Systems and procedures for an exhaust gas recirculation cooler coupled to a cylinder head

Abstract

Exhaust gas recirculation (EGR) system (101, 210), comprising: an EGR cooler module (148, 248) comprising a body and a module EGR inlet port (153, 220), a module EGR outlet port (157, 242), and a module coolant inlet port (165, 218), all extending from the body and arranged parallel to each other on an equal, first side of a cylinder head (134, 235), wherein the module EGR inlet port (153, 220) and the module coolant inlet port (165, 218) are directly coupled to the first side of the cylinder head (134, 235), the module EGR inlet port (153, 220) is arranged on the first side of the cylinder head (134, 235), the EGR cooler module (148, 248) has a first Module flange (214) with the module EGR inlet port (153, 220) and the module coolant inlet port (165, 218) includes the module coolant inlet port (165, 218) in surface-sharing contact with a first engine coolant outlet port (167,267) on the first cylinder head surface (249) of the cylinder head (134, 235) and is in fluidic communication with it, and the EGR cooler module (148, 248) further includes a second module flange (216) which includes a module EGR outlet port (157, 242) and module coolant outlet port (171, 240); and , a radiator (162) which is coupled to the module coolant outlet port (171, 240) via a fourth inner passage (168) of the cylinder head (134, 235).

Description

Area

[0001] The present invention relates generally to methods and systems for a cooler for an exhaust gas recirculation system (EGR system) of an internal combustion engine. Background / Presentation

[0002] Internal combustion engines, such as gasoline engines, produce a variety of exhaust gases that are expelled from the cylinders through the cylinder head during operation. Some of these gases are released into the ambient air, while others are recirculated by the engine using an exhaust gas recirculation (EGR) system. An EGR system can reduce nitrogen oxide (NOx) emissions into the atmosphere by allowing the engine to replace some of its intake gases with exhaust gases. By allowing the EGR system to control the ratio of these gases within the cylinders, cylinder temperatures can be effectively lowered by limiting the amount of combustible intake gas available during each combustion cycle. The reduction in cylinder temperatures provided by an EGR system simultaneously reduces NOx emissions. x Production because of NO xThis occurs primarily within a narrow temperature range near peak cylinder temperatures. One problem that arises with such systems is that the gas from the EGR system is relatively hot compared to the intake gas. Hot gases being recirculated back into the cylinder can lead to valve deterioration, less efficient combustion, and increased cylinder temperatures, thus negating some of the benefits gained from implementing the EGR system.

[0003] One example of a solution to the problem of hot exhaust gas recirculation is to incorporate a cooling system within the EGR system. An EGR cooler helps to reduce the temperature of the recirculated exhaust gases before they are released into the intake manifold (and subsequently the cylinders). EGR coolers often feature a unit with several inlets and outlets for both EGR gases and coolant. The EGR cooler can be mounted on a surface within the engine compartment, close to the engine. EGR coolers may have a number of fittings used to connect to hoses and / or pipes for coolant and gas exchange. German patent application DE 10 2011 103 626 A1 discloses an EGR system with an EGR cooler module. Further prior art is known from German patent application DE 101 19 484 A1.

[0004] However, the inventors recognized potential problems with such systems. For example, EGR cooler fittings are often exposed to intense temperatures and come into prolonged contact with fluids. Consequently, the materials used to construct fittings to meet these requirements are often exotic and / or expensive. Furthermore, assembling and repairing the fittings can be time-consuming and increase labor costs. EGR cooler fittings can develop leaks, and because the coolers are often located near some high-temperature areas of the engine (such as the cylinder head and exhaust manifold), a leak in the fittings can lead to engine deterioration. The coolers and their connections tend to be bulky, increasing the overall volume occupied within the engine compartment.

[0005] The object of the present invention is therefore to provide an EGR system and a method that solves these problems.

[0006] This objective is achieved by the subject matter of the independent claims. Preferred embodiments of the present invention are the subject matter of the dependent claims.

[0007] In one example, the present invention comprises an EGR system comprising an EGR cooler module including a body and an EGR inlet port, a module EGR outlet port, and a module coolant inlet port, all extending from the body and arranged parallel to each other on the same first side of a cylinder head, wherein the module EGR inlet port and the module coolant inlet port are directly connected to the first side of the cylinder head. In this way, the EGR cooler module can communicate directly with coolant and gas passages within the cylinder head. In one example, the bolts that fasten the EGR cooler module to the surface of the cylinder head also compress a gasket that seals the connection between surfaces. The result is that the EGR cooler module has a compact form with fewer fittings.

[0008] It should be noted that the above presentation is intended to provide a simplified introduction to a selection of concepts that are described in more detail in the detailed description. It is not intended to identify important or essential features of the claimed invention, the scope of which is defined solely by the claims appended to the detailed description. Furthermore, the claimed invention is not limited to implementations that overcome any of the disadvantages mentioned above or mentioned in any part of the disclosure. Brief description of the drawings Fig. Figure 1 shows a schematic view of a first embodiment of an engine system comprising an EGR system with an EGR cooler module attached to a cylinder head. Fig. Figure 2 shows an exploded view of a first embodiment of an EGR system comprising a cylinder head and an EGR cooler module attached to the cylinder head. Fig. Figure 3 shows a schematic view of a second embodiment of an engine system comprising an EGR system with an EGR cooler module attached to a cylinder head. Fig. Figure 4 shows a perspective view of a cylinder head of a second embodiment of an EGR system. Fig. Figure 5 shows a perspective view of the cylinder head and an EGR cooler module attached to the cylinder head of the second embodiment of the EGR system. Fig. Figure 6 shows an additional perspective view of the second embodiment of the EGR system including the EGR cooler module with the cylinder head shown in cross-section. Fig. Figure 7 shows a start-up diagram of a process for the flow of exhaust gas and coolant through a cylinder head and an EGR cooler that is attached directly to one side of the cylinder head. Fig. 2 and the Fig. Figures 4 to 6 are shown approximately to scale. Detailed description

[0009] The following description concerns systems and procedures for an exhaust gas recirculation (EGR) system including an EGR cooler module directly attached to a cylinder head. An engine's EGR system may include a cylinder head, an EGR cooler module attached to the cylinder head, and a variety of coolant and gas passages within the cylinder head, as shown in Fig. Figure 1 shows that the cylinder head of the EGR system can include a variety of mounting surfaces designed to allow the EGR cooler module to be directly coupled to the cylinder head, as shown in the Fig. Figures 2 and 5 to 6 are shown. The cylinder head can include a variety of coolant and gas connections, which are formed by the internal passages of the cylinder head, as shown in Fig. Figures 1 to 6 show that the EGR cooler module may include a variety of gas and coolant connections configured to communicate directly with the corresponding parts of the cylinder head when the EGR cooler module is directly coupled to the cylinder head, as shown in the figures. Fig. Figures 1 to 6 show that the cylinder head of the EGR system may optionally include additional passages for guiding gas and coolant from the EGR cooler module back through the cylinder head, as shown in the embodiment of the Fig. Figures 1 to 2 show that the EGR system can optionally include coolant and gas passages outside the cylinder head so that the EGR cooler module returns coolant and gas to the engine system, as in the embodiment of the Fig. 3 to 6 are shown. In addition, there are Fig. 7 a method for flowing coolant and exhaust gas through a cylinder head and an EGR cooler module directly coupled to the cylinder head, such as the cylinder head and the EGR cooler module of one embodiment, in the Fig. Figures 1 to 2 and / or 3 to 6 show this. In this way, the EGR cooler module of the EGR system can communicate with the cylinder head to absorb coolant and exhaust gas and can return gas and coolant to the engine system via passages inside or outside the cylinder head.

[0010] Similar components in the Fig. Numbers 1 to 7 are described with similar reference symbols and can only be described once below and cannot be reintroduced for each figure.

[0011] Fig. Figure 1 shows a schematic view comprising an engine system 100 and an EGR system 101. The engine system 100 includes a multi-cylinder internal combustion engine 102. The engine 102 can include a multitude of cylinders (e.g., combustion chambers) which are covered on top by the cylinder head 134. In the Fig. In the example shown, the engine 102 comprises three cylinders: 120, 122, and 124. It should be noted that the cylinders may share a single cylinder block (not shown) and a crankcase (not shown), with the engine block coupled to and below the cylinder head. The engine system 100 also includes an intake manifold 106, an integrated exhaust manifold (IEM) 132, and a radiator 162.

[0012] Fig. Figure 1 is a schematic view showing the flow of gas and coolant between the components of engine system 100. Therefore, the passages and components are not shown to scale, and the relative positioning, size, and number of passages may vary in physical embodiments (e.g., the one in Fig. 2 embodiment shown).

[0013] Although the engine 102 is shown as an inline three-cylinder engine with three cylinders, it should be noted that other embodiments may include a different number of cylinders and arrangement of cylinders, for example V6, R4, R6, V12, 4-cylinder boxer engine, and other engine types.

[0014] Each cylinder can draw intake air from the intake manifold 106 via an intake passage 104. The intake manifold 106 can include cylinder intake passages (e.g., intake ports) 108, 110, and 112, which are connected to the cylinders via the intake ports 114, 116, and 118, respectively. Each intake port can communicate with the cylinder via one or more intake valves. Cylinders 120, 122, and 124 are in Fig. 1 each depicted with an inlet port, each inlet port containing an inlet valve. For example, cylinder 120 has an inlet port 114, cylinder 122 has an inlet port 116, and cylinder 124 has an inlet port 118. Other embodiments may include a different number of inlet ports and / or inlet valves per cylinder (e.g., two, three, etc.).

[0015] Each cylinder (e.g., cylinders 120, 122, and 124) can receive fuel from fuel injectors (not shown) directly coupled to the cylinder as direct injection, and / or from injectors coupled to the intake manifold 106 as port fuel injectors. Furthermore, air charges within each cylinder can be ignited by a spark from corresponding spark plugs (not shown). In other embodiments, the cylinders of engine 102 can be operated in a compression ignition mode, with or without a spark.

[0016] The intake passage 104 can include an air intake throttle 109. The position of the throttle 109 can be adjusted via a throttle actuator (not shown), which is communicatively coupled to a controller (not shown). By modulating the air intake throttle 109, a quantity of fresh air from the ambient air can be drawn into the engine 102, to which the engine cylinders are supplied via the intake manifold 106. A portion of the intake air can be compressed by a compressor (not shown) and / or cooled by an intercooler (not shown).

[0017] Each cylinder can expel combustion gases through one or more exhaust valves into exhaust ports (e.g., cylinder exhaust ports) connected to it. Cylinders 120, 122, and 124 are in Fig. Figure 1 shows each cylinder with an exhaust port, each including an exhaust valve arranged therein for expelling combustion gases from the corresponding cylinder. For example, cylinder 120 has an exhaust port 126, cylinder 122 has an exhaust port 128, and cylinder 124 has an exhaust port 130. Other embodiments may have a different number of exhaust ports and / or exhaust valves per cylinder (e.g., two, three, etc.).

[0018] Each cylinder can be connected to an exhaust manifold port 144 for the expulsion of exhaust gases. In the example from Fig. 1. An internal exhaust connection 142 within the IEM 132 receives exhaust gases from cylinder 120 via an exhaust port 126, which is coupled to a channel (e.g., exhaust duct) 136, exhaust gases from cylinder 122 via an exhaust port 128, which is coupled to a channel 138, and exhaust gases from cylinder 124 via an exhaust port 130, which is coupled to a channel 140. Exhaust gases entering the internal exhaust connection 142 can mix and converge. Exhaust gases travel from the inner exhaust connection 142 through the exhaust manifold passage 145 to the exhaust manifold connection 144. From there, the exhaust gases are routed via an outer exhaust passage 146 (outside the IEM 132 and the cylinder head 134) to other engine components (such as an emission control unit and / or a turbocharger turbine, which is not shown). It should be noted that in the example from Fig. 1. The channels 136, 138, and 140, as well as the internal exhaust connection 142, exhaust manifold passage 145, and exhaust manifold connection 144 within the cylinder head 134, are collectively integrated as the integrated exhaust manifold (IEM) 132. This means that the components of the IEM 132 are located within the cylinder head 134. Alternative embodiments may include a different number and / or arrangement of channels, exhaust manifold connections, internal exhaust connections, and / or internal exhaust passages.

