EGR Cooler Cleaning via Exhaust Pressure Injection

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Solution Overview

Problem

EGR coolers in vehicles accumulate mass buildup, leading to reduced efficiency and requiring extensive downtime for cleaning, which is time- and labor-intensive.

Innovation Solution

A system and method that allow for automatic determination of the engine's designated state for cleaning, using the engine's exhaust pressure to introduce a cleaning fluid into the EGR cooler while operating, preventing hydro-locking and allowing for steam cleaning without solvents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the EGR cooler is cleaned by dismantling the engine, then the mass buildup can be effectively removed, but the engine experiences substantial downtime and the process becomes time- and labor-intensive

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidengine downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system enables the EGR cooler to be cleaned while the engine remains installed and operational. The cleaning fluid is introduced through the existing EGR cooler inlet port, allowing the cooler to service itself without requiring engine dismantling or external intervention, thus eliminating downtime while maintaining cleaning effectiveness

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The cleaning process is performed while the engine continues to operate, maintaining continuous useful action. The engine runs throughout the cleaning operation, and the cleaning fluid is injected into the flowing exhaust stream, ensuring the cooling system remains functional during maintenance

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If cleaning fluid is introduced into the EGR cooler while the engine is operating, then continuous engine operation is maintained, but there is a risk of hydro-locking the engine if too much liquid is introduced

Engineering Contradiction:

Improveengine operational continuityVSAvoidhydro-lock risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system uses a controller to monitor engine operating conditions and provide feedback control of the cleaning fluid injection. The controller regulates the amount of cleaning fluid introduced based on engine state, preventing excessive liquid introduction that could cause hydro-lock while maintaining effective cleaning

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system changes the physical parameters of the cleaning process by controlling the quantity and delivery rate of cleaning fluid based on engine operating conditions. The controller adjusts injection parameters to optimize cleaning effectiveness while preventing harmful liquid accumulation in the combustion chambers

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the engine is shut down for EGR cooler cleaning, then the cleaning can be performed safely, but the cleaning process becomes time-consuming and labor-intensive

Engineering Contradiction:

Improvecleaning safetyVSAvoidcleaning convenience

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system allows the EGR cooler to clean itself while the engine remains running and the cooler stays installed. The cleaning fluid is delivered through the existing inlet port using the engine's own exhaust flow, eliminating the need for engine shutdown or disassembly and making the maintenance operation simple and convenient

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The cleaning fluid acts as an intermediary substance that is introduced through the EGR cooler inlet port and carried by the exhaust flow through the cooler passages. This intermediary approach enables cleaning without direct access to the cooler interior, eliminating the need for disassembly while maintaining safety

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables continuous operation of the engine during EGR cooler cleaning, reducing downtime and labor, and effectively removing mass buildup without specialized disposal methods.

Implementation Method 1

introducing, with a water pump system, a cleaning liquid into a gas inlet of the EGR cooler

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

An amount of the cleaning liquid relative to an amount of the hot EGR entering the EGR cooler is below a level that would cause hydro-lock of the engine

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

receive hot EGR from an exhaust of the engine and to provide cooled EGR to an intake of the engine

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS11499508B2Cleaning system for an engine exhaust cooler

Publication Date: 2022.11.15 TRANSPORTATION IP HOLDINGS LLC

AI summary

A system and method operate by, while an engine is operating, automatically determining whether the engine is in a designated state for EGR cooler cleaning. The EGR cooler is operably coupled to the engine to receive hot EGR from an exhaust of the engine and to provide cooled EGR to an intake of the engine. The system and method also include, responsive to the engine not being in the designated state, automatically preventing a water pump system from introducing a cleaning liquid into a gas inlet of the EGR cooler.