MIXING DISTRIBUTOR

Abstract

A mixing distributor (154) for mixing intake air and EGR (exhaust gas recirculation) air in an engine system (118) is disclosed. The mixing distributor (154) comprises the following: a distributor chamber (202) in which the intake air and the EGR air are received; a neck region (204) having an upper end (242) at the distributor chamber (202) and extending along a longitudinal axis (251) to a lower end (246), the lower end (246) having a cross-section that is less than the cross-section of the upper end (242);and a collector (206) with a flat body having an upper wall (250) at the lower end (246) of the neck region (204) and a lower wall (254) spaced from the upper wall (250) by side walls (256) defining an internal volume leading from the neck region (204) to a front outlet opening (262), wherein the upper wall (250) is spaced from the lower wall (254) in a longitudinal dimension along the longitudinal axis (251) that is less than a transverse dimension (268) of the flat body between the side walls (256), and wherein the front outlet opening (262) is positioned at a lateral distance from the longitudinal axis (251).

Description

AREA OF REVELATION

[0001] This disclosure relates generally to a mixing distributor and the mixing of intake air and exhaust gas to form EGR (exhaust gas recirculation) air in an engine system. BACKGROUND OF THE REVELATION

[0002] Heavy-duty work vehicles, such as those used in agriculture, construction, forestry, and mining, can utilize various drive systems and powertrains to provide traction for the ground-penetrating wheels or tracks used for the vehicle's travel and work operations. Internal combustion engines, including various compression-ignition engines (such as diesel engines), burn fuel to generate power for these vehicles' travel and work processes. Fuel combustion can produce harmful gases that can be emitted from the vehicle. For example, burning diesel fuel can produce nitrogen oxides (NOx) and other gases. Exhaust gas recirculation (EGR) is a method used to reduce NOx emissions from the engine.In EGR (Exhaust Gas Recirculation) methods, exhaust gas from the engine is combined with fresh air and then recirculated into the engine to reduce the amount of oxygen entering the engine. A mixing chamber can be used to combine the exhaust gas with the fresh air before the EGR gas is introduced into the engine. The purpose of the mixing chamber is to ensure that the fresh air and exhaust gas are combined with an even distribution and then enter the engine in this even distribution. An even distribution of the EGR gas to the cylinders is desirable for improving the control of NOx emissions from the engine. SUMMARY OF THE REVELATION

[0003] In one implementation, a mixing distributor for mixing intake air and EGR (exhaust gas recirculation) air in an engine system is disclosed. The mixing distributor comprises a distributor chamber in which the intake air and the EGR air are received. The distributor chamber is an open, non-mixing chamber without turbulence-inducing passages or devices that promote the mixing of the EGR air with the intake air. The mixing distributor further comprises a neck region having an upper end at the distributor chamber and extending along a longitudinal axis to a lower end. The lower end has a cross-section that is smaller than the cross-section of the upper end.The mixing distributor further comprises a collector with a flat body having an upper wall at the lower end of the neck region and a lower wall spaced from the upper wall by side walls that define an internal volume extending from the neck region to a front outlet opening. The upper wall is spaced from the lower wall in a longitudinal dimension along the longitudinal axis that is less than one transverse dimension of the flat body between the side walls. The front outlet opening is positioned at a lateral distance from the longitudinal axis.

[0004] In one example of the mixing distributor, the front outlet opening has an elongated shape with a longitudinal dimension that is shorter along the longitudinal axis than a transverse dimension perpendicular to the longitudinal axis. In another example of the mixing distributor, the manifold extends toward the front outlet opening such that its longitudinal dimension at the front outlet opening is greater than the longitudinal dimension between the upper wall and the lower wall at a position on the flat body at the lower end of the neck region, and its transverse dimension is greater than the transverse dimension between the side walls at that position. In yet another example of the mixing distributor, the upper wall extends toward the front outlet opening away from the lower wall in the longitudinal direction.

[0005] In another example of the mixing manifold, the collector includes an interface flange surrounding the front outlet opening, with bolt holes for coupling the mixing manifold to a motor of the engine system. In yet another example of the mixing manifold, the lower wall has a rounded projection that extends to the upper wall and along a length of the lower wall.

[0006] In another example of the mixing distributor, intake air and EGR air enter the distributor chamber and move downwards through the throat area to the collector. The collector creates turbulence in the intake and EGR air, promoting their mixing before they exit at the front exhaust port. In yet another example of the mixing distributor, the velocity of the intake and EGR air is increased through the throat area because the cross-section of the upper end narrows towards the cross-section of the lower end. The collector causes the EGR and intake air to move in a spiral as they approach the front exhaust port, and this spiral motion creates turbulence that promotes their mixing.

[0007] In another example of the mixing distributor, a rear wall extends between the side walls opposite the front outlet opening, curved in the transverse dimension of the flat body in a reference plane perpendicular to the longitudinal axis. In yet another example of the mixing distributor, the rear wall and the side walls are integrally formed as a single piece and define a smooth inner surface; and the smooth inner surfaces of the rear wall and the side walls are rounded at the top and bottom walls in the longitudinal dimension of the flat body. In yet another example of the mixing distributor, the distributor chamber, the neck region, and the collector have smooth inner surfaces, and the distributor chamber, the neck region, and the collector are integrally formed as a single piece.

[0008] In another example of the mixing distributor, the distributor chamber includes a top opening through which the intake air is drawn in, and a side opening through which the EGR air is drawn in. The top opening is opposite a bottom opening to the throat area. In yet another example of the mixing distributor, the top opening in the distributor chamber connects an intake pipe to the distributor chamber, and the side opening of the distributor chamber is connected to an EGR intake pipe.