[0019] As described above, each cylinder has an intake valve (located within an intake port) and an exhaust valve (located within an exhaust port). Each intake valve is actuated between an open position, which allows intake air into the respective cylinder, and a closed position, which substantially blocks intake air from the respective cylinder. The intake valves within intake ports 114, 116, and 118 are actuated by a common intake camshaft (not shown). The intake camshaft includes a plurality of intake cams (not shown) configured to control the opening and closing of the intake valves. Each intake valve can be actuated by one or more intake cams, as will be described in more detail below. In some embodiments, one or more additional intake cams may be included to actuate the intake valves.Furthermore, intake confirmation systems can enable the control of the intake valves.

[0020] Each exhaust valve is actuated between an open position, which allows exhaust gas to flow out of a given cylinder, and a closed position, which essentially retains gas within that cylinder. The exhaust valves within exhaust ports 126, 128, and 130 are actuated by a common exhaust camshaft (not shown). The exhaust camshaft includes a plurality of exhaust cams (not shown) configured to control the opening and closing of the exhaust valves. Each exhaust valve can be actuated by one or more exhaust cams, as described below. In some embodiments, one or more exhaust cams may be included to actuate the exhaust valves. Furthermore, exhaust actuation systems may provide control of the exhaust valves.

[0021] Intake valve actuation systems and exhaust valve actuation systems may further include pushrods, rocker arms, tappets, etc. (not shown). Such devices and features can actuate the intake and exhaust valves by converting rotational energy of the cams into linear displacements of the valves. In other examples, the valves may be actuated via additional cam hump profiles on the camshafts, the hump profiles providing varying cam lift heights, durations, and / or timing between the different valves. However, alternative camshaft arrangements (overhead and / or pushrod) could be used if desired. Furthermore, in some examples, cylinders 120, 122, and 124 may each have more than one exhaust valve and / or intake valve.In other examples, exhaust and intake valves can be actuated by a common camshaft. In alternative embodiments, however, at least one of the intake and / or exhaust valves can be actuated by its own independent camshaft or another device.

[0022] The cylinders 120, 122, and 124, as well as the IEM 132 and its components (e.g., channels, connections, etc.) within the cylinder head 134, are surrounded by a multitude of coolant passages 160. The coolant passages 160 are connected to one or more coolant inlet and outlet ports (e.g., a first engine coolant inlet port 166, a first engine coolant outlet port 167, a second engine coolant inlet port 169, and a second engine coolant outlet port 170) to allow the circulation of coolant through the cylinder head 134 and around the IEM 132.

[0023] Upon entering the cylinder head 134 through a coolant inlet (e.g., first engine coolant inlet port 166), the coolant passes through the multiple coolant passages (e.g., coolant passage 160) within the cylinder head 134 and absorbs heat from the components of the cylinder head 134 and the IEM 132. The coolant exits the cylinder head 134 through one or more coolant outlets (e.g., first engine coolant outlet port 167). The coolant then passes through an EGR cooler module 148, which is directly coupled to one side of the cylinder head 134, returns to the cylinder head 134 through a second coolant inlet port (e.g., second engine coolant inlet port 169), and exits the cylinder head 134 again through a second coolant outlet port (e.g.,second engine coolant outlet port 170) and enters the radiator 162 to reduce its thermal energy before re-entering the cylinder head 134 at the first inlet port (e.g., first engine coolant inlet port 166). In the embodiment of . Fig. The second engine coolant outlet port 170 is connected to the radiator 162 via a second external coolant passage 172. The radiator 162 is also connected to the first engine coolant inlet port 166 of the cylinder head 134 via a first external coolant passage 164. The radiator 162 is used to reduce the thermal energy of the coolant. In alternative embodiments, the radiator 162 can be connected to additional devices (e.g., fans) to remove thermal energy from the coolant. It can also optionally or additionally circulate coolant through one or more additional devices (e.g., pumps).

[0024] The EGR cooler module 148 is directly (e.g., directly attached, without any intermediate components separating the EGR cooler module and the cylinder head) attached to the cylinder 134 by means of bolts or other mechanical fixing elements (as shown below). Fig. 2 explained) attached or mounted. The EGR cooler module 148 contains a plurality of ports on an outside of the EGR cooler module 148, each port being capable of fluidic communication with a corresponding port on an outside of the cylinder head (as in Fig. 2 shown).

[0025] A first inner passage 150 of the cylinder head 134 lies within the cylinder head 134 and directs exhaust gas through the cylinder head 134. In the schematic representation from Fig. In this embodiment, the first inner passage 150 is in fluidic communication with an exhaust manifold passage 145 downstream of the inner exhaust connection 142, where exhaust gas from all cylinders converges (e.g., from cylinders 120, 122, and 124). The first inner passage 150 is a peripheral passage to the exhaust manifold passage 145. This means that the first inner passage 150 receives a portion of the exhaust gas flowing through the exhaust manifold passage 145. In alternative embodiments, the first inner passage 150 can receive exhaust gases from upstream of an inner exhaust connection 142 and can be a peripheral passage (as described above) at one or more exhaust channels (such as exhaust channel 136, 138, and 140) of one or more cylinders (such as cylinders 120, 122, and 124).In these alternative embodiments, the first inner passage 150 can receive a portion of the exhaust gas from one or more channels of one or more cylinders, but it does not receive exhaust gases downstream of a connection where exhaust gas from all the cylinders converges (e.g., inner exhaust connection 142). In this way, the first inner passage 150 can receive exhaust gases expelled from one or more cylinders of the engine.

[0026] The first inner passage 150 directs exhaust gases through the cylinder head 134 from the exhaust manifold passage 145 (which can be referred to here as the exhaust manifold) to a first engine EGR outlet port 151. The first engine EGR outlet port 151 is in fluidic communication with an EGR inlet port 153 of the EGR cooler module 148 (as described in the section on Fig. 2 below). The EGR inlet port 153 can subsequently be referred to as module EGR inlet port 153. From the module EGR inlet port 153, exhaust gas is routed through the EGR cooler module 148 and cooled by it. The cooled exhaust gases from the EGR cooler can then exit the EGR cooler 148 via an EGR outlet port (e.g., module EGR outlet port) 157. A second internal passage 152 of the cylinder head 134 is located within the cylinder head 134 and routes cooled exhaust gases from a first engine EGR inlet port 155 to a second engine EGR outlet port 154. The first engine EGR inlet port 155 is in fluidic communication with the module EGR outlet port 157 of the EGR cooler module 148.

[0027] The second engine EGR outlet port 154 is in fluidic communication with an EGR passage (hereinafter referred to as an external EGR passage) 161, which is located outside the cylinder head 134 (e.g., not formed within the cylinder head). An EGR valve 156 is coupled in series with the external EGR passage 161. The external EGR passage 161 is also in fluidic communication with an intake EGR inlet port 163 of the intake manifold 106. The EGR valve 156 can be actuated by an actuator (not shown) to control the exhaust gas flow from the second engine EGR outlet port 154 through the external EGR passage 161 to the intake EGR inlet port 163, and into the intake manifold 106.

[0028] In the embodiment of Fig. 1 is the intake EGR inlet port 163 upstream of the cylinder intake passages 108, 110, and 112 within the intake manifold 106. Alternative embodiments may exist in which the EGR intake inlet port is not upstream of all cylinder intake passages, but downstream of one or more of the cylinder intake passages. Alternative embodiments may additionally include a plurality of outer EGR passages (similar to the outer EGR passage 161) which connect the second engine EGR outlet port to one or more intake EGR inlet ports (similar to an intake EGR inlet port 163) on the intake manifold, and / or include one or more cylinder intake passages.

[0029] The EGR cooler module 148 contains a number of passages (not shown) to facilitate heat transfer from the exhaust gas, which is drawn in through the module's EGR inlet port 153, to a coolant supply within the EGR cooler module 148. The passages within the EGR cooler module 148 containing exhaust gases and the passages within the EGR cooler module 148 containing coolant are separate and do not communicate fluidically with each other. However, the gas passages and coolant passages are located close to each other and can simultaneously be near a material with high thermal conductivity (e.g., a metal). Heat can transfer from the gas within the exhaust gas passages through a nearby thermally conductive material and into the coolant. In this way, the EGR cooler module 148 cools the gas leaving the module such that the gas entering the module has a higher temperature than the gas leaving the module.

[0030] The coolant within the EGR cooler module 148 is supplied through a coolant inlet port 165 (which may be referred to below as the module coolant inlet port) of the EGR cooler module 148. The module coolant inlet port 165 is in fluidic communication with a third inner passage 158 of the cylinder head 134. The third inner passage 158 is located within the cylinder head 134 and extends through the cylinder head 134.

[0031] The third inner passage 158 is in fluidic communication with the multitude of coolant passages 160 within the cylinder head 134, which surrounds the cylinders, channels, and other components within the cylinder head 134. These coolant passages 160 are fluidically isolated from the cylinders, channels, and other components they surround, but they are not fluidically isolated from each other (e.g., coolant can flow within the coolant passages but does not flow into other components of the cylinder head). This means that the coolant passages 160 are separated from the cylinders, channels, and other components by the inner walls of the cylinder head.

[0032] Coolant is guided from the radiator 162 through the coolant passages 160. The radiator 162 is coupled to the first outer coolant passage 164, which is in fluidic communication with the first engine coolant inlet port 166. The first engine coolant inlet port 166 is coupled to the coolant passages 160 such that the coolant flows from the radiator 162 through the first outer coolant passage 164, through the first engine coolant inlet port 166, and into the multitude of coolant passages 160 within the cylinder head 134.

[0033] The coolant entering the multiple passages via the radiator 162 is guided through the third inner passage 158 and exits through a first engine coolant outlet port 167. The first engine coolant outlet port 167 is coupled to the engine coolant inlet port 165 (e.g., directly coupled) and is in fluidic communication with the multiple coolant passages (not shown) within the EGR cooler module 148. In this way, the EGR cooler module 148 receives coolant from the radiator 162 via the passages (e.g., passages 160 and the third inner passage 158) within the cylinder head 134.

[0034] The multiple coolant passages (not shown) within the EGR cooler module 148 return coolant to a module coolant outlet port 171, which is coupled (e.g., directly coupled) to the second engine coolant inlet port 169. The coolant is then routed from the module coolant outlet port 171 to the second engine coolant inlet port 169 and then to a fourth inner passage 168 of the cylinder head 134. The fourth inner passage 168 is located within (e.g., positioned inside) the cylinder head 134 and is formed by the inner walls of the cylinder head 134. The fourth inner passage 168 directs coolant through the cylinder head 134 and to the second engine coolant outlet port 170. The second engine coolant outlet port 170 is coupled to the second outer coolant passage 172.The second outer coolant passage 172 is located outside the cylinder head 134 and is coupled to (and in fluidic communication with) both the radiator 162 and the second engine coolant outlet port 170. In this arrangement, coolant can leave the EGR cooler module 148, flow through the fourth inner passage 168, and enter the radiator 162 via the second outer coolant passage 172, which is coupled to the second engine coolant outlet port 170.

[0035] In the schematic representation of the configuration of the engine system 100 as described above, the EGR cooler module 148 receives coolant via a direct connection between the first engine coolant outlet port 167 and the module coolant inlet port 165, and receives exhaust gas via a direct connection between the first engine EGR outlet port 151 and the module EGR inlet port 153. The internal passages of the EGR cooler module 148 then transfer heat energy away from the exhaust gas and into the coolant. The cooled exhaust gas leaves the EGR cooler module 148 and enters the cylinder head 134 via a first engine EGR inlet port 155, where it is guided through the second internal passage 152 to the second engine EGR outlet port 154. The flow of the cooled gas through the outer EGR passage 161 into the intake EGR inlet closure 163 of the intake manifold 106 is controlled by the actuation of the EGR valve 156.

