Diesel Engine Crankcase Ventilation with Bionic Hood and Intercooler Integration
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Solution Overview
Problem
Achieving highly efficient oil separation in crankcase ventilation systems of internal combustion engines is challenging, requiring significant technical resources and being costly, especially in meeting future emissions regulations.
Innovation Solution
An integrated crankcase ventilation system with a Venturi tube acting as an ejector pump, utilizing the boost pressure from the intercooler to generate negative pressure, and a bionic hood with internal ribbing for optimal airflow and reduced resonance, is implemented within a diesel internal combustion engine with a dual cooling circuit configuration, allowing for line-free installation and efficient coolant management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a highly efficient oil separation system is implemented in the crankcase ventilation system, then oil separation efficiency is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent combines the crankcase ventilation system with the charge air cooling system by integrating a crankcase ventilation duct that connects to the intercooler. This merging allows the intercooler to serve dual functions: cooling charge air and separating oil from crankcase gases, thereby improving oil separation efficiency without adding separate complex oil separation equipment
Solution Approach 2:
The intercooler is designed to perform multiple functions simultaneously: it cools the charge air from the turbocharger and also acts as an oil separator for the crankcase ventilation system. This multi-functionality eliminates the need for dedicated oil separation devices, reducing overall system complexity while maintaining high oil separation efficiency
2Ease of manufacture
If the intercooler is installed on the cylinder head cover in a line-free configuration, then installation complexity is reduced, but space constraints and thermal management challenges increase
Solution Approach 1:
The intercooler is integrated directly onto the cylinder head cover, merging two previously separate components into one unified assembly. This integration eliminates the need for external piping and mounting brackets, achieving a line-free installation that reduces installation complexity while the compact design addresses space constraints
Solution Approach 2:
The intercooler is nested within or directly mounted on the cylinder head cover structure, utilizing the existing engine architecture to accommodate the additional component. This nesting approach minimizes external space requirements and simplifies installation by leveraging the existing structural framework
3Temperature
If the control unit is cooled by its own cooling circuit arranged in the intercooler area, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The control unit cooling circuit is merged with the intercooler's cooling circuit, allowing the same coolant flow to cool both the intercooler and the control unit. This integration improves cooling efficiency by utilizing the cold charge air and coolant flow already present in the intercooler area, while avoiding the need for a completely separate cooling system
Solution Approach 2:
The cooling circuit in the intercooler area is designed to serve multiple components: it cools the intercooler itself and also provides cooling for the control unit. This multi-functionality allows a single cooling circuit to handle multiple thermal management tasks, improving overall cooling efficiency without proportionally increasing system complexity
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 enhances engine performance by minimizing fuel consumption, improving acceleration, and optimizing charge air supply, while reducing installation complexity and noise emission, and enabling efficient oil separation without external energy sources.
Implementation Method 1
An integrated crankcase ventilation system with a Venturi tube acting as an ejector pump, utilizing the boost pressure from the intercooler to generate negative pressure
Implementation Method 2
the cooler of the second cooling circuit of the internal combustion engine is flow-connected to the intercooler
Implementation Method 3
the cooler of the first cooling circuit is flow-connected to the cooling means of the internal combustion engine
Data Source
AI summary
An internal combustion engine, especially a diesel internal combustion engine, having at least one intercooler, at least one control unit, at least a first and a second cooling circuit, whereby the cooler of the first cooling circuit is flow-connected to a cooling circuit of the internal combustion engine, while the cooler of the second cooling circuit of the internal combustion engine is flow-connected to the intercooler.