[0009] In one implementation, an air intake arrangement for an engine system is disclosed. The air intake arrangement comprises an intake pipe configured to supply an intake air flow, an EGR pipe configured to supply an EGR air flow, and a mixing manifold for mixing intake air and EGR air in an engine system. The mixing manifold comprises a distributor chamber in which the intake air from the intake pipe and the EGR air from the EGR pipe are received. The distributor chamber is an open, non-mixing chamber without turbulence-inducing passages or devices that promote the mixing of the EGR air with the intake air. The mixing manifold further comprises a throat region having an upper end at the distributor chamber and extending along a longitudinal axis to a lower end. The lower end has a cross-section that is less than the cross-section of the upper end.The mixing distributor further comprises a collector with a flat body having an upper wall at the lower end of the neck region and a lower wall spaced from the upper wall by side walls that define an internal volume extending from the neck region to a front outlet opening. The upper wall is spaced from the lower wall in a longitudinal dimension along the longitudinal axis that is less than one transverse dimension of the flat body between the side walls. The front outlet opening is positioned at a lateral distance from the longitudinal axis.

[0010] In one example of the air intake arrangement, the front outlet opening has an elongated shape with a longitudinal dimension that is shorter along the longitudinal axis than a transverse dimension perpendicular to the longitudinal axis. The collector extends toward the front outlet opening such that its longitudinal dimension at the front outlet opening is greater than the longitudinal dimension between the upper and lower walls of the flat body, and its transverse dimension is greater than the transverse dimension between the side walls of the flat body. The collector extends longitudinally away from the upper and lower walls toward the front outlet opening.In another example of the air intake arrangement, the collector includes an interface flange surrounding the front outlet opening, with bolt holes for coupling the mixing distributor to a motor of the engine system, and the lower wall has a rounded projection extending to the upper wall and along a length of the lower wall.

[0011] In another example of the air intake arrangement, the intake air and EGR air enter the manifold and move downwards through the throat section to the collector. The collector creates turbulence in the intake and EGR air, promoting their mixing before the combined air exits at the front exhaust port. The velocity of the intake and EGR air is increased by the throat section, as the cross-section narrows from the top to the bottom. The collector causes the intake and EGR air to spiral as they move towards the front exhaust port. This spiral motion creates the turbulence that promotes their mixing.

[0012] In another example of the air intake arrangement, a rear wall extends between the side walls opposite the front outlet opening. This rear wall is curved in the transverse dimension of the flat body in a reference plane perpendicular to the longitudinal axis. The rear wall and the side walls are integrally formed as a single piece and define a smooth inner surface. The smooth inner surfaces of the rear wall and the side walls are rounded at the top and bottom walls in the longitudinal dimension of the flat body. In yet another example of the air intake arrangement, the distributor chamber, the throat region, and the collector have smooth inner surfaces, and the distributor chamber, the throat region, and the collector are integrally formed as a single piece.

[0013] In another example of the air intake arrangement, the distributor chamber includes a top opening through which the intake air is drawn in, and a side opening through which the EGR air is drawn in. The top opening is opposite a bottom opening to the throat area; the top opening in the distributor chamber couples the intake pipe to the distributor chamber; and the side opening of the distributor chamber is coupled to the EGR pipe.

[0014] Further features and aspects become apparent when considering the detailed description, the claims and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a simplified outline of an exemplary work vehicle in the form of an agricultural tractor, into which a mixing distributor of the present disclosure may be integrated, according to at least one aspect of the present disclosure; Fig. Figure 2 is a schematic representation of an exemplary engine system of the work vehicle of Fig. 1 according to at least one aspect of the present disclosure; Fig. Figure 3 is a simplified perspective view of the exemplary engine for the engine system of Fig. 2; Fig. Figure 4 is a simplified and enlarged detailed view of an exemplary mixing distributor, which is attached to the exemplary engine of Fig. 3 is appropriate, according to at least one aspect of the present disclosure; Fig. Figure 5 is a perspective view of the exemplary mixing distributor from Fig. 4; Fig. 6 is a top view of it from the front; Fig. Figure 7 is a cross-sectional view of it along line 7-7 in Fig. 5; Fig. Figure 8 is a cross-sectional view of it along line 8-8 in Fig. 5; Fig. Figure 9 is a cross-sectional view of it along line 9-9 in Fig. 5; Fig. Figure 10 is a perspective view of the exemplary mixing distributor from Fig. 5, which features an integrated intake manifold of the exemplary engine from Fig. 3 is coupled; Fig. Figure 11 is an airflow diagram of the airflow through the exemplary mixing distributor of Fig. 5; Fig. Figure 12 is another airflow diagram of the airflow through the exemplary mixing distributor of Fig. 5; and Fig. Figure 13 is a temperature diagram of the airflow through the exemplary mixing distributor of Fig. 5 and the exemplary intake manifold of Fig. 10.

[0015] In all drawings, identical reference symbols denote the same element. The figures are not necessarily to scale, and the size of some parts may be exaggerated to more accurately illustrate the example shown. Furthermore, the drawings provide examples and / or implementations that correspond to the description; however, the description is not limited to the examples and / or implementations provided in the drawings. DETAILED DESCRIPTION

[0016] The following disclosure describes one or more exemplary embodiments of the disclosed mixing distributor for a work vehicle, as shown in the accompanying figures of the drawings briefly described above. Various modifications of the exemplary embodiments are conceivable for a person skilled in the art. The discussion presented here focuses on the mixing distributor for an engine system for a work vehicle, such as an agricultural tractor; however, the mixing distributor disclosed herein can also be used in other contexts, including other work vehicle platforms in agriculture, construction, forestry, mining, and other industries. OVERVIEW

[0017] Engines for heavy-duty work vehicles can produce harmful gases during fuel combustion. For example, burning diesel fuel can generate nitrogen oxides (NOx) and other gases. Exhaust gas recirculation (EGR) is a method for reducing NOx emissions from the engine. In EGR systems, exhaust gas from the engine is combined with fresh air and then recirculated to reduce the amount of oxygen entering the engine. The fresh air and EGR gas must be combined in a uniform distribution and then enter the engine cylinders in a uniform distribution to improve NOx emission control.

