Digital Waste Gate Valve with Pneumatic Charge Air Actuation
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Solution Overview
Problem
Existing digital waste gate valve arrangements in internal combustion piston engines with turbochargers lack reliability due to harsh operating conditions and inefficient control systems, particularly in managing charge air-exhaust gas flow across wide load ranges.
Innovation Solution
A digital waste gate valve arrangement with a flow control unit comprising more than two individually controllable on-off valve units, actuated by a pneumatic system using pressurized charge air as control gas, with a control gas inlet port connected downstream of the compressor part, and featuring dedicated pneumatic actuators and a control system with check valves to prevent exhaust gas leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical valve is used for the waste gate, then the structure is simple, but the reliability is poor due to harsh operating conditions (high temperature, high velocity exhaust gases)
Solution Approach 1:
The patent replaces the traditional mechanical valve with a digitally controlled pneumatic valve system. The pneumatic actuator uses compressed air from the charge air system to open/close the waste gate, eliminating direct mechanical exposure to harsh exhaust conditions. The digital control system manages the pneumatic actuator through electronic signals, achieving higher reliability while maintaining manageable complexity through standardized pneumatic components.
Solution Approach 2:
The patent introduces a pneumatic intermediary system between the control unit and the waste gate valve. Compressed charge air serves as the intermediary medium to transmit control commands to the valve mechanism, isolating the valve from direct exposure to high-temperature exhaust gases and improving reliability while allowing for sophisticated digital control.
2Ease of operation
If charge air is used as control gas for the pneumatic actuator, then the control gas is readily available and pressurized, but exhaust gas leakage into the actuator system may occur
Solution Approach 1:
The patent extracts and separates the control gas function from the exhaust system by using charge air (intake air) as the control medium. This extraction prevents exhaust gas contamination of the actuator system while maintaining pressurized control gas availability. The control gas passage is dedicated and isolated, ensuring that only clean, pressurized charge air reaches the pneumatic actuator.
Solution Approach 2:
The patent uses charge air as an intermediary control gas that is inherently clean and pressurized. This intermediary medium provides reliable actuator operation while naturally preventing exhaust gas leakage issues, as charge air flows from the intake side through isolated passages to the actuator, creating a barrier against exhaust contamination.
3Measurement precision
If multiple individually controllable on-off valve units are used, then the flow control precision is improved, but the device complexity increases
Solution Approach 1:
The patent segments the waste gate flow control into multiple independent on-off valve units, each可控 by its own pneumatic actuator. This segmentation allows precise control of exhaust gas recirculation flow by selectively opening/closing individual valve units, achieving fine-grained flow regulation. The modular design manages complexity through standardized repeating units rather than a single complex valve mechanism.
Solution Approach 2:
The patent implements dynamic control of multiple valve units with independent actuators, allowing the system to adaptively adjust flow by controlling individual valve states based on real-time engine conditions. This dynamic configuration enables precise flow management across varying operating conditions while maintaining manageable complexity through parallel, identical modules.
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
Enhances operational reliability and efficiency by utilizing readily available pressurized charge air for control, minimizing leakage, and maintaining a predetermined pressure level in the pneumatic actuators, thus improving engine performance across varying load conditions.
Implementation Method 1
pneumatic actuator system arranged to control each on-off valve individually... utilizing readily available pressurized charge air for control
Implementation Method 2
control system with check valves to prevent exhaust gas leakage
Data Source
AI summary
A digital waste gate arrangement in an internal combustion piston engine has at least one turbocharger with a compressor part and a turbine part. A flow control unit has more than two individually controllable on-off valve units, and a pneumatic actuator system is arranged to control each on-off valve individually. At least one control gas inlet port is in connection with the pneumatic actuator system, which control gas inlet port is arranged in connection with a downstream side of a compressor part of the turbocharger via a control gas passage. The control gas for operating the flow control unit is arranged available for the pneumatic actuator sys-tem through the control gas passage.