[0036] The coolant leaves the EGR cooler module 148 through the module coolant outlet port 171 and enters the fourth inner passage 168 of the cylinder head 134 via a direct coupling between the module coolant outlet port 171 and the second engine coolant inlet port 169. The coolant flows from the fourth inner passage 168 through the second engine coolant outlet port 170 and into the second outer coolant passage 172, which is coupled to the radiator 162. In this way, the EGR cooler module 148 uses coolant from the inner coolant passage of the cylinder head 134 and exhaust gas from the inner gas passage of the cylinder head 134 to cool exhaust gases from cylinders 120, 122, and 124. It then guides the cooled gases via a further internal gas passage of the cylinder head 134 into the intake manifold 106 and the coolant via a further internal coolant passage of the cylinder head 134 into the radiator 162.

[0037] By directly coupling the coolant inlets / outlets and EGR inlets / outlets of the EGR cooler module 148 to the corresponding coolant inlets / outlets and EGR inlets / outlets on the cylinder head 134, the EGR cooler module 148 is able to receive and forward EGR gas and coolant from the cylinder head 134 without additional fittings.

[0038] Fig. Figure 2 shows an exploded view of a first embodiment of an EGR system 210 comprising an EGR cooler module 248 (for example, as in Fig. 1 EGR cooler module 148 shown), which is directly attached to a first cylinder head surface 249 of a cylinder head 235 (e.g. the one in Fig. 1 cylinder head 134) shown in an arrangement similar to the configuration described above during the explanations to Fig. 1 is mounted. The first cylinder head surface 249 can be on a single, first side of the cylinder head 235. The EGR cooler module 248 includes a housing (e.g., a housing body or body) 200, a plurality of rigid tubes (e.g., tubes 202, 204, and 206), and a plurality of flanges (e.g., flanges 214 and 216). The housing contains a plurality of internal cooling tubes (for coolant flow) and internal gas passages (for exhaust gas flow). The housing, rigid tubes, and flanges of the EGR cooler module 248 can be made of a material (e.g., metal) that is resistant to wear due to corrosion and / or high temperatures associated with engine fluids and gases. The housing, rigid tubes, flanges, and other components of the EGR cooler module 248 can be formed together (e.g., molded) as one piece and / or joined together (e.g., welded).

[0039] In the example of the embodiment of the EGR cooler module 248, shown in Fig. 2. The housing 200 of the EGR cooler module 248 is designed such that the shape of the EGR cooler module 248 is approximately a rectangular parallelepiped. The housing 200 has an outer surface (hereinafter referred to as the outer module surface) 252, which is parallel to and faces away from the first cylinder head surface 249 of the cylinder head 235 when the EGR cooler module 248 is attached to the cylinder head 235 (as described below). The outer module surface 252 is connected to a plurality of perpendicular module surfaces (e.g.,

[0040] Surfaces 253, 254, 255, and 256) are connected and arranged perpendicular to the outer module surface 252. The perpendicular module surfaces are connected to an inner module surface 257 (e.g., the surface facing the first cylinder head surface 249), which is parallel to (and opposite) the outer module surface 252. In the example of the embodiment of the EGR cooler module 248, shown in Fig. In the second section, the vertical module surfaces 253, 254, and 255 are planar (e.g., flat), whereas module surface 256 has a curvature in the direction of the interior of the EGR cooler module 248. The inner module surface 257 and the outer module surface 252 are both planar (e.g., flat), and the outer module surface 252 is connected to the vertical surfaces with rounded edges, while the inner module surface 257 is connected to the vertical surfaces without rounded edges. Alternative embodiments may exist in which the EGR cooler module has additional or fewer curvatures and / or additional or fewer surfaces.

[0041] The EGR cooler module 248 from Fig. 2 is directly connected (e.g., formed in one piece or welded) to three rigid tubes 202, 204, and 206 (hereinafter referred to as the first module tube 202, the second module tube 204, and the third module tube 206). A first end (e.g., an end coming from the housing) of the first module tube 202 is coupled to a housing coolant inlet 208 of the housing 200. A first end (e.g., an end coming from the housing) of the second module tube 204 is coupled to a housing coolant outlet 251 of the housing 200, and a first end (e.g., an end coming from the housing) of the third module tube 206 is coupled to a housing EGR outlet 271 of the housing 200.

[0042] The rigid pipes 202, 204, and 206 and the housing coolant inlet 208, housing coolant outlet 251, and housing EGR outlet 271 in the example of the in Fig. In the embodiment shown in Figure 2, the inlets / outlets (208, 251, and 271) and first ends (as described above) of the tubes (202, 204, and 206) are arranged such that they are positioned along the plurality of vertical module surfaces 253. The housing coolant inlet 208 (and the first end of the first module tube 202) is positioned along the vertical module surface 253 (which may hereinafter be referred to as the first module vertical surface 253). The housing coolant outlet 251 and the housing EGR outlet 271 (as well as the first end of the second module tube 204 and the first end of the third module tube 206) are positioned along the vertical surface 254 (which may hereinafter be referred to as the second module vertical surface 254).

[0043] The flange 214 (which can be referred to as the first module flange 214) is arranged parallel to the inner and outer module surfaces (257 and 252, respectively) and is connected to the first inner module surface 257 (e.g., integrally formed and / or welded to it). The first module flange 214 projects outwards from the housing 200 of the EGR cooler module 248, away from the vertical module surfaces 253 and 256. Similarly, the flange 216 (which can be referred to as the second module flange 216) is arranged parallel to the inner and outer module surfaces (257 and 252, respectively) and is connected to the inner module surface 257 (e.g., integrally formed and / or welded to it). The second module flange 216 projects outwards from the housing 200 of the EGR cooler module 248, away from the vertical module surface 254. Because the first module flange 214 and the second module flange 216 are simultaneously parallel to the inner and outer module surfaces (257 and 216 respectively).Since the first module flange 214 and the second module flange 216 are parallel to each other (252), the first module flange 214 and the second module flange 216 are also parallel to each other. The first module flange 214 and the second module flange 216 are also parallel to the first cylinder head surface 249 (and to the first side of the cylinder head 235).

[0044] The first module flange 214 includes a module coolant inlet port 218 (e.g., the module coolant inlet port 165, shown in Fig. 1), which is coupled to a second end (e.g., an end not originating from the housing) of the first module tube 202. The module coolant inlet port 218 is in surface-sharing contact with a first engine coolant outlet port 267 (e.g., the first engine coolant outlet port 167 in Fig. 1) on the first cylinder head surface 249 of the cylinder head 235 and is in fluidic communication with it. The first module flange 214 also includes a module EGR inlet port 220 (e.g., the module EGR inlet port 153, shown in Fig. 1) in surface-sharing contact (and in fluidic communication with) a first engine EGR outlet port 247 (e.g. the first engine outlet port 151 shown in Fig. 1) on the first cylinder head surface 249 of the cylinder head 235. In this embodiment, the module coolant inlet port 218 facilitates the flow of coolant from the first engine coolant outlet port 267 into the EGR cooler module 248 via the first module tube 202, which is coupled to the housing coolant inlet 208. The module EGR inlet port 220 facilitates the flow of EGR gas from the first engine EGR outlet port 247 directly into the EGR cooler module 248 via surface-sharing contact between the module EGR inlet port 220 and the first engine EGR outlet port 247 (without the use of a rigid tube).

[0045] The first module flange 214 also includes a plurality of eyelets (e.g., eyelets 224, 226, and 228) that are dimensioned and shaped to receive bolts. In the example embodiment of the first module flange 214, shown in Fig. 2. The first module flange 214 has three eyelets 224, 226, and 228. Alternative embodiments may exist in which the first module flange has a different number of eyelets (e.g., four, five, etc.). The eyelets are arranged on the first module flange 214 in an arrangement that corresponds to the arrangement of a plurality of mounting surfaces on the first cylinder head surface 249. The eyelets 224, 226, and 228 of the first module flange 214 in the Fig. In the embodiment shown in Figure 2, the three mounting surfaces 230, 232, and 234 are arranged to align when the first module flange 214 is placed flush against the mounting surfaces. The mounting surfaces 230, 232, and 234 are designed to accept the threaded ends of the bolt that extends through the eyelets 224, 226, and 228, thereby attaching the first module flange 214 directly to the first side of the cylinder head 235 and the first cylinder head surface 249.

[0046] The module coolant inlet port 218 and the module EGR inlet port 220 are arranged on the first module flange 214 such that when the first module flange 214 is fastened to the mounting surfaces 230, 232, and 234 of the cylinder head 235 by means of bolts, the module coolant inlet port 218 is in surface-sharing contact with the first engine coolant outlet port 267 and the module EGR inlet port 220 is in surface-sharing contact with the first engine EGR outlet port 247.One or more gaskets (not shown) can be secured between the first module flange 214 and the mounting surfaces (230, 232, and 234) of the cylinder head 235 such that the gasket(s) allow leak-free fluidic communication between the module coolant inlet port 218 and the first engine coolant outlet port 267, as well as leak-free fluidic communication between the module EGR inlet port 220 and the first engine EGR outlet port 247. The gasket(s) is / are made of a material suitable for contact with corrosive and / or high-temperature fluids from the cylinder head 235 (e.g., a rubber-like material).

[0047] The second module flange 216 includes a module coolant outlet connection 240 (e.g., module coolant outlet connection 171 shown in Fig. 1), which is coupled to a second end (e.g., an end not originating from the housing) of the second module tube 204. The module coolant outlet port 240 is in surface-sharing contact (and in fluidic communication with) a second engine coolant inlet port 269 (e.g., the second engine coolant inlet port 169, shown in Fig. 1) The second module flange 216 also includes a module EGR outlet port 242 (e.g., a module EGR outlet port 157, shown in Fig. 1), which is connected to a second end (e.g., an end not originating from the housing) of the third module tube 206. The module EGR outlet port 242 is in surface-sharing contact with (and in fluidic communication with) a first engine EGR inlet port 259 (e.g., the first engine EGR inlet port 155 shown in Fig. 1) In this arrangement, the module coolant outlet port 240 facilitates the flow of coolant from the EGR cooler module 248, via the second module pipe 204, which is coupled to the housing coolant outlet port 251, and into the second engine coolant inlet port 269 of the cylinder head 235. The module EGR outlet port 242 facilitates the flow of EGR gas from the EGR cooler module 248, via the third module pipe 206, which is coupled to the housing EGR outlet 271, and into the first engine EGR inlet port 259 of the cylinder head 235.

[0048] The second module flange 216 also includes a plurality of eyelets (e.g., eyelets 244 and 246) that are dimensioned and shaped to receive bolts. In the example of the embodiment of the first module flange 214, shown in Fig. 2, the second module flange 216 has two eyelets 244 and 246. Alternative embodiments may exist in which the first module flange has a different number of eyelets (e.g., three, four, etc.). The eyelets are arranged on the second module flange 216 in an arrangement that corresponds to the arrangement of a plurality of mounting surfaces on the first cylinder head surface 249. The eyelets 244 and 246 of the second module flange 216 in the Fig. In the embodiment shown in Figure 2, the two mounting surfaces 258 and 260 are arranged to align when the second module flange 216 is positioned flush against the mounting surfaces. The mounting surfaces 258 and 260 are designed to accommodate the threaded ends of the bolts that extend through the eyelets 244 and 246.

[0049] The module coolant outlet port 240 and the module EGR outlet port 242 are arranged on the second module flange 216 such that when the second module flange 216 is fastened to the mounting surfaces 258 and 260 of the cylinder head 235 by means of bolts, the module coolant outlet port 240 is in surface-sharing contact with the second engine coolant inlet port 269 and the module EGR outlet port 242 is in surface-sharing contact with the first engine EGR inlet port 259. One or more seals (not shown) can be secured between the second module flange 216 and the mounting surfaces (258 and 260) of the cylinder head 235 in such a way that the seal(s) allow leak-free fluidic communication between the module coolant outlet port 240 and the second engine coolant inlet port 269, as well as leak-free fluidic communication between the module EGR outlet port 242 and the first engine EGR inlet port 259.The seals do not allow fluidic communication between the module coolant outlet port 240 and the module EGR outlet port 242. The seal(s) are made of a material (e.g., a rubber-like material) suitable for contact with corrosive and / or high-temperature fluids from the cylinder head 235.

[0050] An alternative embodiment of the EGR cooler module 248 may include a single gasket that covers both the first and second flanges and provides all of the fluidic communications (and isolations) described above.