[0018] The present disclosure provides a mixing distributor that receives EGR gas and fresh air and delivers them in a uniform distribution to the cylinders of an engine. The mixing distributor allows the mixing to occur over a short overall length before entering the engine. This short mixing length allows the mixing distributor to be used in engines where there is limited space for mixing the EGR gas and fresh air. Although the mixing distributor is designed to perform the mixing of the EGR gas and fresh air over a short length, there is no reason why the mixing distributor cannot be used with engine systems that have a longer mixing length for the EGR gas and fresh air.

[0019] The mixing manifold can be used with various types of intake manifolds. For example, some engines have integrated intake manifolds, where the intake manifold is built into the engine's cylinder heads. In other cases, the intake manifold is a separate component from the cylinder heads. Generally, the integrated intake manifold has a shorter mixing length for the EGR gas and fresh air than the separate intake manifold. In either case, the short mixing length of the mixing manifold allows it to be used with both types of manifolds.

[0020] The short mixing length is made possible by the design of the mixing manifold. The mixing manifold comprises a distributor chamber, a neck section, and a flat collector. The EGR air and fresh air enter the distributor chamber, flow through the neck section to reach the collector, and then exit the collector. The neck section creates optimal throttling for the fresh air and EGR gas to generate good mixing and laminar flow, followed by expansion into the flat collector. Due to the throttling at the neck, a small pressure drop occurs between the distributor chamber and the outlet of the flat collector. This pressure drop is minor and does not significantly affect engine performance, while simultaneously promoting the mixing of the fresh air and EGR gas.The throttling of the fresh air and EGR gas mixture at the neck and its expansion at the flat collector creates turbulence and vortices at the inlet to the neck and within the flat collector, resulting in additional mixing followed by distribution to the front and rear cylinders of the engine. This process allows the mixing to take place over a short distance, making the mixing distributor applicable to many engines and applications.

[0021] The distribution chamber receives the EGR gas and fresh air. The distribution chamber is an open, non-mixing chamber without any turbulence-inducing passages or devices that would promote the mixing of the EGR air with the intake air within the chamber. For example, the distribution chamber is an open volume that receives the EGR gas and fresh air. The distribution chamber has an EGR pipe connector for coupling to an EGR pipe for receiving the EGR gas and an intake connector for coupling to an intake pipe for receiving fresh air. In one configuration, the EGR pipe connector is flush with the inner surface of the distribution chamber. In another configuration, the EGR pipe connector extends beyond the inner surface and into the distribution chamber. In either case, the EGR air and fresh air are routed from the distribution chamber to the intake manifold.

[0022] The neck extends from an upper end at the inlet along a longitudinal axis to an outlet at a lower end. The lower end has a cross-section that is smaller than that of the upper end. In one aspect, the neck may have a gradually decreasing inner diameter from the neck inlet to the neck outlet. For example, the diameter decrease from inlet to outlet may be approximately 30 percent. In an alternative aspect, the neck may have a constant inner diameter from inlet to outlet, with the neck diameter being smaller than the diameter of the distributor chamber. For example, the neck diameter may be 30 percent smaller than the diameter of the distributor chamber. In both aspects, the length of the neck may be approximately 40 mm, which facilitates a short overall mixing path.In both aspects, the velocity of the EGR gas and fresh air increases as they flow through the neck area due to the reduction in diameter compared to the distributor chamber. The EGR gas and fresh air then enter the collector from the neck area.

[0023] The collector has a flat (pancake-like) body shape. It comprises an upper wall at the lower end of the neck region and a lower wall, separated from the upper wall by side walls and a rear wall, defining an internal volume that extends from the neck region to a front outlet. In some versions, the front outlet is located at approximately a 90-degree angle to the neck region inlet. The upper wall is spaced from the lower wall by a longitudinal dimension less than one transverse dimension of the flat body between the side walls. For example, the flat collector may have a width approximately twice, a length approximately 1.7 times, and a height approximately 0.7 times the neck outlet diameter. The collector's shape allows the EGR gas and fresh air mixture to expand into the flat collector after being restricted by the neck region.The expansion is desirable to generate the turbulence necessary to promote the mixing of the EGR gas and the fresh air. Furthermore, the dimensions of the collector expand towards the front outlet opening, thus encouraging greater turbulence in the mixture.

[0024] The turbulence is caused by the path along which the EGR gas and fresh air flow through the manifold. For example, the EGR gas and fresh air enter the manifold at the top wall, and the mixture bounces off the bottom wall and is directed in all directions. At least some of the mixture is directed to the side and rear walls of the manifold, where it follows the side and rear walls back to the top wall and is directed towards the front exhaust port. This loop path causes some of the mixture to spiral towards the front exhaust port, promoting a more uniform mixture of EGR gas and fresh air. In some cases, there are two spirals, one on the left side of the front exhaust port and the other on the right side.The front exhaust port is attached to the engine's intake manifold and allows the more even mixture of EGR gas and fresh air to be distributed to the engine's cylinders.

