EGR Cooler Sealing and Flow Control in Internal Combustion Engines
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Solution Overview
Problem
The existing exhaust gas recirculation (EGR) cooler in internal combustion engines is not fully enclosed by the crankcase contour, leading to water leakage and reduced flow speeds through the cooler fins, which diminishes the cooling effect.
Innovation Solution
Attaching cast fins to the EGR cooler and inserting cast ribs into the crankcase pocket with a small gap to minimize leakage, combined with turbulence generators and optional diaphragms/throttle devices to enhance heat transfer and adjust exhaust gas supply, allowing for improved flow velocities and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the EGR cooler is placed in a pocket in the crankcase without complete enclosure, then the installation is simpler and manufacturing costs are lower, but water flows around the cooler reducing flow velocity and cooling effect
Solution Approach 1:
A sealing plate is introduced as an intermediary component between the EGR cooler and the crankcase pocket. The sealing plate has a contour that matches the cooler contour and includes a sealing edge that engages with the pocket contour, creating a water-tight seal. This allows the simple pocket installation to function effectively by preventing water leakage around the cooler.
Solution Approach 2:
The sealing plate acts as a thin film structure that flexibly adapts to the contours of both the cooler and the crankcase pocket. The sealing edge of the plate creates a flexible seal that prevents water from flowing around the cooler while maintaining the simple pocket installation approach.
2Manufacturing precision
If cast fins are machined on the crankcase side, then the gap width tolerance is reduced improving the throttling effect, but the machining time and production cost increase
Solution Approach 1:
Instead of machining the entire fin structure, only specific local areas are machined - specifically the sealing edge of the casting fin on the crankcase side. This localized machining approach reduces the gap width tolerance in the critical sealing area while minimizing the additional machining time and production cost.
Solution Approach 2:
The solution applies partial machining rather than complete machining of all fins. By machining only the critical sealing edge area of the casting fin, the patent achieves sufficient gap width tolerance control without the excessive machining time and cost that would result from machining the entire fin structure.
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
Significantly reduces leakage losses and enhances the cooling effect by increasing flow velocities through the EGR cooler, while maintaining a compact design and minimizing additional production costs.
Implementation Method 1
The transverse flow allows the entire engine water volume to be made available to the EGR cooler due to the large flow cross-section. In contrast to longitudinal flow, the water also experiences a significantly lower temperature increase.
Implementation Method 2
The cooling water flows through the engine water volume and absorbs heat from the exhaust gas in the EGR cooler.
Implementation Method 3
the cooling section has turbulence generators which ensure even better heat transfer
Data Source
Figure 1~2
Figure 3~4
AI summary
An internal combustion engine with a crankcase (1) and with a cylinder head is described, comprising at least one cylinder block, at least one planar flange surface for accommodating at least one radiator (2), at least one radiator (2), at least one coolant inlet to the radiator (2), at least one coolant outlet (8) from the radiator (2), at least one exhaust-gas inlet to the radiator (2), at least one integrated exhaust-gas leadthrough from the radiator (2), and at least one internal cooling path (3).