, and the other end of the EGR cooler housing 4 is connected to the inlet of the outlet chamber 2. The EGR cooler core 5 is disposed inside the EGR cooler housing.

[0069] The flow valve 3 includes a valve plate 31 and a valve plate controller 32. The opening of the valve plate 31 is adjustable. The valve plate 31 is located in the center of a mounting plane perpendicular to the EGR gas intake direction within the intake chamber 1 (also known as the EGR gas mainstream area). A gap D exists between the edge of the valve plate 31 and the inner wall of the EGR cooler housing 4. This gap D allows EGR gas to pass through the edge of the mounting plane (also known as the peripheral area of ​​the central area). The valve plate 31 controls the EGR gas flow through this central area.

[0070] The valve controller 32 is configured to: adjust the state of the valve plate 31 based on the EGR flow entering the EGR cooler to redistribute the distribution of the EGR gas entering the EGR cooler core 5 and having an EGR flow, so that the cooling performance parameters of the EGR cooler and the utilization rate of the EGR cooler core 5 reach their respective set standards.

[0071] In the above scheme, the shape of the EGR cooler is as follows Figure 2 As shown, the specific structure of the flow valve 3 is as follows Figure 3 As shown. The EGR cooler is designed to be compact and efficient to suit the layout requirements of the engine. Figure 2 In the figure, the shape of the EGR cooler housing 4 and the positional relationship between the EGR cooler housing 4 and the air inlet chamber 1 and the air outlet chamber 2 can be clearly seen. The air inlet chamber 1 is designed with enough space to ensure that the EGR gas can enter smoothly and be evenly distributed. The specific structure of the flow valve 3 is shown in Figure 3 The shape and dimensions of valve plate 31 are precisely calculated to ensure effective control of the EGR gas flow through the center area. Valve controller 32, located on one side of valve plate 31 and connected to it via precise mechanical structures or electronic components, enables precise adjustment of the valve plate's opening.

[0072] It should be noted that the cooling performance of the EGR cooler directly affects the engine power and emission levels.

[0073] By integrating a flow valve 3 within the intake chamber 1, the above solution dynamically adjusts the state of the valve plate 31 according to the EGR flow rate, ensuring uniform distribution of EGR gas within the EGR cooler core 5 and effectively avoiding local overheating or insufficient cooling. This innovative design not only improves the cooling efficiency of the EGR cooler but also significantly enhances engine performance while reducing harmful emissions, meeting the dual requirements of modern engines for high efficiency and environmental protection.

[0074] To demonstrate the effectiveness of the above solution, a series of comparative tests were conducted. For example, with the engine operating at a set speed and maximum torque, the EGR gas temperature at the output of the EGR cooler (also known as the EGR cold temperature) was measured and compared with the flow valve 3, which was switched on and off. The test results showed that the EGR gas temperature was lower when the flow valve 3 was energized than when it was de-energized. This demonstrates that the flow valve 3 effectively adjusts the EGR gas distribution and optimizes the cooling effect.

[0075] Some embodiments of the present disclosure also provide an engine and a motor vehicle corresponding to the above-mentioned EGR cooler.

[0076] The EGR cooler provided by at least one embodiment of the present disclosure is applicable to any existing engine application scenario with an EGR cooler, and the embodiments of the present disclosure are not limited to this. For example, the EGR cooler can be applied to various engine types such as heavy-duty commercial vehicles, light-duty passenger vehicles, engineering machinery vehicles, or ship engines. In these application scenarios, the EGR cooler of the present disclosure can effectively control the flow rate and pressure distribution of the EGR gas, ensuring that the engine maintains good combustion efficiency and power performance while reducing nitrogen oxide emissions. In addition, the design of the EGR cooler is flexible and easy to integrate into the existing engine system, without the need for large-scale modification of the engine, thereby reducing application costs and technical difficulties.