[0025] The mixing manifold can be integrally formed from a single piece comprising the manifold chamber, the neck section, and the collector. The various sections can seamlessly merge, simplifying the manifold's manufacturing process. For example, the manifold chamber can be a non-mixing chamber without turbulence inlet passages, further simplifying production by eliminating the need for internal passages within the chamber to mix the EGR and fresh air. One exemplary manufacturing method for producing the mixing manifold is die casting, which allows for cost-effective production.

[0026] One or more exemplary embodiments of a mixing distributor for the engine of a work vehicle are provided in the figures of this disclosure. The following description should be understood merely as providing a non-restrictive exemplary context in which embodiments of this disclosure are more readily understood. EXEMPLOYABLE MIXING DISTRIBUTOR FOR A WORK VEHICLE ENGINE

[0027] With reference to Fig. Figure 1 shows a work vehicle 110 in which embodiments of the disclosure can be implemented. In the example shown, the work vehicle 110 is depicted as an agricultural tractor. However, it is understood that other configurations are possible, including configurations in which the work vehicle 110 is a different type of tractor, a harvester, a forwarder, a road grader, or one of various other work vehicle platforms. The work vehicle 110 comprises a chassis or frame 112, which is supported on front and rear wheels (or tracks) 114. An engine housing 116 is positioned at a front end region of the chassis 112, in which an engine system 118 is located. The engine system 118 transmits power via an associated drive train 119 to an output element (e.g., a motor, a drive, or a power unit).an output shaft (not shown) which in turn transfers power to the axle(s) of the work vehicle 110 to provide propulsion force thereon and / or a power take-off shaft, for example, to operate a work device located on or associated with the work vehicle 110.

[0028] The 118 engine system is used in Fig. 2 is illustrated in more detail according to an exemplary implementation. With reference to Fig. 2. The engine system 118 comprises an internal combustion engine 120 (hereinafter referred to as "engine"), which in various embodiments can be a compression-ignition or spark-ignition internal combustion engine. The engine 120 of the engine system 118 comprises an engine block 122 with several piston-cylinder assemblies 124, which are operated to effect combustion events. In the implementation shown, the engine 120 is an inline six-cylinder compression-ignition engine (e.g., a diesel engine) that defines six piston-cylinder assemblies 124; however, in alternative implementations, different engine types and designs can be used.

[0029] The engine system 118 further comprises an intake manifold 126, which is fluid-connected to the engine 120, and an exhaust manifold 128, which is fluid-connected to the engine 120. In some aspects, the intake manifold 126 is integrated with the cylinder heads. The intake manifold 126 includes a mixing distributor 154, a manifold inlet 142, and several outlets 144 in fluid flow connection with a corresponding piston-cylinder assembly 124 to supply air to it. Fresh air is drawn from the surrounding environment through an air inlet 146, which may include one or more intake components (e.g., an air filter, an air cooler, etc.) arranged in an air inlet passage 150 that leads to an air inlet throttle valve 152 and then to the mixing distributor 154.The air intake 148 (via an air cooler) can reduce the temperature of the intake air before it is supplied to the engine 120, thereby increasing the intake air density for improved volumetric efficiency. The mixing distributor 154 receives exhaust gas through an EGR passage 172 and air through the intake throttle valve 152. The purpose of the mixing distributor 154 is to mix the air and exhaust gas to form EGR gas with an even distribution of air and exhaust gas. The mixing distributor 154 discharges the EGR gas into the manifold inlet 142, where the EGR gas flows through the multiple outlets 144. Thus, the air intake throttle valve 152 and the mixing distributor 154 regulate and enable the supply of fresh air, which is supplied through the intake manifold 126.

[0030] The exhaust manifold 128 of the engine system 118 comprises several secondary exhaust passages 156, each of which is in flow communication with a corresponding piston-cylinder assembly 124 and directs the exhaust gases generated by the engine 120 to a main exhaust outlet 158 ​​and into an exhaust passage 160. Exhaust gas generated by the engine 120 is directed from the exhaust manifold 28, flows through the exhaust passage 160, through an exhaust throttle valve 161, through an aftertreatment passage 162, and into an aftertreatment system 164. The aftertreatment system 64 treats the exhaust gas before it is released to the surrounding environment via an exhaust outlet 165. The aftertreatment system 64 may include one or more components or devices that further treat the exhaust gas, such as... B. an SCR (selective catalytic reduction) catalyst, a diesel oxidation catalyst, a diesel particulate filtering device (DPF (diesel particulate filtration) device) and the like.

[0031] Furthermore, an exhaust gas recirculation (EGR) system 170 is provided in the engine system 118. This system functions by recirculating a portion of the exhaust gas produced by the engine 120, thereby reducing NOx formation during combustion. Exhaust gas is drawn from the exhaust manifold 128 and recirculated via the EGR system 170 into the intake manifold 126. The EGR system 170 comprises an EGR passage 172, an EGR cooler 174, and an EGR pump 176. The EGR passage 172 draws in a portion of the exhaust gas flowing in the exhaust passage 160 for recirculation through the EGR system 170. The EGR passage 172 draws in exhaust gas from the exhaust passage 60 at a point upstream of the exhaust throttle valve 161. The EGR cooler 174 is arranged in series with the EGR passage 172 for the purpose of cooling the exhaust gas flowing through the EGR passage 172 and can be located upstream of the EGR manifold 176 (as in Fig. (as shown in Figure 2) or downstream of the EGR pump 176. The EGR pump 176 has an inlet side 179 in flow connection with the exhaust manifold 128 and an outlet side 181 in flow connection with the inlet manifold 126. For example, the outlet side 181 can be in flow connection with the mixing distributor 154. In one embodiment, the EGR pump 176 is designed as a Roots pump with rotors 182 driven by an electric motor 184. The EGR pump 176 can be electrically controlled to selectively control the flow of exhaust gas that is recirculated from the exhaust passage 160 to the engine 120 via the EGR passage 172. Thus, the EGR pump 176 and the mixing distributor 154 regulate and enable the supply of exhaust gas, which is fed in through the intake manifold 126.

