EGR Valve Control via Component Flow Limits
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Solution Overview
Problem
Existing EGR systems do not effectively control EGR flow rates based on operating parameters of components like air-to-air after coolers, EGR coolers, and condensation in the air intake system, leading to components being taxed beyond their limits without detection.
Innovation Solution
A power system with a monitoring system and controller that determines maximum EGR flow rates for each component based on monitored operating parameters, ensuring the flow rate does not exceed predetermined limits, and controls the EGR valve to maintain a flow rate no greater than the lowest maximum flow rate determined.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If EGR flow rate is increased to reduce emissions, then emissions reduction is improved, but components may be taxed beyond their operating limits
Solution Approach 1:
The system continuously monitors operating parameters of EGR system components (ATAAC inlet temperature, EGR cooler inlet temperature, condensation levels) and uses this feedback to dynamically adjust and limit EGR flow rate, preventing components from exceeding their operating limits while maximizing emissions reduction benefits
Solution Approach 2:
The controller determines maximum EGR flow rate values for each component based on monitored operating parameters before EGR flow rate is increased, establishing preventive limits in advance to avoid component damage
2Object-generated harmful factors
If EGR flow rate is regulated based on engine operating conditions, then emissions control is improved, but components like ATAAC and EGR cooler are not directly protected
Solution Approach 1:
The system segments the EGR control into separate component-level maximum flow rate determinations for each monitored component (ATAAC, EGR cooler, condensation levels), allowing independent protection of each component while maintaining overall emissions control
Solution Approach 2:
The controller changes the control parameter from general engine operating conditions to specific component operating parameters (ATAAC inlet temperature, EGR cooler inlet temperature, condensation levels), enabling direct protection of each component
3Object-generated harmful factors
If EGR flow rate is increased to improve emissions reduction, then emissions control is improved, but condensation in air intake track becomes problematic
Solution Approach 1:
The system monitors condensation levels in the air intake track as a feedback parameter and uses this information to limit EGR flow rate, preventing excessive condensation while maintaining emissions reduction benefits
Data Source
AI summary
A power system including an exhaust producing engine, an exhaust system and an exhaust gas recirculation (EGR) system is provided. The EGR system may include an EGR flowpath and an air intake system. The EGR system may also include an EGR valve configured to regulate the flow of exhaust gases through the EGR flowpath. The power system may also include a monitoring system configured to monitor operating parameters of at least two components of the EGR system. The power system may also include a controller configured to determine, based on the monitored operating parameters, a maximum flowrate value for each of the components. Each of the maximum flowrate values may represent the maximum EGR flowrate for that component. The controller may be configured to control the EGR valve, based on the maximum flowrate values, to result in an EGR flowrate no greater than the lowest of the maximum flowrate values.