Compressor Stage EGR Injection via Distribution Cavity
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Solution Overview
Problem
Existing turbocharger systems face inefficiencies due to the need for high pressure differentials between the intake and exhaust manifolds, leading to increased brake specific fuel consumption and lower powertrain efficiency, particularly when throttling exhaust gas flow to manage exhaust gas recirculation.
Innovation Solution
The system incorporates an EGR distribution cavity and inlet channel within the compressor body, directing EGR gas into the high-velocity area of the compressor wheel, reducing the static pressure requirement for EGR passage and eliminating the need for an exhaust throttle valve, thereby optimizing pressure differentials and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If exhaust gas flow is throttled to manage EGR, then EGR control is achieved, but brake specific fuel consumption increases and powertrain efficiency decreases
Solution Approach 1:
The invention extracts the exhaust gas flow control function from the exhaust manifold throttle valve and relocates it to the compressor inlet. By positioning the EGR control at the compressor inlet, the system achieves EGR management without throttling exhaust gas flow in the exhaust manifold, thereby avoiding the associated energy losses and improvements in brake specific fuel consumption and powertrain efficiency.
Solution Approach 2:
The compressor inlet acts as an intermediary location for EGR control. Instead of directly throttling exhaust gas flow in the exhaust manifold, the system uses the compressor inlet as a mediation point to regulate EGR, achieving the desired control effect while maintaining efficient exhaust gas flow and reducing energy losses.
2Power
If high pressure differential is maintained between intake and exhaust manifolds, then turbine performance is improved, but work to recompress gas increases
Solution Approach 1:
The invention changes the parameter control approach by regulating EGR at the compressor inlet rather than maintaining high pressure differential through exhaust throttling. This parameter change allows the system to achieve desired EGR levels while reducing the work required to recompress gas, as the pressure differential is optimized at the compressor inlet where it is most effective.
3Productivity
If EGR is introduced at compressor inlet, then pressure differential is optimized, but complex EGR distribution system is required
Solution Approach 1:
The compressor inlet structure serves multiple functions: it acts as the EGR introduction point, the distribution cavity for even EGR mixing, and the integration point with the compressor housing. This multi-functionality reduces overall system complexity by combining several components into one universal structure, achieving pressure differential optimization without requiring a separately complex EGR distribution system.
Solution Approach 2:
The invention merges the EGR distribution cavity with the compressor housing structure, integrating the EGR distribution function into the existing compressor components. This merging eliminates the need for separate, complex EGR distribution components and reduces system complexity while maintaining effective EGR introduction and distribution at the compressor inlet.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces the pressure differential across the cylinder head, lowers emissions, and improves fuel economy by minimizing the work needed to recompress gas, allowing for a higher flowing turbine and increased powertrain efficiency.
Implementation Method 1
a compressor wheel may be disposed on the shaft... A diffuser may extend radially outward from the chamber and may receive gas from the compressor wheel
Implementation Method 2
exhaust gas generated by the combustion of fuel passes through a turbine which drives a compressor
Data Source
AI summary
A product may include a bearing housing in which a shaft may be supported by a bearing so that it may rotate. A compressor wheel may be disposed on the shaft. A compressor cover may be connected with the bearing housing, which may form a compressor body and may define a chamber within which the compressor wheel may rotate. A diffuser may extend radially outward from the chamber and may receive gas from the compressor wheel. An inlet may be provided to the compressor body, which may receive a supply of exhaust gas. An EGR distribution cavity may be defined within the compressor body and may extend around the shaft. An EGR inlet channel may extend into the bearing housing from the inlet to the EGR distribution cavity. An EGR passage may extend from the EGR distribution cavity to the diffuser.