[0051] As explained in the explanatory notes Fig. As described in Figure 1, the first engine EGR outlet port 247 is directly adjacent to (e.g., formed by) a first inner passage (e.g., a first inner passage 150, shown in Figure 1). Fig. 1) of the cylinder head 235 coupled, the first engine EGR inlet port 259 is directly connected to (e.g. formed by) a second inner passage (e.g. the second inner passage 152 shown in Fig. 1) of the cylinder head 235 coupled, the first engine coolant outlet port 267 is directly connected to (e.g. formed by) a third inner passage (e.g. the third inner passage 158 shown in Fig. 1) of the cylinder head 235 coupled, and the second engine coolant inlet port 269 is directly connected to (e.g. formed by) a fourth inner passage (e.g. the fourth inner passage 168 shown in Fig. 1) of the cylinder head 235 coupled.

[0052] By designing the EGR cooler module 248 and the cylinder head 235 in this way, the EGR cooler module 248 is able to receive coolant from the first engine coolant outlet port 267 of the cylinder head 235 via the module coolant inlet port 218 of the first module flange 214. The coolant flows from the first engine coolant outlet port 267 of the cylinder head 235 and through the module coolant inlet port 218 of the first module flange 214 into the first module tube 202. The first module tube 202 then directs the coolant flow to the housing coolant inlet 208 of the EGR cooler module 248. The EGR cooler module 248 is able to return coolant to the second engine coolant inlet port 269 of the cylinder head 235 via the module coolant outlet port 240 of the second module flange 216. The coolant flows from the housing coolant outlet 251 and through the second module tube 204.The second module tube 204 then directs the coolant flow to the module coolant outlet port 240 of the second module flange 216, which is directly coupled to the second engine coolant inlet port 269.

[0053] The EGR cooler module 248, which utilizes this configuration, is also capable of receiving exhaust gases from the first engine EGR outlet port 247 of the cylinder head 235 via the module EGR inlet port 220 of the first module flange 214. The exhaust gas flows from the first engine EGR outlet port 247 of the cylinder head 235 and through the module EGR inlet port 220 (directly coupled to the first engine EGR outlet port 247) of the first module flange 214 into the EGR cooler module 248. Furthermore, the EGR cooler module 248 is capable of returning cooled exhaust gas to the first engine EGR inlet port 259 of the cylinder head 235 via the module EGR outlet port 242 of the second module flange 216. The cooled exhaust gas flows from the housing EGR outlet 271 and through the third module pipe 206.The third module tube 206 then directs the flow of the cooled exhaust gas to the module EGR outlet port 242 of the second module flange 216, which is directly coupled to the first engine EGR inlet port 259.

[0054] In this configuration, the flanges of the EGR cooler module 248 can be bolted to the first cylinder head surface 249 of the cylinder head 235, so that the inlet / outlet ports (e.g., ports 218, 220, 240, and 242) of the EGR cooler module 248 are in surface-sharing contact with the corresponding ports (e.g., 267, 247, 269, and 259) of the cylinder head 235. This eliminates the need for additional fittings and / or passages for conveying fluids to / from the EGR cooler module 248 and results in a compact form for the EGR cooler module 248. For example, the embodiment of the EGR cooler module 248 shown in Fig. 2. Four inlet / outlet ports (e.g., two inlet ports and two outlet ports) are directly coupled to corresponding engine ports on the same side of the cylinder head 235 to facilitate the transfer of coolant and EGR gas to / from the EGR cooler module 248. All four ports are parallel to each other on the same side of the cylinder head 235 and are arranged in a common plane. Furthermore, all four ports are in surface-sharing contact with (or are shaped to couple with) their corresponding ports on the cylinder head 235 (e.g., the engine coolant outlet port is in surface-sharing contact with the module coolant inlet port, the engine EGR outlet port is in surface-sharing contact with the module EGR inlet port, etc.).

[0055] Fig. Figure 3 shows a schematic representation including a second embodiment of an engine system 300 and including an EGR system 301. The in Fig. The 300 engine system shown includes an engine 302, a cylinder head 334, and an integrated exhaust manifold (IEM) 332. Many of the components included in the 300 engine system are also included in the 100 engine system. Fig. 1 includes and are with similar reference symbols in Fig. 3 are specified and do not need to be described again. The in Fig. The passages and components shown in the 3 are not to scale, and the relative positioning, size, and number of passages may vary between physical embodiments (e.g., the one shown in the Fig. 4 to 6 embodiment shown).

[0056] The embodiment of the motor system 300 from Fig. 3 includes an EGR cooler module 348, which is directly coupled to a single side of the cylinder head 334. The EGR cooler module 348 has a coolant inlet port 365, a module coolant outlet port 371, a module EGR inlet port 353, and a module EGR outlet port 357.

[0057] The through Fig. The engine system 300 shown comprises three cylinders 120, 122, and 124, each with intake ports 114, 116, and 118, and exhaust ports 126, 128, and 130. The engine system 300 also includes exhaust ports 136, 138, and 140, which are connected to cylinders 120, 122, and 124, respectively. The exhaust ports converge at the inner exhaust connection 142, which leads through the exhaust manifold passage 145 to the exhaust manifold connection 144. The exhaust manifold connection 144 is fluidically connected to an outer exhaust passage 146, as shown in Figure 3. Fig. 1 described above, coupled. The engine system 300 also includes an intake passage 104, a throttle 109, an intake manifold 106, and cylinder intake passages 108, 110, and 112 for the intake of combustible gases. The inner passage 150 (e.g., the first inner passage 150 shown in Fig. 1) is a peripheral exhaust passage downstream of an internal exhaust connection 142 (and is within the cylinder head 334) and is fluidically coupled to both the exhaust manifold passage 145 and the first engine EGR outlet port 151 (as discussed above by the discussion of Fig. 1 described).

[0058] The inner passage 150 (e.g., located inside the cylinder head 334 and leading through the cylinder head 334) receives a portion of the exhaust gas flowing through the exhaust manifold passage 145 (as discussed in the section on Fig. 1 described). In alternative embodiments, the first inner passage 150 can be positioned upstream of an inner exhaust connection 142 and can be a peripheral passage (as described above) to one or more exhaust channels (e.g., exhaust channels 136, 138, and 140) of one or more cylinders (e.g., cylinders 120, 122, and 124). In these alternative embodiments, the first inner passage 150 can receive a portion of the exhaust gas from one or more channels of one or more cylinders, but it does not receive exhaust gases downstream of a connection where exhaust gas from all of the cylinders converges (e.g., the inner exhaust connection 142).

[0059] The inner passage 150 directs gases through the cylinder head 134 from the exhaust manifold passage 145 to the first engine EGR outlet port 151. The first engine EGR outlet port 151 is in fluidic communication with the module EGR inlet port 353 of the EGR cooler module 348 (as explained in the Fig. (4 to 6 described below). The module EGR outlet port 357 of the EGR cooler module 348 is in fluidic communication with an external EGR passage 361 (e.g., outside of both the cylinder head 334 and the EGR cooler module 348) via an EGR inlet port 355 of the external EGR passage 361. An EGR valve 156 is coupled in series with the external EGR passage 361. The outer EGR passage 361 is also in fluidic communication with the EGR inlet port 163 of the intake manifold 106. The EGR valve 156 can be actuated by an actuator (not shown) to control the flow of gas from the module EGR outlet port 357 of the EGR cooler module 348 through the outer EGR passage 361, to the intake EGR inlet port 163, and into the intake manifold 106.

[0060] In the embodiment of Fig. 3 is the intake EGR inlet port 163 upstream of the cylinder intake passages 108, 110, and 112 within the intake manifold 106. Alternative embodiments may exist in which the intake EGR inlet port is not upstream of all the cylinder intake passages and may be downstream of one or more cylinder intake passages. Alternative embodiments may additionally include a plurality of external EGR passages (similar to external EGR passage 361) which connect the module EGR outlet port 357 to one or more intake EGR inlet ports (similar to intake EGR inlet port 163) on the intake manifold and / or one or more cylinder intake passages.

[0061] The radiator 162 is coupled to the first engine coolant inlet port 166 via the first outer coolant passage 164. The first engine coolant inlet port 166 is fluidically connected to the multiple coolant passages 160 within the cylinder head 334 and surrounding the cylinder head components, as explained above. Fig. 1 described, coupled. The multitude of coolant passages 160 are fluidically coupled to the inner passage 158 (e.g., the third inner passage 158 shown in Fig. 1), which is fluidically coupled to the first engine coolant outlet port 167.

[0062] Similar to the example of the EGR cooler module 148, shown in Fig. 1. The EGR cooler module 348 contains a multitude of passages (not shown) to facilitate the transfer of heat from the exhaust gas, which is drawn in through the module's EGR inlet port 353, to a coolant supply within the EGR cooler module 348. The passages within the EGR cooler module 348 containing exhaust gases and the passages within the EGR cooler module 348 containing coolant are separate and do not communicate fluidically with each other. However, the gas passages and coolant passages are located close to each other and can simultaneously be near a material with high thermal conductivity (e.g., metal). Heat can be transferred from the gas within the exhaust gas passages through a nearby thermally conductive material and into the coolant. In this way, the EGR cooler module 348 cools the gas leaving the module such that the gas entering the module has a higher temperature than the gas leaving the module.

[0063] The coolant within the EGR cooler module 348 is supplied through the module coolant inlet port 365 of the EGR cooler module 348. The module coolant inlet port 365 is fluidically and directly coupled to the first engine coolant outlet port 167 and receives coolant from the inner passage 158. Coolant is fed through the coolant passages 160 from the radiator 162 and into the inner passage 158 (as discussed above). Fig. 1 described).

[0064] The multiple coolant passages (not shown) within the EGR cooler module 348 return coolant to the module coolant outlet port 371, which is fluidically coupled to a coolant inlet port 369 of a second outer coolant passage 372 (e.g., outside of both the cylinder head 334 and the EGR cooler module 348). The coolant passes from the module coolant outlet port 371 into the second outer coolant passage 372 via the coolant inlet port 369. The second outer coolant passage 372 is coupled to (and in fluidic communication with) both the radiator 162 and the coolant inlet port 369. In this arrangement, coolant can exit the EGR cooler module 348 through the module coolant outlet port 371 and into the directly coupled coolant inlet port 369. The coolant then flows through the second outer coolant passage 372 and enters the radiator 162.

[0065] In the configuration of engine system 300, as described above, the EGR cooler module 348 receives coolant from the first engine coolant outlet port 167 and exhaust gas from the first engine EGR outlet port 151. The internal passages of the EGR cooler module 348 then transfer heat energy from the exhaust gas to the coolant. The cooled exhaust gas exits the EGR cooler module 348 via the module EGR outlet port 357 and enters the outer EGR passage 361 via the EGR inlet port 355, where it is routed to the EGR inlet port 163 of the intake manifold 106. The flow of the cooled gas through the outer EGR passage 361 into the intake manifold 106 is controlled by the EGR valve 156.

[0066] The coolant leaves the EGR cooler module 348 through the module coolant outlet port 371 and enters the second outer coolant passage 372 via the coolant inlet port 369 (which is directly connected to the module coolant outlet port 371). The coolant flows from the second outer coolant passage 372 into the radiator 162. In this way, the EGR cooler module 348 uses coolant from an inner coolant passage 158 of the cylinder head 334 and exhaust gas from an inner gas passage 150 of the cylinder head to cool exhaust gases from the cylinders (120, 122, and 124). It then directs cooled gases into the intake manifold 106 via an EGR passage 361 outside the cylinder head 334 and directs coolant into the radiator 162 via a coolant passage (e.g. second outer coolant passage 372) outside the cylinder head 334.

[0067] By directly coupling to the cylinder head surface and directly communicating with the coolant outlet and the EGR outlet on the cylinder head, the EGR cooler module is able to absorb EGR gas and coolant from the cylinder head without additional fittings and can transfer coolant and EGR gas to passages outside the cylinder head. For example, the one in Fig. Figure 3 shows an embodiment of the EGR cooler module with four module inlet / outlet ports (e.g., two inlet ports and two outlet ports), wherein two of the ports are directly coupled to corresponding engine ports on the same side of the cylinder head to facilitate the transfer of coolant and EGR gases to the EGR cooler module. Both ports directly coupled to the same side of the cylinder head are also parallel to the same side of the cylinder head (e.g., both ports are parallel to a common plane). Furthermore, both ports are in surface-sharing contact with (and are shaped to couple to) their corresponding ports on the cylinder head (e.g., the engine coolant outlet port is in surface-sharing contact with the module coolant inlet port, and the engine EGR outlet port is in surface-sharing contact with the module EGR inlet port).