[0077] Compared to related technologies, the present disclosure proposes an EGR cooler with a flow valve 3. By embedding the flow valve 3 within the intake chamber 1, the distribution of EGR gas can be adjusted according to varying EGR flow rates, thereby improving the utilization rate of the edge area of ​​the EGR cooler core 5, thereby extending the service life of the EGR cooler and stabilizing engine performance. Furthermore, the adaptive control scheme for adjusting the distribution of EGR gas according to varying EGR flow rates offers excellent control accuracy and effectiveness, achieving the EGR cooler's performance requirements of uniform carbon deposit distribution and high cooling efficiency, thereby stabilizing the power performance and emissions levels of engines using the EGR route.

[0078] The main function of the intake chamber 1 is to guide the EGR gas into the interior of the EGR cooler core 5. The inlet of the intake chamber 1 is connected to the exhaust pipe of the engine. In order to achieve a compact structure, the cross-sectional area of ​​the EGR cooler core 5 is usually larger than the intake end area (also known as the inlet area) of the EGR cooler. Therefore, the intake chamber 1 has a flared structure. For a flared structure, if there is no pressure regulating device, that is, the flow valve 3 used in the present disclosure is used, the pressure distribution on the outlet plane of the intake chamber 1 is uneven, mainly concentrated in the central area of ​​the intake chamber 1.

[0079] The main function of the outlet chamber 2 is to guide the EGR gas into the interior of the EGR cooler core 5. The outlet of the outlet chamber 2 is connected to the engine's air intake line. To achieve a compact structure, the cross-sectional area of ​​the EGR cooler core 5 is usually larger than the outlet end area (also known as the outlet area) of the EGR cooler. Therefore, the outlet chamber 2 has a tapered structure. The tapered structure allows the EGR gas to transition more smoothly when leaving the EGR cooler core 5, reducing the generation of turbulence and eddies, thereby reducing pressure loss and improving the overall efficiency of the EGR system.

[0080] The main function of the circulation valve 3 is to redistribute the distribution of the EGR gas entering the EGR cooler core 5 and having an EGR flow rate, so as to achieve the performance requirements of improving the uniform distribution of carbon deposits and high cooling efficiency of the EGR cooler, and at the same time, to extend the service life of the EGR cooler. The circulation valve 3 is installed in the intake chamber 1 in an embedded manner. Compared with the solution of using a circulation valve to control the EGR flow or coolant flow in the related art, the solution of redistributing the distribution of EGR gas using a circulation valve disclosed in the present invention has achieved unexpected technical effects. The circulation valve 3 has an adjustable function, which can flexibly adjust the flow and distribution of the EGR gas according to the engine operating conditions and the requirements of the EGR system, thereby further improving the performance and reliability of the EGR cooler.

[0081] The primary function of the EGR cooler housing 4 is to protect and support the EGR cooler core 5, ensuring a stable and uninterrupted flow path for the EGR gas. The EGR cooler housing 4 is typically made of high-temperature and corrosion-resistant materials to withstand the high temperatures generated by engine operation and the corrosive substances that may be present in the EGR gas.

[0082] The primary function of the EGR cooler core 5 is to efficiently cool the EGR gas flowing through it. By designing cooling channels and heat dissipation structures, the EGR cooler core 5 can quickly remove heat from the EGR gas, lowering its temperature and effectively preventing the adverse effects of high-temperature EGR gas on the engine.

[0083] In some embodiments, in order to enable the EGR cooler to adapt to the flow requirements of EGR gas under different working conditions, the ratio of the area of ​​the valve plate 31 to the installation plane of the intake chamber 1 can be obtained through simulation calculation. The area occupied by the mainstream gas when the EGR flow is maximum can be taken, and the circulation valve 3 is set for the central area with this area. Among them, after the area ratio of the valve plate 31 is accurately calculated, it can ensure that when the EGR flow reaches the maximum value, the mainstream gas can pass smoothly, while reducing airflow resistance and energy loss. The area setting of the valve plate 31 of the circulation valve 3 further optimizes the flow path of the gas, so that the EGR gas can be more evenly distributed in the cooler core, thereby improving the cooling efficiency. In addition, this design also enhances the adaptability and flexibility of the EGR cooler, so that it can adapt to the flow requirements of the EGR gas under different working conditions.