[0032] The EGR pump 176 is configured as a reverse-flow pump, capable of operating in two different modes – a forward mode and a reverse mode – with the EGR pump 176 being electrically controlled to selectively control its operating mode. In forward mode, the EGR pump 176 is operated to recirculate a portion of the exhaust gas from the exhaust passage 160 back into the intake manifold 126. In reverse mode, the EGR pump 176 operates in the opposite direction to forward mode, preventing exhaust gas from escaping through it, which could occur if the EGR pump 176 were simply switched off when not operating in forward mode. When operating in reverse mode, the rotational speed of the EGR pump 176 can be controlled to determine its flow rate, allowing the EGR pump to be operated at a speed that essentially prevents exhaust gas from flowing through it (i.e.,a throughput of zero), or with a rotational speed that provides a flow of air, which is not exhaust air (i.e. fresh air), through it in a direction opposite to that of the exhaust flow.

[0033] With reference to Fig. 2 The engine system comprises a control system 186 and various sensors, including: an engine speed sensor 188; one or more sensors 190 located in the intake manifold 126 or the air intake passage 150, which measure air mass flow and / or air temperature and / or air pressure in the intake manifold 126 and / or the air intake passage 150; one or more sensors 192 in the exhaust manifold 56, which can measure oxygen content and / or temperature and / or pressure of the exhaust gas produced by the engine 120; one or more aftertreatment sensors 194, which determine the condition of the aftertreatment system 164. For example, the condition of the aftertreatment system 164 may include an amount of soot retained in a DPF device, an amount of sulfur or other contaminant that has accumulated in a component of the aftertreatment system 64, and / or a temperature of a component of the aftertreatment system 164.

[0034] The control system 86 monitors signals or data received from the sensors 188, 190, 192, and 194 described above and adjusts the operation of the engine system 118 and other components to ensure that the work vehicle 110 can meet the requirements placed on it by an operator, while simultaneously managing fuel efficiency and reducing the release of hazardous exhaust gases into the surrounding environment. The control system 86 may, for example, include an engine control unit (ECU) that optimizes the operation of the engine 120, an operator interface control, an air conditioning control, a traction system control, an auxiliary unit and / or hydraulic system control, and various other components.The various control units can exchange signals and / or data with each other as needed to maintain efficient and clean operation of the engine system 118 (and thus of the work vehicle 110).

[0035] The various controls of the control system 186 can be implemented using hardware, software, firmware, or combinations thereof. Such controls of the control system 86 can be implemented by one or more appropriately programmed computer-based devices, some or all of which include a processing module and memory. The memory contains, among other things, programming instructions that are executed by one or more processing modules to cause the various controls to perform functions of the motor system 118. Each computer-based device can, for example, include a computer, a device that uses one or more ASICs (application-specific integrated circuits) and / or FPGAs (field-programmable gate arrays), and / or combinations thereof.These devices can be unitary or distributed across multiple data processing devices, and one or more of these data processing devices can be installed locally on the work vehicle 110 or remotely from it. Each data processing device can communicate with another data processing device via one or more networks, such as a local area network (LAN), a control area network (CAN), a cellular network, a wide area network (WAN), such as the internet, and the like. One or more controllers of the control system 186 can also be coupled to and respond to one or more user devices (not shown), such as a keyboard, mouse, display, touchscreen, joystick, etc. (not shown), through which an operator can monitor and control the operation of the work vehicle 110.

[0036] With simultaneous reference to Fig. 3 and Fig. In Figure 4, the mixing distributor 154 is attached to the intake manifold 126 of the engine 120. The mixing distributor comprises a distributor chamber 202, a neck section 204, and a collector 206. In at least one aspect, the distributor chamber 202, the neck section 204, and the collector 206 are integrally formed as a single, one-piece part. The inner surfaces of the distributor chamber 202, the neck section 204, and the collector 206 are smooth and transition seamlessly from one area to the next. In at least one aspect, the collector 206 includes an interface flange 208, which can be attached to a manifold inlet 142 on the intake manifold 126. For example, the interface flange 208 can include screw holes 222, and screws 210 can pass through the screw holes 222 to attach the interface flange 208 to the manifold inlet 142.

[0037] The distributor chamber 202 comprises an inlet connector 212 and an EGR connector 214. The inlet connector 212 has an upper opening 218 through which fresh air is drawn in. An inlet pipe (not shown) can be attached to the inlet connector 212 to supply fresh air to the mixing distributor 154 through the upper opening 218. For example, the inlet connector 212 can include a projection 234 that allows a seal to be formed with a hose. The EGR connector 214 defines a side opening 220 through which EGR gas from the exhaust manifold 128 is drawn in. An EGR passage 172 can be attached to the EGR connector 214 to supply EGR gas to the mixing distributor 154 through the side opening 220. For example, the EGR passage 172 can be inserted into the EGR connecting piece 214 in the opening 236 in order to attach the EGR passage 172 to the EGR connecting piece 214.The distribution chamber 202 is an open non-mixing chamber without turbulence-inducing passages or devices that promote the mixing of the EGR air with the intake air.

[0038] The properties of the fresh air can be monitored by the control system 186 via sensor 190, and the properties of the EGR gas can be monitored by sensor 192. The quantity, temperature, etc., of the fresh air and the EGR gas can be controlled by the control system 186 before the fresh air and the EGR gas enter the distributor chamber 202.