[0068] The cylinder head 334 of the engine system 330 from Fig. 3 does not include a second inner passage 152, a fourth inner passage 168, a first engine EGR inlet port 155, a second engine EGR outlet port 154, a second engine coolant inlet port 169, or a second engine coolant outlet port 170. However, there may be alternative embodiments in which one or more or all of these components are included with the cylinder head.

[0069] The Fig. Figures 4 to 6 show a second embodiment of an EGR system comprising an EGR cooler module that is directly coupled to one side of a cylinder head of an engine system. In particular, Figure 4 shows Fig. 4. A perspective view of a first side of a cylinder head in an arrangement similar to the cylinder head configuration shown above in connection with Fig. 3 was explained. The cylinder head is part of a second embodiment of the design described in the Fig. The second embodiment of the EGR system, shown in Figures 4 to 6, includes the EGR system shown in Figures 4 to 6. Fig. 4 to 6, is similar to the arrangement of the EGR system, which in the embodiment of the in Fig. The 3 engine systems shown are included. Fig. Figure 4 illustrates the first side of the cylinder head with the EGR cooler module not attached, to show the ports and mounting surfaces of the first side of the cylinder head. Fig. Figure 5 shows an alternative perspective view of the same EGR system, including the same in Fig. The cylinder head shown in Figure 4 has the EGR cooler module directly coupled to two of the cylinder head's ports. The EGR cooler module is also coupled to an external EGR passage and includes a port that may be coupled to an external coolant passage (not shown). Fig. Figure 6 shows a third view of the EGR system including the cylinder head and EGR cooler, as shown in Fig. 4 to 5, showing the cylinder head in cross-section. The by Fig. Figure 6 illustrates the circulation paths of coolant and EGR gases between the EGR cooler module, the cylinder head, and external passages, with the components of the EGR system having the same arrangement as in the Fig. Figures 4 to 5 show a common set of axes in each of the Fig. 4 to 6 are included for comparison purposes.

[0070] Fig. Figure 4 shows a first perspective view of an embodiment of an EGR system 413 of an engine system 415 including a cylinder head 434 (e.g. cylinder head 334 made of Fig. 4) in a configuration similar to that shown in the schematic view Fig. 3 shown. The cylinder head 43 includes a first cylinder head surface 400 (on a first side of the cylinder head) and a second cylinder head surface 401 (on another, second side of the cylinder head). The first and second cylinder head surfaces are approximately perpendicular to each other (as shown by the axes 411). The first cylinder head surface 400 includes two mounting surfaces 409 and 410 (e.g., first mounting surface 409 and second mounting surface 410). The mounting surfaces 409 and 410 are planar or flat (e.g., flat) sections of the first cylinder head 400 and are parallel to each other. The first mounting surface 409 includes two lugs (e.g., holes) 405 and 406, as well as a first engine EGR outlet port 451 (e.g., first engine EGR outlet port 151 shown in Fig. 3) The second mounting surface 410 includes two eyelets (e.g. holes) 407 and 408, as well as a first engine coolant outlet connection 467 (e.g. a first engine coolant outlet connection 167, shown in Fig. 3) The eyelets of the first mounting surface 409 and the second mounting surface 410 (e.g. eyelets 405 and 406, or eyelets 407 and 408) are dimensioned and shaped to accommodate bolts.

[0071] In the example of the embodiment of the EGR system 413, shown in Fig. 4. Each mounting surface (409 and 410) has two eyelets. Alternative embodiments may exist in which each mounting surface has a different number of eyelets (e.g., three, four, etc.) and each mounting surface may have a different number of eyelets than the other mounting surface (e.g., the first mounting surface 409 has a different number of eyelets than the second mounting surface 410). The eyelets of mounting surfaces 409 and 410 are designed such that they can accept the threaded end of a bolt.

[0072] Fig. Figure 4 shows an outer EGR passage 461 (e.g., the outer EGR passage 361 shown in Figure 461). Fig. 3) An outer passage flange 402 is coupled to one end of the outer EGR passage 461. An EGR inlet port 455 (e.g., an EGR inlet port 355) is incorporated into the outer passage flange 402. The outer EGR passage 461 and the outer passage flange 402 are coupled (or formed together) such that fluid (e.g., EGR gases) can pass through the EGR inlet port 455 and into the outer EGR passage 461.

[0073] The outer passage flange 402 includes a plurality of eyelets (e.g., eyelets 403 and 404) that are dimensioned and shaped to receive bolts. The eyelets (e.g., holes or openings) of the outer passage flange 402 are formed such that each eyelet can accept a threaded end of a bolt. In the example of the embodiment of the EGR system 413, shown in Fig. 4, the outer passage flange 402 has two eyelets 403 and 404. Alternative embodiments may exist in which the outer passage flange has a different number of eyelets (e.g. three, four, etc.).

[0074] Fig. 4 also includes an optional connection 417 of the cylinder head 434. In the embodiment of the EGR system 413, shown in Fig. In configurations 4 to 6, the optional port 417 is not used (e.g., the port is inactive and does not supply fluid to / from the cylinder head). However, in alternative embodiments of the EGR system, the optional port can function as an engine coolant inlet port to facilitate the transfer of coolant from the EGR cooler module to an internal passage in the cylinder head. In this way, the EGR cooler can receive coolant from the first engine coolant outlet port and return coolant to the engine coolant inlet port (e.g., the optional port).

[0075] Fig. Figure 5 shows a perspective view of the second embodiment of the EGR system, shown in Fig. 4, and includes an EGR cooler module 548, which is mounted on the cylinder head 434. As described above, the embodiment of the EGR system 413 includes in the Fig. 4 to 6, including the EGR cooler module 548, which is directly coupled to the cylinder head 434 (shown in Fig. 5), with regard to their arrangement, the EGR system 301, shown in Fig. 3, similarly. The EGR cooler module 548 is located on the first cylinder head surface 400 of the cylinder head 434 in the configuration described during the explanation of the Fig. The EGR cooler module 548 is assembled as described in sections 3 to 4. It comprises a housing 500, a variety of rigid tubes (e.g., tubes 502, 504, and 506), and a variety of flanges (e.g., flanges 514, 515, and 516). The housing, rigid tubes, and flanges of the EGR cooler module 548 can be made of a material (e.g., metal) that is resistant to wear from corrosion and / or high temperatures associated with engine fluids and gases. The housing, rigid tubes, flanges, and other components of the EGR cooler module can be formed (e.g., cast) as a single piece and / or joined together (e.g., welded). As introduced above, the housing (e.g. body) 500 of the EGR cooler module 548 includes a variety of cooling hoses and exhaust passages that were incorporated to facilitate the heat exchange from exhaust gas to coolant.

[0076] In the example of the embodiment of the EGR cooler module 548, shown in Fig. 5. The housing 500 of the EGR cooler module 548 is designed such that the shape of the EGR cooler module 548 corresponds approximately to a rectangular parallelepiped. The housing 500 has an outer module surface 552 (e.g., the outward-facing surface with respect to the cylinder head) that is parallel to the first cylinder head surface 400 of the cylinder head 434 when the EGR cooler module 548 is mounted on the cylinder head 434 (as described below). The outer module surface 552 is connected to a plurality of right-angled module surfaces (e.g., surfaces 553, 554, 555, and 556) that are arranged perpendicular to the outer module surface 552. The perpendicular module surfaces are connected to an inner module surface 557 (e.g., facing the first cylinder head surface 400) that is arranged parallel to (and opposite) the outer module surface 552. In the example of the embodiment of the EGR cooler module 548, shown in Fig. In section 5, the vertical module surfaces 553, 554, and 555 are planar (e.g., flat), whereas the vertical module surface 556 has a multitude of curves that form a curved end of the housing 500. The inner module surface 557 and the outer module surface 552 are both planar (e.g., flat), and both the outer module surface 552 and the inner module surface 557 can be connected at the vertical surfaces with or without rounded edges. Alternative embodiments may exist in which the EGR cooler module has additional or fewer curves and / or additional or fewer surfaces.

[0077] The housing 500 of the EGR cooler module 548 made of Fig. 5 is directly (e.g., formed in one piece or connected) to the three rigid tubes 502, 504, and 506 (hereinafter referred to as the first module tube 502, the second module tube 504, and the third module tube 506) of the EGR cooler module 548. A first end (e.g., an end coming from the housing) of the first module tube 502 is connected to a housing coolant inlet 565 of the housing 500. A first end (e.g., an end coming from the housing) of the second module tube 504 is connected to a housing coolant outlet 571 of the housing 500, and a first end (e.g., an end coming from the housing) of the third module tube 506 is connected to a housing EGR inlet 561 of the housing 500.

[0078] The rigid tubes 502, 504, and 506, and the housing coolant inlet 565, housing coolant outlet 571, and housing EGR inlet 561 in the example of the embodiment shown in Fig. The five components are arranged such that the housing inlets (565, 571, and 561) and the first ends (as described above) of the tubes (502, 504, and 506) are positioned along the plurality of vertical module surfaces. The housing coolant inlet 565 (and the first end of the first module tube 502) is positioned along the vertical module surface 553 (which may be referred to below as the first module vertical surface 553). The housing coolant outlet 671 (as well as the first end of the second module tube 504) is positioned along the vertical surface 555 (which may be referred to below as the second module vertical surface 555). The housing EGR inlet 561 (as well as the first end of the third module tube 506) is positioned along the vertical surface 554.

[0079] The flange 514 (which can be referred to as the first module flange 514) is arranged parallel to the inner and outer module surfaces (552 and 577, respectively) and is connected to the inner module surface 557 (e.g., by integral part and / or welding). The first module flange 514 projects outwards from the housing 500 of the EGR cooler module 548 and from the vertical module surface 556. The flange 515 (which can be referred to as the second module flange 515) is arranged parallel to the inner and outer module surfaces (557 and 552, respectively) and is connected to a second end (e.g., the end not originating from the housing 500) of the first module tube 502 (e.g., by integral part and / or welding). The second module flange 515 and the first module flange 502 project away from the housing 500 of the EGR cooler module 548 and from the vertical module surface 553. The flange 516 (which can be referred to as the third module flange 516) is parallel to the inner and outer module surfaces (557 and 558, respectively).552) and connected to a second end (e.g., the end not originating from the housing 500) of the third module tube 506 (e.g., by forming and / or welding). The third module flange 516 and the third module tube 506 project outwards from the housing 500 of the EGR cooler module 548, away from the vertical module surface 554. Because the first module flange 514, the second module flange 515, and the third module flange 516 are simultaneously parallel to the inner and outer module surfaces (557 and 552, respectively), the first module flange 514, the second module flange 515, and the third module flange 516 are also parallel to each other. The first module flange 514, second module flange 515, and third module flange 516 are all parallel to the first cylinder head surface 400 (and first side of the cylinder head).

[0080] The first module flange 514 includes a module EGR outlet port 518, which is fluidically coupled (and in surface-sharing contact) to the EGR inlet port 455 of the outer EGR passage 461. In this arrangement, the module EGR outlet port 518 facilitates the flow of coolant from the EGR cooler module and into the EGR inlet port 455 of the outer EGR passage 461.

[0081] The first module flange 514 includes a plurality of eyelets (e.g., eyelets 524 and 526) that are dimensioned and shaped to receive bolts. In the example embodiment of the first module flange 514, shown in Fig. 5, the first module flange 514 has two eyelets 524 and 526. Alternative embodiments may exist in which the first module flange has a different number of eyelets (e.g., three, four, etc.). The eyelets (e.g., holes or openings) are arranged on the first module flange 514 in an arrangement that corresponds to the arrangement of the plurality of eyelets (e.g., eyelets 403 and 404, shown in Fig. 4) of the outer passage flange 402 fits. The eyelets 524 and 526 of the first module flange 514 in the embodiment shown in Fig. The 5 are designed to be aligned with the eyelets 403 and 404 when the first module flange 514 is directly coupled to the outer passage flange 402 and is in surface-dividing contact with it. The eyelets 403 and 404 are designed to accommodate the threaded ends of the bolts that extend through the eyelets 524 and 526.