[0084] In some embodiments, to ensure the high-temperature resistance of the EGR cooler, the valve plate 31 is made of metal. Specifically, the use of titanium-aluminum alloy or nickel-based high-temperature alloy can ensure high-temperature resistance and low weight of the valve plate 31. The low weight of the valve plate 31 ensures that the flow valve 3 can be effectively controlled by the valve controller 32 even after soot is deposited on the EGR cooler, without increasing the driving force required at the output of the valve controller 32 due to the increased viscosity of the soot.

[0085] Figure 4 A schematic diagram of the structure of another flow valve provided by at least one embodiment of the present disclosure. Figure 4 As shown, in Figure 3On the basis of the above, the circulation valve 3 also includes a circulation valve housing 33, a valve plate housing 34, a valve stem 35, and a support frame 36. The circulation valve housing 33 is integrated with the EGR cooler housing 4, and a valve plate controller 32 is installed on the outside of the circulation valve housing 33. The valve plate housing 34 is located in the middle of the circulation valve housing 33 and is used to separate the central area of ​​the installation plane in the intake chamber 1 from the edge area of ​​the installation plane. It also serves as a support. One end of the valve stem 35 is connected to the output shaft of the valve plate controller 32, and the other end of the valve stem 35 passes through the valve plate housing 34 and is connected to the circulation valve housing 33. The valve plate 31 is fixed in the middle of the valve stem 35 and is located in the valve plate housing 34, allowing the valve plate 31 to rotate around the valve stem 35 within the valve plate housing 34. One end of the support frame 36 is connected to the circulation valve housing 33, and the other end of the support frame 36 is connected to the valve plate housing 34. Among them, the support frame 36 is used to increase the structural stability of the circulation valve 3. The circulation valve 3 controls the rotation of the valve stem 35 through the valve plate controller 32, thereby driving the valve plate 31 to rotate in the valve plate housing 34. When the valve plate 31 rotates to a certain position, the flow of EGR gas in the intake chamber 1 can be accurately controlled to achieve the adjustment of the cooling efficiency of the EGR cooler. In addition, the integrated design of the circulation valve housing 33 and the EGR cooler housing 4 not only simplifies the structure of the EGR cooler, but also improves the integrity and sealing of the EGR cooler. The setting of the valve plate housing 34 not only effectively separates the different areas in the intake chamber 1, but also enhances the supporting strength of the circulation valve 3. The addition of the support frame 36 further enhances the structural stability of the circulation valve 3, ensuring its reliability and durability during long-term use. In summary, the EGR cooler of this solution achieves more precise control of the cooling efficiency by adding the circulation valve 3 and its related components, thereby improving the overall performance and service life of the cooler.

[0086] In some embodiments, to improve the EGR cooler's response speed and control accuracy, the EGR cooler control unit is integrated into the engine controller (ECU). Furthermore, the flow valve controller is equipped with an engine wiring harness connector for connection to the ECU, enabling the ECU to control the opening of valve plate 31. The ECU calculates the optimal EGR rate based on engine operating conditions, such as speed, load, and temperature, and sends instructions to the flow valve controller via the engine wiring harness connector to adjust the opening of valve plate 31, thereby achieving precise control of the EGR gas flow rate. This integrated control approach not only improves the EGR cooler's response speed and control accuracy, but also effectively reduces system complexity and cost.

[0087] In some embodiments, to achieve precise control of valve plate 31, the center of valve plate 31, the center of valve plate housing 34, and the center of the inlet of intake chamber 1 are aligned. The centers of valve plate 31 and valve plate housing 34 must align with the center of the inlet of intake chamber 1. This design ensures that EGR gas flows smoothly into intake chamber 1 as it passes through valve plate 31, avoiding eddies and turbulence, and further improving EGR cooler performance. Furthermore, the alignment of the centers also facilitates precise control of EGR gas flow, ensuring optimal EGR rates under various engine operating conditions.