[0039] With simultaneous reference to Fig. 5-9 The distribution chamber 202 includes an opening 226 that allows access to the internal volume of the distribution chamber 202 for the sensor 190. The distribution chamber 202 also defines an opening 228 that allows a passage 231 for coupling the distribution chamber 202 with a flow sensor. As in Fig. As shown in Figure 7, the EGR connector 214 defines the side opening 220. The EGR connector 214 terminates at the inner surface 230 and does not extend past the inner surface 230 into the inner volume of the distributor chamber 202. In an alternative view, the EGR connector 214 extends past the inner surface 230 and into the inner volume of the distributor chamber 202.

[0040] The distribution chamber 202 comprises a wall 216, which defines an interior volume of the distribution chamber 202. The wall 216 defines an interior surface area 230 of the distribution chamber 202. In at least one aspect, the wall 216 extends from the upper opening 218 to a lower opening 238 of the distribution chamber 202. The lower opening 238 is positioned opposite the upper opening 218. In at least one aspect, the lower opening 238 and the upper opening 218 have the same diameter or size.

[0041] As in Fig. As shown in Figure 8, the interior surface 230 is smooth and transitions seamlessly into an interior surface 232, which is defined by a wall 248 of the neck region 204. The wall 216 transitions seamlessly into the wall 248. The wall 248 defines an interior volume of the neck region 204 and the interior surface 232. The neck region 204 also includes an upper opening 240 and a lower opening 244, which is positioned opposite the upper opening 240, with the wall 248 extending from the upper opening 240 to the lower opening 244. The upper opening 240 is positioned at an upper end 242 of the neck region 204, and the lower opening 244 is positioned at a lower end 246 of the neck region 204. The lower opening 238 borders the upper opening 240, allowing the mixture of fresh air and EGR gas to flow from the distributor chamber 202 to the neck area 204.The inner surface 232 is smooth and extends from the upper opening 240 at the upper end 242 to the lower opening 244 at the lower end 246.

[0042] The neck region 204 and the distribution chamber 202 define a longitudinal axis 251. The upper opening 218, the lower opening 238, the upper opening 240, and the lower opening 244 are axially aligned with the longitudinal axis 251. The distribution chamber 202 and the neck region 204 both extend along the longitudinal axis 251. For example, the wall 216 and the wall 248 both extend along the longitudinal axis 251. In at least one aspect, the neck region 204 has a longitudinal dimension of 40 mm. In an alternative aspect, the neck region 204 has a longitudinal dimension between 30 mm and 60 mm.

[0043] The upper opening 240 is larger than the lower opening 244. For example, the upper opening 240 may have a diameter d1 and the lower opening 244 may have a diameter d2, where diameter d1 is larger than diameter d2. In at least one aspect, diameter d2 is 30% smaller than diameter d1. In an alternative aspect, diameter d2 is 20% to 50% smaller than diameter d1. The neck region 204 has a diameter that gradually decreases from diameter d1 to diameter d2. The lower end 246 has a wall cross-section 248 that is less than the cross-section of the wall 248 at the upper end 242. For example, the cross-section of the neck region 204 narrows from the upper end 242 to the lower end 246. Thus, the neck region 204 forms an air nozzle in the mixing distributor 154.Alternatively, the throat area 204 can have a constant inner diameter that is smaller than the diameter of the distributor chamber 202. In both cases, the throat area 204 can be used to create optimal throttling for the air-EGR gas mixture to ensure good mixing and laminar flow. In yet another alternative configuration, the upper opening 240 and the lower opening 244 can have a shape other than a circle, such as an oval, square, rectangular shape, etc.

[0044] In at least one aspect, the distributor chamber 202 has a constant inner diameter that corresponds to the diameter 274 of the upper opening 240 of the neck region 204. In an alternative aspect, the distributor chamber 202 has an inner diameter that changes along the longitudinal axis 251, and the diameter of the lower opening 238 corresponds to the diameter of the upper opening 242.

[0045] The inner surface 232 is smooth and transitions seamlessly into an inner surface 252 of the collector 206. The wall 248 transitions seamlessly into the upper wall 250 of the collector 206. The collector comprises the upper wall 250, a lower wall 254, two side walls 256, and a rear wall 258. The walls 250, 254, 256, and 258 define an inner volume and the inner surface 252 of the collector 206. The collector 206 includes an upper opening 260 and a front outlet opening 262. The collector 206 defines a lateral axis 264 that runs transversely to the longitudinal axis 251. In at least one aspect, the lateral axis 264 is orthogonal to the longitudinal axis 251. The front outlet opening 262 is positioned along the lateral axis 264. The upper opening 260 is positioned at the lower opening 244 of the neck area 204.The upper opening 260 borders the lower opening 244, allowing the mixture of fresh air and EGR gas to flow from the neck area 204 to the collector 206 and through the collector 206 out of the front outlet opening 262.

[0046] The inner surface 252 is smooth and extends from the upper opening 260 to the front outlet opening 262. The front outlet opening 262 is positioned at a lateral distance from the longitudinal axis 251. Thus, the collector 206 extends away from the longitudinal axis 251 and along the lateral axis 264. The mixing distributor 154 includes a structural projection 286, which is attached to the collector 206, the neck section 204, and the distributor chamber 202 for increased structural stability. The structural projection 286 is attached to the interface flange 208 and the upper wall 250, extending along the upper wall 250 to the wall 248 of the neck section 204 and the wall 216 of the distributor chamber 202. In at least one aspect, the structural projection 286 is triangular in shape, which provides additional stability.

