Engine Exhaust Valve Linkage for Single-Actuator EGR Control
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Solution Overview
Problem
Existing engine systems for heavy-duty vehicles are expensive, cumbersome, and prone to failure due to the presence of multiple actuators required to operate various valves, which complicates manufacturing and reliability.
Innovation Solution
An engine system design that utilizes a single actuator and a kinematic chain to operate three valves (two proportional exhaust valves and one recirculation valve) through a mechanism of cam systems and followers, reducing the need for multiple actuators and enhancing compactness and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple actuators are used to operate the proportional exhaust valves and recirculation valve, then the engine system can control exhaust gas flow precisely, but the system becomes expensive, cumbersome and prone to failure
Solution Approach 1:
The patent combines multiple actuator functions into a single actuator that operates all three valves (first proportional exhaust valve, second proportional exhaust valve, and recirculation valve) through a shared mechanical linkage system. This merging reduces the number of actuators from three to one, thereby reducing cost, compactness, and potential failure points while maintaining precise control capability through coordinated valve operation.
Solution Approach 2:
The single actuator is designed with multi-functionality to control multiple valves serving different functions: exhaust gas flow control to turbocharger, exhaust gas recirculation control, and engine braking control. The actuator achieves universal control through a kinematic chain with cam mechanisms that distribute its motion to the three different valves, allowing one component to perform the work of multiple dedicated actuators.
2Ease of manufacture
If three separate actuators are used for the three valves, then each valve can be controlled independently, but the manufacturing cost increases and the system becomes more cumbersome
Solution Approach 1:
The patent merges three separate actuator assemblies into a single actuator unit with a shared motor, control electronics, and mechanical transmission system. This consolidation reduces manufacturing costs by eliminating redundant components while maintaining the functional independence of each valve through the cam-based kinematic chain that translates single actuator motion into coordinated multi-valve operation.
3Volume of moving object
If multiple actuators are installed in the engine system, then comprehensive valve control is achieved, but the system compactness is reduced and space requirements increase
Solution Approach 1:
The patent consolidates three actuator units into one compact actuator assembly located in a single engine bay position. The mechanical linkage system with cams and followers enables this single actuator to control all three valves without requiring the space of three separate actuator installations, thereby improving system compactness and reducing the volume occupied by the actuation system.
Data Source
AI summary
An engine system includes an internal combustion engine with two sets of cylinders, a turbocharger, two exhaust conduits providing fluid communication between the turbocharger and an exhaust of the cylinders, and an exhaust gas recirculation system including a recirculation valve. Two proportional exhaust valves are adapted to control a flow of exhaust gas in the two exhaust conduits. An actuator includes an output component operating the recirculation valve and the two exhaust valves. In a neutral position, the two exhaust valves are open and the recirculation valve is closed. A first movement of the output component, from its neutral position towards a first position, open the recirculation valve and close a first of the two exhaust valve. A second movement, from the first position and in the same direction as the first movement, close the second exhaust valve and hold open the recirculation valve and closed the first exhaust valve.