Integrated EGR Heat Exchanger and Coolant Rail Mounting
Solution Overview
Problem
The challenge is to create a compact and cost-effective cooling system and exhaust gas recirculation system for internal combustion engines, given the increasingly restricted installation space and the need to minimize additional coolant lines between components.
Innovation Solution
The solution involves mounting the coolant collecting rail directly to the engine housing and the EGR heat exchanger directly to the coolant collecting rail, eliminating the need for additional coolant lines and allowing for a compact, twin or triple configuration of engine components, including a short circuit duct connection to the coolant pump and optional integration with a vehicle brake device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the EGR heat exchanger and coolant collecting rail are mounted separately with additional coolant lines, then the system is easier to manufacture individually, but the installation space increases and component complexity increases
Solution Approach 1:
The patent merges the EGR heat exchanger and coolant collecting rail into a single integrated component assembly. The heat exchanger is mounted directly on the coolant collecting rail, eliminating the need for separate mounting and additional coolant lines. This integration directly reduces installation space while maintaining manufacturability through modular assembly of the combined unit.
2Device complexity
If the coolant collecting rail is mounted directly to the engine housing, then the number of coolant lines is reduced, but the mounting complexity increases
Solution Approach 1:
The coolant collecting rail is designed as an integrated assembly that combines the rail structure, mounting features, and heat exchanger into a single unit. This merging allows the entire assembly to be mounted to the engine housing as one component, reducing coolant line connections while maintaining ease of manufacture through standardized mounting interfaces and modular design.
3Adaptability or versatility
If multiple separate components are used for the cooling and EGR systems, then each component can be optimized independently, but the overall system size and installation space increase
Solution Approach 1:
The patent combines multiple functional components (coolant collecting rail, EGR heat exchanger, and mounting structures) into an integrated assembly that maintains the design independence of each functional element while achieving compact integration. This allows each component to be optimized for its specific function while the integrated design reduces overall installation space through shared mounting interfaces and compact arrangement.
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 minimizes installation space, reduces component complexity, and enhances the efficiency of the cooling system while maintaining cost-effectiveness by eliminating unnecessary coolant lines and allowing for direct connections between key components.
Implementation Method 1
an EGR heat exchanger for cooling the recirculated exhaust gas is arranged in the EGR line
Implementation Method 2
a coolant pump for feeding a cooled coolant to the engine
Data Source
AI summary
In an internal combustion engine with a cooling system and an exhaust gas recirculation (EGR) system including an EGR heat exchanger with a coolant inlet opening connected to a coolant outlet opening of the engine for receiving coolant therefrom and the engine including a coolant collecting rail mounted directly to the engine and having a coolant inlet opening connected to the EGR heat exchanger and at least one other coolant inlet opening in communication directly with at least one other coolant outlet opening of the engine.