[0047] The upper wall 250, the lower wall 254, the two side walls 256, and the rear wall 258 are integrally formed as a single piece and define a flat body. The lower wall 254 is spaced from the upper wall 250 by the side walls 256. A rear wall 258 extends between the side walls 256 and is positioned opposite the front outlet opening 262. In at least one aspect, the rear wall 258 is curved in the transverse dimension of the flat body in a reference plane perpendicular to the longitudinal axis 251. The upper wall 250 is spaced from the lower wall 254 in a longitudinal dimension L1 along the longitudinal axis 251 that is less than a first transverse dimension L2 of the flat body between the side walls 256. In at least one aspect, the first transverse dimension L2 is twice the diameter d2 and the second transverse dimension L3 is 1.7 times the diameter d2.In an alternative aspect, the first transverse dimension L2 can be greater than 1.5 times the diameter d2, and the second transverse dimension L3 can be greater than 1.5 times the diameter d2. Furthermore, in this aspect, the longitudinal dimension L1 can be 0.7 times the diameter d2.

[0048] Dimensions L1, L2, and L3 ensure the flat body shape, which promotes turbulence in the flow that is desirable for a uniform distribution of fresh air and EGR gas in the mixture. Because dimensions L2 and L3 are at least 1.5 times the diameter d2, the mixture is allowed to expand into the collector 206 after being throttled in the neck region 204. The fact that the longitudinal dimension L1 is less than the first transverse dimension L2 and the second transverse dimension L3 serves to keep the upper wall 250 and the lower wall 254 relatively close to each other, thus facilitating that the incoming mixture impinges on the lower wall 254 and is then guided from the lower wall 254 into the collector 206. The design and dimensions of the collector 206 serve to promote turbulence for mixing the fresh air and the EGR gas in the mixture, as required by… Fig. This is discussed in more detail in sections 11-13. As previously discussed, the rear wall 258 and the side walls 256 are integrally formed as a single piece and define part of the smooth inner surface 252. The smooth inner surfaces 252 of the rear wall 258 and the side walls 256 are rounded at the upper wall 250 and the lower wall 254 in the longitudinal dimension of the collector 206. The rounded areas of the inner surfaces 252 allow the mixture to move along and between the walls 250, 254, 256, and 258. The upper wall 250, the lower wall 254 and the side walls 256 extend from the rear wall 258 to the front outlet opening 262. The front outlet opening 262 has an elongated shape with a longitudinal dimension 278 measured along the longitudinal axis 251, which is shorter than a transverse dimension 272 orthogonal to the longitudinal axis 251 and the lateral axis 264.The collector 206 extends longitudinally towards the front outlet opening 262 along the lateral axis 264. The longitudinal dimension 278 at the front outlet opening 262 is larger than the longitudinal dimension 266 between the upper wall 250 and the lower wall 254 at the lower opening 260, and its transverse dimension 272 is larger than the transverse dimension 268 between the side walls 256 at the upper opening 260. With reference to . Fig. 9 The side walls 256 extend away from each other towards the front outlet opening 262. With reference to Fig. 8 The upper wall 250 extends from the lower wall 254 towards the front outlet opening 262. With regard to at least one aspect Fig. 5 and Fig. 9 the lower wall 254 is angled towards the front outlet opening 262 towards the side walls 256.

[0049] The front outlet opening 262 includes an interface flange 208 for coupling the mixing distributor 154 to an engine (e.g., the engine 120). The interface flange 208 can be coupled to an intake manifold 126 of the engine. The intake manifold 126 could be an integrated intake manifold, in which the cylinder heads and the intake manifold are integrated together, or the intake manifold 126 could be a separate component from the cylinder heads. The interface flange 208 surrounds the front exhaust port 262 to seal the front exhaust port 262 against the intake manifold 126. The interface flange 208 includes bolt holes 222 for coupling the interface flange 208 to the intake manifold 126. The bolt holes 222 are located in the transverse dimension of the interface flange 208. The number of bolt holes 222 could be more or fewer than those shown in Fig. Figures 3-9 show the components, and the positions of the holes 222 may differ. The interface flange 208 also includes holes 282 and one hole 280, each in the longitudinal dimension. These holes 280 and 282 can be used to attach fixtures to the manifold at these locations.

[0050] In at least one aspect, the interface flange 208 includes a screw hole 222 in the lower center of the interface flange 208. In this aspect, the lower wall 254 can include a rounded projection 284 that extends to the upper wall 250 and along the length of the lower wall 254 along the lateral axis 264. The rounded projection 284 can accommodate the screw hole 222 in the lower center of the interface flange 208. For example, with reference to Fig. 8 The rounded projection 284 in the lower wall 254 provides space for a screw that extends along the length of the lower wall 254 and is inserted into the screw hole 222 in the lower center of the interface flange 208. The rounded projection 284 can be formed by moving a section of the lower wall 254 towards the upper wall 250, thereby creating space for a screw.

[0051] The rounded projection 284 is rounded on all sides, so that there is a seamless transition from the rounded projection 284 to the back wall 258 and other parts of the lower wall 254.