[0082] The module EGR outlet port 518 of the first module flange 514 is configured such that when the first module flange 514 is directly coupled to the outer passage flange 402 of the outer EGR passage 461 (e.g., fastened by means of bolts), the module EGR outlet port 518 is in surface-sharing contact with the EGR inlet port 455 of the outer EGR passage 461. A gasket (not shown) can be installed between the first module flange 514 and the outer passage flange 402 in such a way that the gasket allows leak-free fluidic communication between the module EGR outlet port 518 and the EGR inlet port 455. The gasket can be made of a material suitable for contact with corrosive and / or high-temperature gases from the cylinder head 434 (e.g., a rubber-like material).

[0083] The second module flange 515 includes a module coolant inlet port 540, which is fluidically and directly (and in surface-dividing contact) connected to the first engine coolant outlet port 467 (as described by Fig. (as shown in Figure 4) is coupled to the cylinder head 434. The module coolant inlet port 540 is also fluidically coupled to a second end (e.g., an end not originating from the housing 500) of the first module tube 502 (and in surface-sharing contact with it). In this arrangement, the module coolant inlet port 540 facilitates the flow of coolant from the first engine coolant outlet port 467, through the first module tube 502, and into the housing coolant inlet 565 of the housing 500.

[0084] The second module flange 515 also includes a plurality of eyelets (e.g., eyelets 544 and 546) that are dimensioned and shaped to receive bolts. In the example embodiment of the second module flange 515, shown by Fig. 5, the second module flange 515 has two eyelets 544 and 546. Alternative embodiments may exist in which the second module flange has a different number of eyelets (e.g., three, four, etc.). The eyelets (e.g., holes or openings) are arranged on the second module flange 515 in an arrangement that corresponds to the arrangement of the plurality of eyelets (e.g., eyelets 407 and 408) of the second mounting surface 410 of the cylinder head 434 (shown in Fig. 4) The eyelets 544 and 546 of the second module flange 515 in the Fig. In the embodiment shown in Figure 5, the eyelets 407 and 408 are arranged to be aligned when the second module flange 515 is positioned flush with the second mounting surface 410. The eyelets 407 and 408 are shaped such that they can receive the threaded ends of the bolts that extend through the eyelets 544 and 546.

[0085] The module coolant inlet port 540 of the second mounting surface 515 is configured such that when the second module flange 515 is fastened to the second mounting surface 410 of the cylinder head 434 by means of a screw, the module coolant inlet port 540 is directly coupled to the first engine coolant outlet port 467 of the cylinder head 434 and is in surface-dividing contact with it. A gasket (not shown) can be secured between the second module flange 515 and the second mounting surface 410 in such a way that the gasket allows leak-free fluidic communication between the module coolant inlet port 540 and the first engine coolant outlet port 467. The gasket can be made of a material suitable for contact with corrosive and / or high-temperature fluids from the cylinder head 434 (e.g., a rubber-like material).

[0086] The third module flange 516 includes a module EGR inlet port 525, which is directly and fluidically connected to the first engine EGR outlet port 451 (as in Fig. The module EGR inlet port 525 is coupled to (and in surface-sharing contact with) the cylinder head 434 (as shown in Figure 4). The module EGR inlet port 525 is also fluidically coupled to a second end (e.g., an end not originating from the housing 500) of the third module tube 506 (and is in surface-sharing contact with it). In this arrangement, the module EGR inlet port 525 facilitates the flow of coolant from the first engine EGR outlet port 451, through the third module tube 506, and into the housing EGR inlet 561 of the housing 500.

[0087] The third module flange 516 also includes a plurality of eyelets (e.g., eyelets 521 and 523) that are dimensioned and shaped to receive bolts. In the example embodiment of the third module flange 516, shown in Fig. 5, the third module flange 516 has two eyelets 521 and 523. Alternative embodiments may exist in which the third module flange has a different number of eyelets (e.g., three, four, etc.). The eyelets (e.g., holes or openings) are arranged on the third module flange 516 in an arrangement that corresponds to the arrangement of the plurality of eyelets (e.g., eyelets 405 and 406) of the first mounting surface 409 of the cylinder head 434 (as in Fig. 4 shown). The eyelets 521 and 523 of the third module flange 516 in the in Fig. In the embodiment shown in Figure 5, the eyelets 405 and 406 are arranged to be aligned when the third module flange 516 is coupled in surface-dividing contact with the first mounting surface 409. The eyelets 405 and 406 are shaped such that they can accept the threaded ends of the bolts that extend through the eyelets 521 and 523.

[0088] The module EGR inlet port 525 of the third module flange 516 is configured such that when the third module flange 516 is directly coupled to the first mounting surface 409 of the cylinder head 434 (e.g., fastened by means of bolts), the module EGR inlet port 525 is in surface-sharing contact with the first engine EGR outlet port 451 of the cylinder head 434. A gasket (not shown) can be secured between the third module flange 516 and the first mounting surface 409 in such a way that the gasket allows leak-free fluidic communication between the module EGR inlet port 525 and the first engine EGR outlet port 451. The gasket can be made of a material suitable for contact with corrosive and / or high-temperature fluids from the cylinder head 434 (e.g., a rubber-like material).

[0089] As explained in the text of Fig. As described in section 3, the first engine EGR outlet port 451 is directly connected to an inner passage (e.g., the inner passage 150, shown in [reference]). Fig. 3) of the cylinder head 434 coupled (e.g. formed by), and the first engine coolant outlet port 467 is directly connected to an internal passage (e.g. an internal passage 158 shown in Fig. 3) of the cylinder head 434 (e.g. formed by).

[0090] By configuring the EGR cooler module 548 and the cylinder head 434 in this way, the EGR cooler module 548 is able to receive coolant from the first engine coolant outlet port 467 of the cylinder head 434 via the module coolant inlet port 540 on the second module flange 515. The coolant flows from the first engine coolant outlet port 467 of the cylinder head 434 and through the module coolant inlet port 540 into the first module tube 502. The first module tube 502 then directs the flow of coolant to the housing coolant inlet 565 of the housing 500. Furthermore, the EGR cooler module 548 is able to draw coolant from a radiator (e.g., radiator 162 shown in [reference missing]). Fig. 3) via an external coolant passage (e.g. the second external coolant passage 372 shown in Fig. 3) attributable to the coolant flow. The coolant flows from the module coolant outlet port 571 and through the second module tube 504. The second module tube 504 then directs the flow of coolant to a module coolant outlet port 573, which is located within a second end (e.g., an end not originating from the housing 500) of the second module tube 504. The module coolant outlet port 573 is in surface-sharing contact and fluidically coupled to an inlet of an outer coolant passage (e.g., the second outer coolant passage 372, shown in Figure 3). Fig. 3) The external coolant passage then directs coolant to the radiator (e.g., radiator 162 shown in Fig. 3).

[0091] The EGR cooler module 548, which utilizes this configuration, is also capable of receiving exhaust gases from the first engine EGR outlet port 451 of the cylinder head 434 via the module EGR inlet port 525 on the third module flange 516. The exhaust gas flows from the first engine EGR outlet port 451 of the cylinder head 434 and through the module EGR inlet port 525 (directly coupled to the first engine EGR outlet port 451) of the third module flange 516 into the EGR cooler module 548. Furthermore, the EGR cooler module 548 is capable of directing cooled exhaust gas via the module EGR outlet port 518 on the first module flange 514 to the outer EGR passage 461. The module EGR outlet port 518 is fluidically (and directly) coupled to the EGR inlet port 455 of the outer passage flange 402 and directs the flow of cooled exhaust gas into the outer EGR passage 461.

[0092] In this configuration, the second and third flanges (515 and 516) of the EGR cooler module 548 can be directly coupled to the first cylinder head surface 400 of the cylinder head 434 (e.g., fastened by means of bolts), so that the connections (e.g., module coolant inlet port 540 and module EGR inlet port 525) of the second and third flanges (each) of the EGR cooler module 548 are in surface-sharing contact with corresponding connections (e.g., first engine coolant outlet port 467 and first engine EGR outlet port 451) of the cylinder head (and are fluidically coupled) to facilitate the transfer of coolant and EGR gas into the EGR cooler module 548. This eliminates the need for additional fittings and / or passages to direct fluids into the EGR cooler module 548 and achieves a compact form for the EGR cooler module 548.

[0093] Fig. Figure 6 shows an additional perspective view of the embodiment of the EGR system 413, which is described in the Fig. The 415 engine system shown in sections 4 to 5 is included. Fig. Figure 6 shows the cylinder head 434 in cross-section, with the EGR cooler module 548 directly coupled to the first cylinder head surface 400 of the cylinder head 434. The in Fig. The perspective shown in Figure 6 is approximately perpendicular to the one in the Fig. Figures 4 to 5 are shown (as indicated by axes 411). The flow of gas and coolant through the cylinder head 434 is shown by a multitude of arrows indicating the direction of flow.

[0094] The cylinder head 434 of the engine system 415 communicates with a plurality of cylinders, such as cylinder 601. Although a four-cylinder configuration is shown in the embodiment of the engine system 415, other embodiments may include a different number of cylinders (e.g., three, six, eight, etc.). Each cylinder is shown coupled to a plurality of exhaust ports, which direct flow to a plurality of exhaust channels. Although the cylinders in the embodiment of the engine system 415 and EGR system 413, shown in Fig. 6, which are coupled to two exhaust ports and two exhaust channels each, other embodiments may show each cylinder coupled to a different number of exhaust ports and / or exhaust channels (e.g. one, three, etc.).

[0095] Cylinder 601 is shown coupled to exhaust ports 603 and 605. Cylinder 601 can expel gases through exhaust ports 603 and 605 via an exhaust valve located within each exhaust port (as explained in the explanatory notes). Fig. (described in section 3). Exhaust port 603 is fluidically coupled to exhaust channel 609, and exhaust port 605 is fluidically coupled to exhaust channels 607 as part of an integrated exhaust manifold (IEM) 617. The flow of exhaust gas from cylinder 601 through exhaust channel 609 is approximated by arrow 600. The flow of exhaust gas from cylinder 601 through exhaust channel 607 is approximated by arrow 602. The flows, as represented by arrows 600 and 602, mix and meet at an internal exhaust connection 619 within the IEM 617.

[0096] A peripheral exhaust passage 621 (e.g. similar to the first inner passage 150, shown in Fig. 3) is fluidically connected to the inner exhaust connection 619 and the first engine EGR outlet port 451. A portion of the exhaust gases from cylinder 601 (e.g., the portion of the gases not flowing in the direction of arrow 604) flows through the peripheral exhaust passage 621 along a path approximately indicated by arrow 606. The exhaust gases flow through the first engine EGR outlet port 451 and into the EGR cooler module 548 via the module EGR inlet port 525, as explained above. Fig. 5 described. The exhaust gases pass through the EGR cooler module 548 and, due to the proximity of the gases to the coolant passages contained within (e.g. inside) the EGR cooler module 548, experience a reduction in thermal energy, as described in Fig. 3 explained above. The cooled exhaust gas then leaves the EGR cooler module 548 via the module EGR outlet port 518 and enters the outer EGR passage 461 via a direct coupling between the module EGR outlet port 518 and the EGR inlet port 455, as explained in section 3 above. Fig. 5 described above and indicated by the flow direction arrow 608.

[0097] The embodiment of the EGR system 413 shown by Fig. 6 includes the peripheral exhaust passage 621, which is fluidically coupled to the exhaust flow downstream of cylinder 601 and not downstream of additional engine cylinders. This other path, as in Fig. As shown in Figure 6, the peripheral exhaust passage 621 is fluidically coupled to only one cylinder (cylinder 601) of the engine. However, other embodiments may include the peripheral exhaust passage 621 being coupled downstream of one or more, or each, engine cylinder. The peripheral exhaust passage 621 may also be located downstream of another cylinder, or downstream of another cylinder and one or more, or each, of the cylinders in addition to the fluidically coupled cylinders.