[0088] In some embodiments, in order to achieve rapid adjustment of the valve plate 31, the opening of the valve plate 31 is positively correlated with the EGR flow entering the EGR cooler, and there is no sealing structure between the valve plate 31 and the valve plate housing 34, and a certain gap is set between the valve plate 31 and the valve plate housing 34. Among them, this design enables the valve plate 31 to respond more sensitively to control instructions when the opening changes, thereby achieving rapid adjustment of the EGR flow. At the same time, the design without a sealing structure reduces the friction resistance between the valve plate 31 and the valve plate housing 34, and improves the movement flexibility and response speed of the valve plate 31. The existence of the gap allows the EGR gas to flow smoothly between the valve plate 31 and the valve plate housing 34, further reducing the resistance to gas flow and improving the overall performance of the EGR cooler. This design not only optimizes the flow control of the EGR gas, but also improves the reliability and durability of the EGR cooler.

[0089] In order to verify the positive correlation between the opening of the valve plate 31 and the EGR flow entering the EGR cooler, multiple sets of tests were conducted. The test results show that when the opening of the circulation valve 3 is set to 5% to 10%, the EGR flow is small; when the opening of the circulation valve 3 is set to 50%, the EGR flow is moderate; when the opening of the circulation valve 3 is set to 80%, the EGR flow is large, and the EGR flow is greater than the EGR flow corresponding to the opening of the circulation valve 3 being set to 50%. In addition, when the opening of the circulation valve 3 is gradually increased to 100%, the EGR flow reaches its maximum value. This test result clearly demonstrates the positive correlation between the opening of the valve plate 31 and the EGR flow, verifying the correctness of the design concept. These test data not only provide strong support for the performance optimization of the EGR cooler, but also lay a solid foundation for its precise control in practical applications.

[0090] In some embodiments, the flow valve housing 33 can be connected to the intake chamber 1 by welding, but is not limited to welding. The choice of welding can ensure a firm and tight connection between the flow valve housing 33 and the intake chamber 1, effectively preventing EGR gas leakage and ensuring the normal operation of the EGR cooler.

[0091] Figure 5 A schematic structural diagram of another EGR cooler provided in at least one embodiment of the present disclosure. Figure 6 A schematic diagram of another EGR cooler provided by at least one embodiment of the present disclosure. Figure 5 and Figure 6 As shown, to facilitate connection of the EGR cooler with other components in the engine, the EGR cooler also includes an inlet flange 6 and an outlet flange 7. The inlet flange 6 is located at the inlet of the intake chamber 1 and is used to connect to the upstream pipeline of the EGR cooler, namely the engine's exhaust pipe. The outlet flange 7 is located at the outlet of the outlet chamber 2 and is used to connect to the downstream pipeline of the EGR cooler, namely the engine's intake pipe. The design of the inlet flange 6 and outlet flange 7 not only facilitates connection of the EGR cooler with other components in the engine system, but also ensures the stability and continuity of the EGR gas during its flow. The inlet flange 6, by tightly connecting to the upstream pipe, can effectively guide the EGR gas into the intake chamber 1, while the outlet flange 7, by connecting to the downstream pipe, smoothly discharges the cooled EGR gas to the engine's intake manifold or other designated location. This design not only improves the installation convenience of the EGR cooler, but also enhances the reliability and performance of the entire EGR system.

[0092] like Figure 5 and Figure 6 As shown, to ensure effective cooling, the EGR cooler also includes a water pipe 8. This pipe receives coolant and transfers it to the EGR cooler core 5 to cool the EGR gas. The design of the water pipe 8 optimizes the coolant flow path, ensuring that the coolant flows evenly and efficiently through the EGR cooler core 5, thereby maximizing the absorption of heat from the EGR gas. This design not only improves the cooling efficiency of the EGR cooler, but also further enhances its overall reliability and durability.

[0093] In some embodiments, in order to ensure that both the central area and the edge area of ​​the EGR cooler core 5 are effectively utilized and to ensure the overall performance of the engine is stable, the EGR cooler also includes an EGR cooler control unit, which is used to control the action of the circulation valve 3 after the engine is started, and the EGR cooler control unit is configured to execute the following steps S10-step S40.

[0094] Step S10: Obtain the EGR flow rate entering the EGR cooler.

