Exhaust-Gas Recirculation Module with Integrated Pre-Cooler
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Solution Overview
Problem
Existing exhaust-gas recirculation modules face challenges in minimizing constructional space requirements and assembly expenditure while maintaining high cooling performance and protecting the exhaust-gas recirculation valve from overheating and soot deposition.
Innovation Solution
The design integrates an outer housing with an inner exhaust-gas cooler and a coolant channel between the inner and outer housings, functioning as a pre-cooler to reduce thermal stress on the exhaust-gas recirculation valve, and incorporates ribs for enhanced heat dissipation and minimized pressure loss, eliminating the need for separate ducts and reducing soot deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the exhaust-gas recirculation conduit is arranged closer to the motor block, then the cooling performance is improved, but the temperature of the exhaust gas becomes too high causing thermal overstressing of the electric motor and control unit
Solution Approach 1:
The exhaust-gas recirculation module is divided into functionally separate components: an exhaust-gas cooler with inner/outer housings, a recirculation valve, and a pre-cooler duct. This segmentation allows the high-temperature exhaust gas to be cooled in stages - first in the pre-cooler duct before reaching the valve, then further cooled in the exhaust-gas cooler, thereby protecting the valve and motor from thermal stress while maintaining cooling performance.
Solution Approach 2:
The pre-cooler duct is positioned upstream of the exhaust-gas recirculation valve to perform preliminary cooling of the exhaust gas before it reaches the valve. This preliminary action reduces the temperature of the exhaust gas to a level that prevents thermal overstressing of the valve and associated components, while still allowing the main exhaust-gas cooler to provide additional cooling.
2Temperature
If two individual cooling devices are used to cool the exhaust gas, then the cooling performance is improved, but the constructional space requirement and assembly expenditure increase
Solution Approach 1:
The exhaust-gas cooler and pre-cooler duct are merged into a single integrated module with a unified housing structure. The pre-cooler duct is formed as an integral part of the outer housing, eliminating the need for separate cooling devices and their associated tube conduits. This merging reduces constructional space requirements and assembly complexity while maintaining the dual-stage cooling function.
Solution Approach 2:
The outer housing serves multiple functions: it provides structural support, contains the exhaust-gas cooler, forms the pre-cooler duct for upstream cooling, and houses the recirculation valve. This multi-functionality eliminates the need for separate cooling devices and reduces overall constructional space requirements while maintaining high cooling performance.
3Object-affected harmful factors
If the exhaust gas is cooled to a lower temperature, then the thermal stress on the exhaust-gas recirculation valve is reduced, but the soot deposition on the valve increases
Solution Approach 1:
The pre-cooler duct performs preliminary cooling of the exhaust gas to a temperature that reduces thermal stress on the recirculation valve, while the main exhaust-gas cooler provides additional cooling downstream. This staged approach allows the valve to operate at reduced thermal stress without excessive soot deposition, as the gas temperature is controlled to remain above the soot deposition threshold while still providing sufficient cooling to protect the valve.
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 achieves high cooling efficiency and minimizes soot deposition within a compact space, ensuring the exhaust-gas recirculation valve operates effectively with reduced thermal stress and assembly complexity.
Implementation Method 1
a coolant channel arranged between the inner housing and the exhaust-gas duct
Implementation Method 2
incorporates ribs for enhanced heat dissipation and minimized pressure loss
Data Source
AI summary
An exhaust-gas recirculation module for an internal combustion engine includes an outer housing, an exhaust-gas cooler comprising an inner housing arranged within the outer housing, an exhaust-gas recirculation valve arranged upstream of the exhaust-gas cooler, an exhaust-gas duct formed in the outer housing arranged upstream of the exhaust-gas recirculation valve, and a coolant channel arranged between the inner housing and the exhaust-gas duct.