[0098] Coolant leaves the cylinder head 434 and enters the EGR cooler module 548 via the module coolant inlet port 540 from a passage 623 (e.g., the third passage 158 shown in Fig. 3) within the cylinder head 434 (e.g., a passage through the interior of the cylinder head). The coolant leaves the cylinder head via the first engine coolant outlet port 467 and enters the EGR cooler module 548 via the module coolant inlet port 540, as described in the section on Fig. 5 explained and indicated by the flow direction arrow 610. The coolant absorbs heat energy from the exhaust gas within the EGR cooler module 548 via a multitude of close passages as explained in the section on Fig. 3 described. The coolant then leaves the EGR cooler module 548 and enters an external coolant passage (not shown) via the module coolant outlet port 573, as explained in section 3. Fig. 5 described and indicated by the flow direction arrow 612.

[0099] The Fig. 2 as well as Fig. Figures 4 to 6 show exemplary configurations with the relative positioning of the various components. If depicted as directly contacting or directly coupled, such elements can then be described as directly contacting or directly coupled in at least one example. Similarly, elements depicted as continuous or adjacent can be continuous or adjacent to each other in at least one example. For example, components that are in surface-dividing contact with each other can be described as being in surface-dividing contact with each other. As another example, elements that are spaced apart with only a gap between them and no other components can be described as such in at least one example. As yet another example, elements that are stacked on top of each other or...Elements located one below the other, on opposite sides to each other, or left and right of each other, can be described as such, in at least one example. Furthermore, as shown in the figures, a topmost element or point of an element can be described as a "top" or "top" of the component, and a bottommost element or point of an element can be described as a base of the component, in at least one example. When using the terms top / bottom, upper / lower, above / below, these can be relative to a vertical axis of the figures and used to describe the positioning of elements of the figures relative to each other. Thus, elements depicted above other elements are positioned vertically above the other elements, in one example. As yet another example, the shapes of the elements depicted within the figures can be described as having these shapes (e.g.,(circular, straight, planar or two-dimensional, curved, round, chamfered, angled, or the like). Furthermore, elements that overlap each other can be referred to as overlapping elements or intersecting each other, in at least one example. Additionally, an element that is represented inside or outside another element can be referred to as such, in one example.

[0100] Fig. Figure 7 shows a flowchart 700, which describes a method for routing exhaust gases from cylinders of a cylinder head and through an EGR system, which includes an EGR cooler module, e.g. an EGR system 201 and an EGR cooler module 248 shown in Fig. 2, or an EGR system 413 and an EGR cooler module shown in Fig. 5 to 6, includes.

[0101] In step 702, the procedure involves routing exhaust gas internally through a cylinder head from an exhaust passage downstream of an engine cylinder to an EGR inlet port (e.g., module EGR inlet port 220 shown in Fig. 2, or module EGR inlet port 525, shown in the Fig. 5 to 6) of an EGR cooler, which is directly coupled to a first side of the cylinder head. For example, exhaust gas can pass through an exhaust passage within the cylinder head (e.g., first inner passage 150 shown in Fig. 1 and Fig. 3) and into an EGR cooler module (e.g. EGR cooler module 248 shown in Fig. 2 or EGR cooler module 548 shown in the Fig. 5 to 6) are routed via the respective inlet connections described above.

[0102] In step 704, the procedure involves flowing exhaust gas through the EGR cooler from the EGR inlet port to an EGR outlet port (e.g., module EGR outlet port 242 shown in Fig. 2 or module EGR outlet 518 shown in Fig. 5 to 6) of the EGR cooler (e.g. EGR cooler module 248 shown in Fig. 2 or EGR cooler module shown in Fig. 5 to 6), and then to an intake manifold. In a first embodiment, the flow of exhaust gas to the intake manifold at 704 comprises the internal routing of exhaust gas through the cylinder head from the EGR outlet port to a cylinder head outlet port (e.g., the second engine EGR outlet port 154 shown in Fig. 1), which is coupled to the intake manifold. For example, in the first embodiment, the EGR cooler module (e.g., the EGR cooler module 248, shown in Fig. 2) the exhaust gas flow at a module EGR inlet connection (e.g. module EGR inlet connection 242, shown in Fig. 2) The gas then flows through a passage (e.g., module EGR outlet passage 152 shown in Fig. 1) within a cylinder head (e.g. cylinder head 235 shown in Fig. 2) to an intake manifold (e.g. intake manifold 106 shown in Fig. 1) In a second embodiment, the flow of gas to the intake manifold includes the flow of exhaust gas from the EGR outlet port of the EGR cooler and outside the intake manifold via an external EGR passage located outside the cylinder head. For example, in the second embodiment, the EGR cooler module (e.g., EGR cooler module 548 shown in Fig. 5) the exhaust gas flow at a module EGR inlet connection (e.g. module EGR inlet connection 525 shown in Fig. 5) and discharges cooled exhaust gas to a module EGR outlet port (e.g., module EGR outlet port 518 shown in Fig. 5) The cooled gas then flows from the module's EGR outlet port into an external EGR passage (e.g., external EGR passage 461, shown in the Fig. 4 to 6) via an EGR inlet port (e.g. EGR inlet port 455) of the outer EGR passage.

[0103] In step 706, the procedure involves flowing coolant from inside the cylinder head to a coolant inlet port (e.g., module coolant inlet port 218 shown in Fig. 2, or module coolant inlet port 540 shown in the Fig. 5 to 6) of the EGR cooler (e.g. EGR cooler module 248 shown in Fig. 2 or EGR cooler module 548 shown in the Fig. 5 to 6) and then through the EGR cooler. For example, coolant can be routed through a coolant passage within the cylinder head (e.g., the third inner passage 158 shown in Fig. 1 and Fig. 3) and into the EGR cooler module via an engine coolant outlet port (e.g., first engine coolant outlet port 167 shown in Fig. 1 and Fig. 3), which connects directly to a module coolant inlet port (e.g., the first engine coolant inlet port 218 shown in Fig. 2, or module coolant inlet port 540, shown in Fig. 5 to 6) of the EGR cooler module is coupled.

[0104] In step 708, the procedure involves flowing coolant from a coolant outlet port (e.g., module coolant outlet port 240 shown in Fig. 2, or module coolant outlet connection 573 shown in the Fig. 5 to 6) of the EGR cooler to a radiator, where the EGR inlet port, EGR outlet port, and coolant inlet port of the EGR cooler face the same side of the cylinder head. In a first embodiment, the method in step 709 comprises flowing coolant from a coolant outlet port to the radiator by internally routing coolant through the cylinder head from the coolant outlet port to a cylinder head outlet port coupled to the radiator. For example, coolant can be drawn from the coolant outlet port (e.g., module coolant outlet port 240, shown in Fig. 2) of the EGR cooler module (e.g. EGR cooler module 248 shown by Fig. 2) to an internal coolant passage (e.g. fourth internal passage 168 shown in Fig. 1) within the cylinder head, and into the radiator (e.g., radiator 162 shown in Fig. 1) flow. In a second embodiment, the method at 708 comprises the flow of coolant from the coolant outlet port to the radiator via an external coolant passage located outside the cylinder head. For example, coolant can flow from the coolant outlet port (e.g., module coolant outlet port 573, shown in the Fig. 5 to 6) of the EGR cooler module (e.g. EGR cooler module 648, shown in Fig. 5 to 6) to the outer coolant passage (e.g. second outer coolant passage 372 shown in Fig. 3) outside the cylinder head, and flow into the radiator (e.g., radiator 162 shown in Fig. 3).

[0105] In this way, an EGR cooler module, which is part of an EGR system, can be mounted directly to a single side of an engine's cylinder head. The EGR cooler module can be directly connected (e.g., mounted) to a number of intake / exhaust ports located on that single side of the cylinder head, creating interfaces between the intake / exhaust ports of the EGR cooler module and the corresponding intake / exhaust ports of the cylinder head. The technical effect of directly mounting the EGR cooler module to a single side of the cylinder head and creating interfaces between the corresponding intake / exhaust ports is to allow coolant and EGR gases to be transferred from the cylinder head to the intake ports of the EGR cooler module, and from the exhaust ports of the EGR module to the radiator or intake manifold.This eliminates the need for additional external fittings to connect the EGR cooler to the cylinder head passages, improving ease of installation and reducing fitting deterioration over time. Furthermore, the arrangement described above can reduce the overall engine installation space. The transfer of coolant / EGR gas from the cylinder head to the EGR cooler module inlet ports is achieved by directly connecting the module inlet ports to corresponding cylinder head outlet ports, which are fluidically coupled to coolant / EGR gas passages within the cylinder head.The transfer of coolant / EGR gas from the EGR cooler module to the radiator and intake manifold is achieved by coupling the EGR cooler module outlet port to additional coolant / EGR passages within the cylinder head (as in the first embodiment) or by coupling the EGR cooler module outlet ports to coolant / EGR passages outside the cylinder head (as in the second embodiment).

[0106] In one embodiment, an exhaust gas recirculation (EGR) system comprises an EGR cooler module including a body and an EGR inlet port, an EGR outlet port, and a coolant inlet port, all extending from the body and arranged parallel to each other and on the same first side of a cylinder head, wherein the EGR inlet port and the coolant inlet port are directly coupled to the first side of the cylinder head, the EGR inlet port is located on the first side of the cylinder head, the EGR cooler module includes a first flange with the EGR inlet port and the coolant inlet port, the coolant inlet port is in surface-sharing contact with an engine coolant outlet port on the first cylinder head surface of the cylinder head and is in fluidic communication with it, and the EGR cooler module further includes a second flange.which includes an EGR outlet port and a module coolant outlet port; and a radiator which is coupled to the module coolant outlet port via an internal passage of the cylinder head. In a first example of the EGR system, the EGR outlet port is directly coupled to an engine EGR inlet port, the EGR inlet port is directly coupled to an engine EGR outlet port located on the first side of the cylinder head, and the coolant inlet port is directly coupled to an engine coolant outlet port located on the first side of the cylinder head. A second example of the EGR (exhaust gas recirculation) system optionally includes the first example and further includes, wherein the engine EGR outlet port is directly coupled to the internal EGR passage,a third example of an EGR system optionally includes one, more, or both of the first and second examples, and further includes, wherein the exhaust passage is an exhaust channel from only one cylinder of a plurality of engine cylinders, and wherein only exhaust gas from that one cylinder is routed through the EGR cooler module. A fourth example of an EGR system optionally includes one, more, or each of the first to third examples, and further includes, wherein the engine coolant outlet is directly coupled to a first internal coolant passage that is routed through the interior of the cylinder head from a second internal coolant passage.the coolant circulates around the engine cylinders and the engine coolant inlet port. A fifth example of the EGR system optionally includes one or more or each of the first through fourth examples, and further includes a gasket between the first flange and the cylinder head, and a second gasket between the second flange and the cylinder head. A sixth example of the EGR system optionally includes one or more or each of the first through sixth examples, and further includes a gasket between the first flange and the cylinder head, and a second gasket between the second flange and the cylinder head, on a common plane. A seventh example of the EGR system optionally includes one or more or each of the first through sixth examples, and further includes, wherein the engine EGR inlet port is directly coupled to an internal EGR passage,which is routed through the interior of the cylinder head from the engine EGR port to a cylinder head outlet port located on a second side of the cylinder head and coupled to an external EGR passage that is connected between the cylinder head outlet port and an intake manifold of an engine.

[0107] An eighth example of the EGR system optionally includes one or more or each of the first through seventh examples, and further includes wherein the module coolant outlet port is directly coupled to an engine coolant port located on the first side of the cylinder head, and wherein the engine coolant inlet port is directly coupled to an internal coolant passage connected through the interior of the cylinder head. A ninth example of the EGR system optionally includes one or more or each of the first through eighth examples, and further includes wherein the module coolant outlet port is directly coupled to the internal passage of the cylinder head.