[0095] Step S20 : ​​In response to the EGR flow rate being less than the preset EGR flow rate lower limit, a first control instruction for placing the valve plate 31 in a closed state is sent to the valve plate controller 32 .

[0096] Step S30 : In response to the EGR flow being greater than the EGR flow lower limit and the EGR flow being greater than the preset EGR flow upper limit, a second control instruction for dynamically adjusting the opening of the valve 31 is issued to the valve controller 32 .

[0097] Step S40 : In response to the EGR flow rate being greater than the EGR flow rate upper limit, a third control instruction for placing the valve plate 31 in a fully open state is issued to the valve plate controller 32 .

[0098] Among them, the opening degree of the circulation valve 3 is controlled in stages through steps S10 to S40. When executing step S20, when the EGR flow rate is low, the valve plate 31 of the circulation valve 3 will be closed. Since the EGR flow rate is small at this time, the EGR cooler will not have a large resistance problem. Therefore, after closing the valve plate 31 of the circulation valve 3, the EGR gas will bypass the central area of ​​the EGR cooler core 5, be cooled by the edge area of ​​the cooler, and then flow out. In step S30, when the EGR flow rate is at a medium level, in order to ensure that the EGR cooler core 5 has sufficient flow area, the valve plate 31 of the circulation valve 3 will be opened to a certain angle. This measure helps to reduce the flow resistance of the EGR gas while ensuring that most of the EGR gas is cooled by the edge area of ​​the cooler. In step S30, when the EGR flow rate is large, the valve plate 31 of the circulation valve 3 will be fully opened, which helps to further reduce the flow resistance of the EGR gas and ensure sufficient flow area.

[0099] To verify the effectiveness of the solution from steps S10 to S40, a comparative test was conducted to examine the effect of the circulation valve 3 on the utilization of the central and peripheral regions of the EGR cooler core 5 at varying EGR flow rates. The test results showed that, with the circulation valve 3 in place, the pressure distribution in the EGR cooler core 5 was more uniform, regardless of EGR flow rate. This effectively avoided the technical issue of uneven EGR gas distribution limiting the overall performance and service life of the EGR cooler. This series of test data fully validated the effectiveness and practicality of the aforementioned solution and provided strong support for the optimized design of the EGR cooler.

[0100] In some embodiments, in order to ensure that the EGR cooler in the carbon deposit state continues to be used, the EGR cooler control unit is further configured to perform the following steps S50 to S60.

[0101] Step S50: Obtaining the EGR gas pressure drop between the air inlet and air outlet of the EGR cooler.

[0102] Step S60 : In response to the EGR gas pressure drop being greater than a preset pressure drop limit, a third control instruction for placing the valve plate 31 in a fully open state is sent to the valve plate controller 32 .

[0103] It should be noted that the EGR gas pressure drop between the inlet and outlet of the EGR cooler can indicate the current carbon deposit status of the EGR cooler. The greater the carbon deposit, the greater the obstruction to the flow of EGR gas within the EGR cooler, resulting in a corresponding increase in the EGR gas pressure drop. Therefore, by monitoring this pressure drop, the degree of carbon deposit in the EGR cooler can be indirectly assessed.

[0104] During step S60, if the EGR cooler's carbon deposits cause the EGR gas pressure drop between the inlet and outlet ends of the EGR cooler to exceed the normal range, the high EGR gas pressure drop detected indicates that the carbon deposits are severe. Appropriate measures are then required to fully open the valve plate 31 to reduce the additional flow resistance caused by the carbon deposits and ensure proper engine operation. This embodiment, while implementing graded control of the opening of the circulation valve 3 based on the real-time EGR flow rate, adaptively adjusts the opening of the circulation valve 3 by comprehensively considering the current carbon deposit situation in the EGR cooler, thereby improving the control accuracy of the EGR cooling effect.