[0052] With reference to Fig. Fresh air and EGR air, which are drawn into the distributor chamber 202, form a mixture that flows through the distributor chamber 202, the throat area 204, the collector 206, and out of the front exhaust port 262. The mixture exits the front exhaust port 262 and enters the manifold inlet 142 of the intake manifold 126, which distributes the mixture to the cylinders 224a-224f of the engine 120. In at least one aspect, the interface flange 208 is bolted to the manifold inlet 142 by bolts 210. In some aspects, the intake manifold 126 is integrated into the cylinder heads of the engine 120. In some alternative aspects, the intake manifold 126 is separate from the cylinder heads. The distribution chamber 202, the neck area 204 and the collector 206 have smooth inner surfaces 230, 232, 252 that seamlessly transition from one area to the next.These seamless transitions allow the EGR and air mixture to move evenly through the mixing distributor 154. With reference to... Fig. 11 and Fig. 12. The EGR gas and fresh air enter the distributor chamber 202 and form a mixture. The mixture moves from a lower opening 238 of the distributor chamber 202 and through an upper end of the neck section 204. The mixture then moves through the neck section 204, where the velocity of the mixture is increased because the neck section 204 narrows from the upper end 242 to the lower end 246. For example, the cross-section of the upper end 242 narrows towards the cross-section of the lower end 246. The mixture exits the lower opening 244 of the neck section 204 at an increased velocity and enters the upper opening 260 of the collector 206. The shape of the collector allows for rapid expansion of the mixture after the throttling effect of the neck section 204. This expansion generates turbulence and vortices to promote the distribution of the EGR gas and fresh air in the mixture.

[0053] The mixture enters through the upper wall 250 and rebounds from the lower wall 254, being directed in all directions. As in Fig. As shown in Figure 11, at least a portion of the mixture is directed to the side walls 256 and the rear wall 258, where it follows the side walls 256 and the rear wall 258 back to the upper wall 250 and is directed to the front outlet port 262. This loop path causes the mixture to move spirally towards the front outlet port 262, thus promoting a more uniform mixture of EGR gas and fresh air. In some aspects, there are two spirals, one located on the left side of the front outlet port 262 and the other on the right side. The collector 206 extends towards the front outlet port 262, creating more space and facilitating the spiral movement and mixing. The more uniform mixture then exits from the front exhaust port 262 and enters the manifold inlet 142 of the intake manifold 126.

[0054] In at least one aspect, the rounded projection 284, extending from the lower wall 254, promotes the loop path that generates the helical motion of the mixture. For example, the rounded projection 284 can help direct more of the mixture to the side walls 256 and the rear wall 258, thereby increasing the degree of mixing by generating the helical motion. It is noted that even without the rounded projection 284, a loop path still occurs that causes a helical motion of the mixture.

[0055] The narrowing of the intake manifold 204 from the distributor chamber 202 to the collector 206 creates optimal throttling, followed by expansion in the flat collector. This generates turbulence to promote the mixing of the EGR gas and the fresh air while maintaining laminar flow. The throttling results in a small pressure drop from the distributor chamber 202 to the outlet of the collector 206. This pressure drop is small and does not significantly affect engine performance, while simultaneously promoting the mixing of the fresh air and the EGR gas. At least one aspect of the design results in a pressure drop of 5.5 kPa. At the other aspect, the pressure drop is less than 6 kPa.

[0056] With simultaneous reference to Fig. 13 The mixture of EGR gas and fresh air is distributed more evenly as it moves through the mixing distributor 154. The mixture exits the front exhaust port 262 and flows through the intake manifold 126 to reach cylinders 224a-224f. The EGR gas and fresh air continue to mix as the mixture flows through the intake manifold. The mixture that then reaches the cylinder heads 224a-224f is more evenly mixed over a short mixing distance.

[0057] The airflow images from Fig. 11 and Fig. Figure 12 shows the flow of the mixture through the mixing distributor 154. The design of the mixing chamber 202, the throat section 204, and the collector 206 creates turbulence in the mixture flowing through the mixing distributor 154, thereby promoting the mixing of the fresh air and the EGR air. For example, throttling the flow through the throat section 204 increases the flow velocity. The increased flow velocity causes the mixture to enter the collector 206 through the upper wall 250 at a higher speed and impinge on the lower wall 254. The lower wall 254 then directs the mixture further into the collector 206, where at least a portion of the mixture flows upwards along the side walls 256 and the rear wall 258 to reach the upper wall 250 and move towards the front outlet opening 262. This loop path can cause the spiral movement of the flow towards the front outlet opening 262, as shown in Fig. Figure 11 shows that the spiral motion promotes the mixing of the fresh air and the EGR gas, resulting in a more uniform mixture. A uniform mixture is advantageous because it allows each cylinder of the engine to receive the same amount of oxygen, thus enabling better control of NOx emissions from the engine. An uneven mixture would allow one or more cylinders to receive more oxygen than others, thereby allowing one or more cylinders to produce higher NOx emissions than desired.

[0058] A predominantly uniform mixture of fresh air and EGR air at the cylinders is shown in the temperature diagram of Fig. Figure 13 shows that the EGR air enters the mixing chamber 202 through passage 172, and the fresh air enters at the top of the diagram. The initial EGR gas has a higher temperature than the initial fresh air temperature. The fresh air and EGR gas flow through the distributor chamber 202 and the throat area 204, where they begin to mix. The collector 206 shows how the mixture temperature becomes more consistent and levels off to a temperature between the initial EGR temperature and the initial fresh air temperature, thus demonstrating that the fresh air is mixing with the EGR gas. The more consistent temperature in the collector 206 may result from the flow turbulence generated in the collector 206, as discussed above. Fig. 11 and Fig. 12 is discussed. The mixture continues to mix as it enters the intake manifold 126, and the temperature of the mixture entering the cylinders is largely uniform throughout. This uniformity of temperature is important, demonstrating that the mixture is a uniform distribution of EGR gas and fresh air. If the mixture were not uniform upon entering the cylinders, there would be one cylinder receiving a portion of the mixture at a significantly different temperature, exhibiting an area of ​​predominantly fresh air or predominantly EGR gas. This is not the case, as shown in Fig. Figure 13 shows where each cylinder receives the mixture at largely the same temperature.

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