[0108] A method for an EGR system comprises routing exhaust gas internally through a cylinder head from an exhaust passage downstream of an engine cylinder through a first flange and a first gasket to an EGR inlet port of an EGR cooler, which is coupled directly to a first side of the cylinder head via the first flange; routing exhaust gas through the EGR cooler from the EGR inlet port through the first flange and the first gasket to an EGR outlet port of the EGR cooler and then through the second flange and a second gasket to the cylinder head at an intake manifold, the EGR outlet port being coupled directly to the first side of the cylinder head via the second flange; routing coolant from within the cylinder head,through the first flange to a coolant inlet port of the EGR cooler and then through the EGR cooler; and flow of coolant from a coolant outlet port of the EGR cooler through the second flange to a radiator via the inner passage of the cylinder head, wherein the EGR inlet port, the EGR outlet port, and the coolant inlet port of the EGR cooler face the same side of the cylinder head. In a first example of the method, the method comprises the flow of exhaust gas to an intake manifold,which includes the flow of exhaust gas from the EGR outlet port of the EGR cooler to the intake manifold via an EGR passage. A second example of the method optionally includes the first example and further includes adjusting the flow of exhaust gas from the exhaust passage to the intake manifold by adjusting the position of an EGR valve. A third example of the method optionally includes one, more, or both of the first and second examples, and further includes, wherein the flow of exhaust gas to the intake manifold includes the internal routing of exhaust gas through the cylinder head from the EGR outlet port to a cylinder head exhaust port coupled to the intake manifold. A fourth example of the method includes one, more, or each of the first through third examples, and further includes adjusting the flow of exhaust gas from the exhaust passage to the intake manifold by adjusting the position of an EGR valve.which is arranged in a passage coupled between the cylinder head exhaust port and the intake manifold. A fifth example of the method optionally comprises one or more or each of the first to fourth examples, and further comprises wherein the flow of coolant from the coolant outlet port to the radiator includes the internal routing of coolant through the internal passage of the cylinder head from the coolant outlet port to a cylinder head exhaust port coupled to the radiator.

[0109] In another embodiment, an EGR system includes an EGR cooler module comprising a housing with a body and four engine connection ports comprising an EGR inlet port, a module EGR inlet port, a module coolant inlet port, and a module coolant outlet port, wherein the four engine connection ports extend from the body and are all arranged in a common plane, the module EGR inlet port and the module coolant inlet port are arranged by a first flange, and the module EGR outlet port and the module coolant outlet port are positioned by a second flange;a cylinder head comprising a single side with four module connection ports, comprising an engine EGR outlet port shaped to couple to the module EGR inlet port, an engine EGR outlet port shaped to couple to the module EGR outlet port, an engine coolant outlet port shaped to couple to the module coolant inlet port, and an engine coolant inlet port shaped to couple to the module coolant outlet port, a first gasket between the cylinder head and the first flange, and a second gasket between the cylinder head and the second flange; and; A radiator is connected to the module coolant outlet via an internal passage. In a first example of the EGR system, the cylinder head includes an internal gas passage within the cylinder head, which is connected between an exhaust gas passage downstream of an engine cylinder and the engine EGR outlet, and where the exhaust gases are routed internally through the cylinder head via the internal gas passage and to the EGR cooler module.

[0110] It should be noted that the exemplary control and estimation routines presented here can be used with various engine and / or vehicle system configurations. The control methods and routines disclosed herein can be stored as executable instructions in non-volatile memory and can be executed by the control system, including the controller, in combination with the various sensors, actuators, and other engine hardware. The specific routines described here can represent one, more, or any number of processing strategies, such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. Thus, various actions, operations, and / or functions shown can be performed in the sequence shown, in parallel, or in some cases, omitted.Likewise, the processing sequence is not strictly necessary to achieve the features and advantages of the exemplary embodiments described here; rather, this sequence serves for better understanding and illustration. One or more of the described processes, operations, and / or functions can be performed repeatedly, depending on the strategy employed. Furthermore, the described processes, operations, and / or functions can graphically represent code that is to be programmed into non-volatile memory of the computer-readable storage medium in the engine control system. The described processes are carried out by executing the instructions in a system comprising the various engine hardware components in combination with the electrical controller or control unit.

[0111] It should be noted that the configurations and routines disclosed herein are exemplary in nature, and that these specific embodiments are not to be understood as limiting, because numerous variations are possible. For example, the above technology can be used for a V6, inline-4, inline-6, V12, 4-cylinder boxer engine, and other engine types. The subject matter of this disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, and other features, functions, and / or properties disclosed herein.

[0112] The following claims specifically disclose certain combinations and subcombinations that are considered novel and to possess inventive step. These claims may relate to "one" element or "a first" element, or equivalents thereof. Such claims shall be understood as covering one or more such elements, without requiring or excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by extending the present claims or by filing new claims in this or a related application. Such claims, whether broader, narrower, the same, or different in their scope of protection from the original claims, shall also be considered to be included within the subject matter of the present disclosure.

Claims

[1] Exhaust gas recirculation (EGR) system (101, 210), comprising: an EGR cooler module (148, 248) including a body and a module EGR inlet port (153, 220), a module EGR outlet port (157, 242), and a module coolant inlet port (165, 218), all extending from the body and arranged parallel to each other on a same, first side of a cylinder head (134, 235), where the module EGR inlet port (153, 220) and the module coolant inlet port (165, 218) are directly coupled to the first side of the cylinder head (134, 235), the module EGR inlet port (153, 220) is arranged on the first side of the cylinder head (134, 235), the EGR cooler module (148, 248) has a first Module flange (214) with the module EGR inlet port (153, 220) and the module coolant inlet port (165, 218), the module coolant inlet port (165, 218) in surface-sharing contact with a first engine coolant outlet port (167,267) is on the first cylinder head surface (249) of the cylinder head (134, 235) and is in fluid communication therewith, and the EGR cooler module (148, 248) further includes a second module flange (216) including a module EGR outlet port (157, 242) and module coolant outlet port (171, 240); and, a radiator (162) coupled to the module coolant outlet port (171, 240) via a fourth internal passage (168) of the cylinder head (134, 235). [2] The EGR system (101, 210) of claim 1, wherein the module EGR outlet port (157, 242) is directly coupled to a first engine EGR inlet port (155, 259), the module EGR inlet port (153, 220) is directly coupled to a first engine EGR outlet port (151, 247) located on the first side of the cylinder head (134), and the module coolant inlet port (165, 218) is directly coupled to a first engine coolant outlet port (167, 267) located on the first side of the cylinder head (134). [3] The EGR system (101, 210) of claim 2, wherein the first engine EGR outlet port (151, 247) is directly coupled to an internal EGR passage (150) that leads from the first engine EGR outlet port (151, 247) through an interior of the cylinder head (134, 235) to an exhaust passage (145) downstream of a cylinder and within the cylinder head (134, 235). [4] The EGR system (101, 210) of claim 3, wherein the exhaust passage (145) is an exhaust port of only one of a plurality of engine cylinders (120, 122, 124), and wherein only exhaust gas from the one cylinder is passed through the EGR cooler module (148, 248). [5] The EGR system (101, 210) of claim 2, wherein the first engine coolant outlet port (167, 267) is directly coupled to a third internal coolant passage (158) that is passed through an interior of the cylinder head (134, 235) from a plurality of coolant passages (160) that circulate coolant around cylinders of an engine (102) and the second engine coolant inlet port (169, 269). [6] The EGR system (101, 210) of claim 2, further comprising a seal between the first module flange (214) and mounting surfaces (230, 232, and 234) of the cylinder head (134, 235) and a second seal between the second module flange (216) and mounting surfaces (258 and 260) of the cylinder head (134, 235). [7] The EGR system (101, 210) of claim 2, wherein the first engine EGR inlet port (155, 259) is directly coupled to a second internal EGR passage (152) leading from the first engine EGR inlet port (155, 259) through an interior of the cylinder head (134, 235) to a second engine EGR outlet port (154) located on a second side of the cylinder block and coupled to an external EGR passage (161) coupled between the second engine EGR outlet port (154) and an intake manifold (106) of an engine (102). [8] The EGR system (101, 210) of claim 2, wherein the module coolant outlet port (171, 240) is directly coupled to a second engine coolant inlet port (169, 269) disposed on the first side of the cylinder block, the second engine coolant inlet port (169, 269) being directly coupled to a fourth internal coolant passage (168) extending through an interior of the cylinder. [9] The EGR system (101, 210) of claim 1, wherein the coolant is passed from the module coolant outlet port (171, 240) into the second engine coolant inlet port (169, 269) and then into the fourth internal passage (168) of the cylinder head (134, 235). [10] Method comprising: Directing exhaust gas internally through a cylinder head (134, 235) from an exhaust passage (145) downstream of an engine cylinder through a first module flange (214) and a first seal to a module EGR inlet port (153, 220) of an EGR cooler (148, 248) coupled to a first side of the cylinder head (134, 235) immediately via the first module flange (214); Flowing exhaust gas through the EGR cooler (148, 258) from the module EGR inlet port (153, 220) through the first module flange (214) and the first seal to a module EGR outlet port (157, 242) of the EGR cooler (148, 258) and then through the second module flange (216) and a second seal to the cylinder head (134, 235) to an intake manifold (106), wherein the module EGR outlet port (157, 242) is coupled to the first side of the cylinder head (134, 235) immediately via the second module flange (216); Flowing coolant from within the cylinder head (134, 235), through the first module flange (214) to a module coolant inlet port (165, 218) of the EGR cooler (148, 248) and then through the EGR cooler (148, 248); and Flowing coolant from a module coolant outlet port (171, 240) of the EGR cooler (148, 248) through the second module flange (216) to a radiator (162) via the fourth internal passage (168) of the cylinder head (134), wherein the module EGR inlet port (153, 220), the module EGR outlet port (157, 242), and the module coolant inlet port (165, 218) of the EGR cooler (148, 248) face a same side of the cylinder head (134). [11] The method of claim 10, wherein flowing exhaust gas to the intake manifold (106) comprises flowing exhaust gas from the module EGR outlet port (157, 242) of the EGR cooler (148, 248) to the intake manifold (106) via an EGR passage (161) located outside the cylinder head (134, 235). [12] The method of claim 11, further comprising adjusting a flow of exhaust gas from the EGR passage (161) to the intake manifold (106) by adjusting a position of an EGR valve (156). [13] The method of claim 10, wherein flowing exhaust gas to the intake manifold (106) comprises routing exhaust gas internally through the cylinder head (134, 235) from the module EGR outlet port (157, 242) to a second engine EGR outlet port (154) coupled to the intake manifold (106). [14] The method of claim 13, further comprising adjusting a flow of exhaust gas from the EGR passage (161) to the intake manifold (106) by adjusting a position of an EGR valve (156) disposed in an EGR passage (161) coupled between the second engine EGR outlet port (154) and the intake manifold (106). [15] The method of claim 10, wherein flowing coolant from the module coolant outlet port (171, 240) to the radiator (162) comprises internally routing coolant through the fourth internal passage (168) of the cylinder head (134) from the module coolant outlet port (171, 240) to a second engine coolant outlet port (170) coupled to the radiator (162). [16] EGR system (210), comprising: an EGR cooler module (248) including a housing (200) including a body and four engine connection ports including a module EGR inlet port (220), a module EGR outlet port (242), a module coolant inlet port (218), and a module coolant outlet port (240), wherein the four engine connection ports extend from the body and are all arranged in a common plane, the module EGR inlet port (220) and the module coolant inlet port (218) are arranged by a first flange (214), and the module EGR outlet port (242) and the module coolant outlet port (240) are positioned by a second module flange (216); a cylinder head (235) including a single side with four module connection ports including a first engine EGR outlet port (247) shaped to couple with the module EGR inlet port (220), a first engine EGR inlet port (259) shaped to couple with the module EGR outlet port (242), a first engine coolant outlet port (267) shaped to couple with the module coolant inlet port (218), and a second engine coolant inlet port (269) shaped to couple with the module coolant outlet port (240); a first seal between the cylinder head (235) and the first module flange (214), and a second seal between the cylinder head (235) and the second module flange (216); and a radiator (162) coupled to the module coolant outlet port (240) via a fourth internal passage (168) of the cylinder head (235). [17] The EGR system (210) of claim 16, wherein the cylinder head (235) includes a first internal gas passage (150) within an interior of the cylinder head (235) and is coupled between an exhaust manifold passage (145) downstream of an engine cylinder and the first engine EGR outlet port (247), and where exhaust gases are routed internally through the cylinder head (235) via the first internal gas passage (150) and to the EGR cooler module (248).

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