[0105] As a preferred embodiment, the pressure drop limit is a dynamic value and is configured to be related to the current EGR flow rate and the EGR air temperature at the intake end of the EGR cooler. This embodiment further comprehensively considers the EGR flow rate at the intake end of the EGR cooler and the current carbon deposit situation at the EGR cooler to adaptively adjust the opening of the circulation valve 3. Specifically, the pressure drop limit is not fixed but is adjusted according to real-time operating conditions. When the EGR flow rate increases, the pressure drop limit is increased accordingly to maintain the stable operation of the EGR system, ensuring accurate assessment of the carbon deposit level even at higher EGR flow rates. Furthermore, the EGR air temperature at the intake end of the EGR cooler is also a significant influencing factor. At higher temperatures, the density of the EGR gas decreases, reducing flow resistance, so the pressure drop limit is adjusted accordingly to accommodate this change. By comprehensively considering the EGR flow rate and EGR air temperature, a pressure drop limit is established that more accurately reflects the actual operating conditions of the EGR cooler, thereby enabling more precise adaptive adjustment of the opening of the circulation valve 3 and achieving optimal EGR cooling.

[0106] In some embodiments, in order to further improve the service life of the EGR cooler, the EGR cooler control unit is further configured to: in response to the EGR gas pressure drop being continuously greater than the pressure drop limit within a set time, issue a warning signal for indicating that the carbon deposits in the EGR cooler are excessive. Among them, the warning signal can trigger a series of countermeasures, such as automatically adjusting the engine's operating parameters to reduce the flow of EGR gas, or notifying the operator to manually clean the carbon deposits inside the EGR cooler. In addition, the warning signal can also be connected to the vehicle's fault diagnosis system to record the information of excessive carbon deposits in the vehicle's fault code to facilitate subsequent maintenance and inspection. In this way, the carbon deposit problem of the EGR cooler can be discovered and solved in a timely manner to ensure the stable operation and emission performance of the engine.

[0107] In some embodiments, in order to better control the cooling performance of the EGR cooler, the second control instruction is configured to include a set opening of the circulation valve 3, and when the EGR flow is greater than the EGR flow lower limit value and the EGR flow is greater than the pre-set EGR flow upper limit value, the EGR cooler control unit is also configured to execute the following steps S70-S90.

[0108] Step S70: Acquire the EGR air temperature at the intake end of the EGR cooler and the EGR gas pressure drop between the intake end and the outlet end of the EGR cooler.

[0109] Step S80: Generate a set opening degree of the circulation valve 3 based on the current EGR flow rate, EGR air temperature, and EGR gas pressure drop.

[0110] Step S90 : Generate a second control command based on the set opening of the circulation valve 3 .

[0111] Among them, through steps S70 to S90, the flow performance of the EGR cooler can be adjusted in real time to ensure that the EGR system operates efficiently while avoiding energy loss and possible equipment damage caused by overcooling. Specifically, the EGR air temperature and EGR gas pressure drop data obtained in step S70 can reflect the current working state and load conditions of the EGR cooler. The opening setting of the circulation valve 3 generated based on these data in step S80 is a precise regulation of the cooling efficiency according to the real-time working conditions. Finally, the second control instruction generated based on the set opening in step S90 directly acts on the circulation valve 3, realizing precise control of the EGR flow, thereby ensuring the stability and efficiency of the EGR system.

[0112] In some embodiments, in order to precisely control the working state of the EGR cooler, step S80 is refined to include the following sub-steps S801 to S803 .

[0113] Sub-step S801: Generate a basic opening degree based on the EGR flow rate and the EGR air temperature.

[0114] Sub-step S802: Generate a corrected opening degree based on the EGR gas pressure drop.

[0115] Sub-step S803: Generate the set opening of the circulation valve 3 based on the basic opening and the corrected opening.

[0116] Among them, through sub-steps S801 to S803, the opening of the circulation valve 3 can be further accurately adjusted to adapt to different EGR flow rates, air temperatures and pressure drop conditions. In sub-step S801, the basic opening generated based on the EGR flow rate and EGR air temperature reflects the initial cooling demand of the cooler for the EGR gas. In sub-step S802, considering the aging and performance deterioration of the EGR cooler, the corrected opening generated according to the EGR gas pressure drop takes into account the flow resistance of the gas in the cooler, and makes necessary corrections to the basic opening. Finally, in sub-step S803, the basic opening and the corrected opening are combined to generate the set opening of the circulation valve 3. This set opening not only meets the cooling efficiency requirements, but also ensures smooth gas flow, thereby achieving precise control of the working state of the EGR cooler.

