Interchangeable Particle Filter for EGR Heat Exchanger
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current EGR heat exchangers require complete replacement when the particulate filter becomes clogged, leading to inefficiencies and increased costs due to the constraints of smaller engine designs and reduced space for integration, as well as the need for improved cleanliness in low-pressure applications.
Innovation Solution
An interchangeable particulate filter design is integrated into the gas line unit, allowing for removability and easy replacement, with a structural element and seal configuration that ensures gas-tight mounting and easy installation/removal, such as a peripheral frame with a non-through groove and complementary coupling means for secure attachment to the connection flange or gas tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the particulate filter is integrated as a fixed component in the EGR heat exchanger, then the filtration function is stable and reliable, but the entire heat exchanger must be replaced when the filter becomes clogged, increasing maintenance costs and reducing operational efficiency
Solution Approach 1:
The particulate filter is designed as a separate, detachable component that can be independently removed from the EGR heat exchanger. The filter assembly includes a filter element housed in a casing with connection means that allow it to be detached from the heat exchanger body, enabling replacement of only the filter rather than the entire assembly.
Solution Approach 2:
The filter is extracted as an independent replaceable component from the integrated heat exchanger system. The connection means allow the filter to be taken out and replaced separately, while the heat exchanger body remains in place and continues to function.
2Productivity
If the particulate filter is made as a separate replaceable component, then maintenance costs are reduced and operational efficiency is improved, but the device complexity increases due to additional connection means and sealing requirements
Solution Approach 1:
The connection means integrate multiple functions into a single assembly: mechanical attachment (lugs and slots), sealing (gasket), and gas-tight connection. This merging reduces the number of separate components and assembly steps compared to having separate mounting brackets, seals, and fasteners.
Solution Approach 2:
The connection means are designed to provide multiple functions simultaneously: structural support, sealing, gas-tight connection, and easy detachment. The peripheral flange with lugs and slots serves as both a mounting structure and a alignment guide, while the gasket provides sealing across multiple interfaces.
3Object-affected harmful factors
If the filter is positioned to maximize filtration efficiency, then gas cleanliness is improved, but the space available for other components is reduced due to smaller engine designs
Solution Approach 1:
The filter casing is positioned within or adjacent to the heat exchanger body, utilizing the existing spatial envelope. The filter assembly nests into the available space without requiring additional external volume, as it integrates with the heat exchanger's existing structure and flow paths.
Solution Approach 2:
The filter is arranged in a position that utilizes three-dimensional space efficiently, positioning it close to an extreme side of the tube bundle to maximize filtration path length while minimizing overall assembly volume. The peripheral flange extends radially to provide connection interfaces without increasing the primary flow path dimensions.
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 solution allows for the filter to be replaced without replacing the entire EGR exchanger, improving efficiency and reducing maintenance costs by enabling filter replacement after a certain mileage, while maintaining effective gas filtration and heat exchange performance.
Implementation Method 1
a particulate filter arranged between a gas inlet and a gas outlet of the exchanger, so that the gases pass through it
Implementation Method 2
The main function of EGR exchangers is the exchange of heat between the exhaust gases and the coolant, with the aim of cooling the gases
Implementation Method 3
a heat exchanger block intended for the circulation of gases with heat exchange with a heat transfer fluid
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an exchanger which comprises: a heat-exchanger unit intended for circulating gases with heat exchange with a heat-transfer fluid; a gas pipe unit attached to one end of said heat-exchanger unit, so that it remains in fluid communication with the latter in order for the gases to pass through same; and an interchangeable particle filter (3) removably mounted in the gas pipe unit or in the heat-exchanger unit. The assembly comprises a gas pipe unit with an interchangeable particle filter (3) removably mounted therein.