[0117] Figure 7 A control diagram of an EGR cooler control logic example provided by at least one embodiment of the present disclosure. Figure 7As shown, the EGR cooler control logic controls circulation valve 3 based on the current EGR flow rate, the air temperature before the EGR cooler, and the pressure drop before and after the EGR cooler. The specific control logic is as follows: the current EGR flow rate is acquired in real time. When the EGR flow rate is less than the EGR flow lower limit, circulation valve 3 is set to fully closed, that is, its opening is set to 0%. When the EGR flow rate is greater than the EGR flow upper limit or the EGR gas pressure drop is greater than the pressure drop limit, circulation valve 3 is set to fully open, that is, its opening is set to 100%. The pressure drop limit is obtained by checking the pressure drop limit MAP based on the current EGR flow rate and the EGR air temperature before the EGR cooler. When the EGR flow rate is between the upper and lower limits of the EGR flow rate, the set opening of the circulation valve 3 is determined by the current EGR flow rate, the EGR air temperature before the EGR cooler, and the EGR gas pressure drop before and after the EGR cooler. The base opening of the circulation valve 3 is obtained by searching the circulation valve base opening setting MAP based on the EGR flow rate and the EGR air temperature before the EGR cooler. The base opening is then corrected based on the EGR gas pressure drop before and after the EGR cooler to obtain the set opening of the circulation valve 3. The correction scheme based on the pressure drop can be a table value retrieved based on the EGR gas pressure drop before and after the EGR cooler. The EGR gas pressure drop of the EGR cooler changes continuously with the use time of the EGR cooler. Therefore, it is necessary to query the correction coefficient or correction amount in real time to correct the opening of the valve plate 31. The larger the EGR gas pressure drop value, the greater the internal resistance of the current EGR cooler. The opening of the valve plate 31 should be increased to guide the gas to flow into more EGR cooler fins to reduce system resistance and ensure its cooling effect.

[0118] Figure 8 This is a structural block diagram of an engine provided by at least one embodiment of the present disclosure. Figure 8 As shown, the engine 100 includes the EGR cooler 101 according to the above embodiment.

[0119] Figure 9 A structural block diagram of a motor vehicle provided by at least one embodiment of the present disclosure. Figure 9 As shown, the motor vehicle 200 includes the EGR cooler 101 according to the above-described embodiment.

[0120] Although the embodiments of the present disclosure have been shown and described above, it is understood that the above embodiments are illustrative and are not to be construed as limitations on the present disclosure. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present disclosure.

Claims

1. An EGR cooler, applied to an engine, characterized in that: include: an air intake chamber, the air intake chamber being used to connect to an exhaust pipe of the engine; an air outlet chamber, the air outlet chamber being used to connect to an air intake pipe of the engine; a circulation valve, the circulation valve being integrated into the interior of the air inlet chamber; An EGR cooler housing, one end of the EGR cooler housing being connected to the outlet of the air inlet chamber, and the other end of the EGR cooler housing being connected to the inlet of the air outlet chamber; as well as, An EGR cooler core, the EGR cooler core being disposed inside the EGR cooler housing; The flow valve includes a valve plate and a valve plate controller; the valve plate is arranged in the central area of ​​a mounting plane perpendicular to the EGR gas intake direction within the intake chamber, and a gap is formed between the edge of the valve plate and the inner wall surface of the EGR cooler housing, the gap being used to allow the EGR gas to pass through the edge area of ​​the mounting plane. The opening of the valve plate is in an adjustable state, and the valve plate is used to control the EGR gas flowing through the central area; The valve controller is configured as follows: The state of the valve plate is adjusted based on the EGR flow entering the EGR cooler to redistribute the distribution of the EGR gas entering the EGR cooler core and having the EGR flow, so that the cooling efficiency of the EGR cooler and the utilization rate of the EGR cooler core reach their respective set standards.

2. The EGR cooler according to claim 1, characterized in that Also includes: An EGR cooler control unit is configured to control the operation of the flow valve after the engine is started, and the EGR cooler control unit is configured to: Obtaining an EGR flow rate entering the EGR cooler; In response to the EGR flow being less than a preset EGR flow lower limit, issuing a first control instruction for placing the valve plate in a closed state to the valve plate controller; In response to the EGR flow being greater than the EGR flow lower limit and the EGR flow being less than a preset EGR flow upper limit, issuing a second control instruction for dynamically adjusting the opening of the valve to the valve controller; as well as, In response to the EGR flow rate being greater than the EGR flow rate upper limit, a third control instruction for placing the valve plate in a fully open state is issued to the valve plate controller.

3. The EGR cooler according to claim 2, characterized in that The EGR cooler control unit is further configured to: Obtaining an EGR gas pressure drop between an air inlet end and an air outlet end of the EGR cooler; and In response to the EGR gas pressure drop being greater than a preset pressure drop limit, a third control instruction for placing the valve plate in a fully open state is issued to the valve plate controller.

4. The EGR cooler according to claim 2 or 3, characterized in that: The second control instruction includes a set opening of the flow valve, and the EGR cooler control unit is further configured to: Obtaining an EGR air temperature at an intake end of the EGR cooler and an EGR gas pressure drop between an intake end and an outlet end of the EGR cooler; generating a set opening of the flow valve based on the current EGR flow rate, the EGR air temperature, and the EGR gas pressure drop; as well as, The second control command is generated based on the set opening of the flow valve.

5. The EGR cooler according to claim 4, characterized in that Generating the set opening of the flow valve based on the current EGR flow rate, the EGR air temperature, and the EGR gas pressure drop includes: generating a basic opening degree based on the EGR flow rate and the EGR air temperature; generating a corrected opening degree based on the EGR gas pressure drop; and A set opening degree of the flow valve is generated based on the basic opening degree and the corrected opening degree.

6. The EGR cooler according to claim 3, characterized in that The pressure drop limit is a dynamic value, and is configured to be related to the current EGR flow rate and the EGR air temperature at the intake end of the EGR cooler; and the EGR cooler control unit is further configured to: In response to the EGR gas pressure drop being continuously greater than the pressure drop limit value within a set time, a warning signal indicating that carbon deposits in the EGR cooler exceed a standard is issued.

7. The EGR cooler according to any one of claims 1 to 3, characterized in that: The flow valve further comprises: a circulation valve housing, wherein the circulation valve housing is integrated with the EGR cooler housing, and the valve plate controller is installed on the outer side of the circulation valve housing; a valve plate housing, the valve plate housing being arranged in the middle of the circulation valve housing and being used to separate the central area of ​​the mounting plane in the air inlet chamber from the edge area of ​​the mounting plane; a valve stem, one end of which is connected to the output shaft of the valve controller, the other end of which passes through the valve housing and is connected to the circulation valve housing, and the valve is fixed to the middle position of the valve stem and is disposed in the valve housing so that the valve rotates around the valve stem in the valve housing; and A support frame, one end of the support frame is connected to the circulation valve housing, and the other end of the support frame is connected to the valve plate housing.

8. The EGR cooler according to claim 2 or 3, characterized in that: The EGR cooler control unit is integrated into the engine controller; and The flow valve controller is provided with an engine harness connector for connecting to the engine controller, so that the engine controller controls the opening of the valve plate.

9. The EGR cooler according to claim 7, characterized in that The center of the valve plate, the center of the valve plate housing and the center of the inlet of the air inlet chamber are located on the same straight line; and The opening of the valve plate is positively correlated with the EGR flow rate entering the EGR cooler; There is no sealing structure between the valve plate and the valve plate housing, and a gap is provided between the valve plate and the valve plate housing.

10. An engine, characterized in that: The engine comprises the EGR cooler according to any one of claims 1 to 9.

11. A motor vehicle, characterized in that: The motor vehicle comprises the EGR cooler according to any one of claims 1 to 9.

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