Integrating Intake Pipe with Head Cover for Crankcase Gas Recirculation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing head cover structures for internal combustion engines face challenges in accurately detecting the inadvertent disengagement or removal of pipes or tubes in the crankcase gas recirculation system due to time delays and inaccurate pressure sensor readings, primarily caused by zero offset issues.
Innovation Solution
A head cover structure with an auxiliary cover that integrates a gas-liquid separation passage and an intake pipe, allowing crankcase gas to flow directly into the intake passage without external components, thereby preventing disengagement and enhancing lubricating oil separation through a curved passage design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate pipes or tubes are used to connect the crankcase chamber with the intake passage, then the system allows flexible installation and maintenance, but the pipes may become inadvertently disengaged or removed leading to detection difficulties
Solution Approach 1:
The patent integrates the separate pipe components into a single integrally formed auxiliary cover structure. The auxiliary cover includes the crankcase gas introduction passage, intake pipe, and oil supply passage as one unified component that is directly connected to the head cover, eliminating the need for separate detachable pipes and preventing inadvertent disengagement while maintaining manufacturing feasibility through integral forming processes
2Reliability
If pressure sensors are used to detect pipe disconnection, then the system can identify faults, but time delays and zero offset errors reduce detection accuracy
Solution Approach 1:
The patent incorporates a pressure sensor within the integrally formed auxiliary cover structure to directly monitor pressure at the source of crankcase gas recirculation. This integrated feedback mechanism provides real-time pressure data to the control unit, enabling immediate detection of disconnection faults without the time delays and accuracy issues associated with external pressure sensing arrangements
3Ease of manufacture
If multiple separate components are used for gas recirculation and oil supply, then the system allows independent manufacturing and assembly, but the overall engine size and weight increase
Solution Approach 1:
The patent combines the auxiliary cover, intake pipe, and oil supply passage into a single integrally formed component. This merging reduces the total number of parts, eliminates the need for multiple separate connections and fasteners, and reduces overall material usage, thereby decreasing engine weight while maintaining ease of manufacture through integral forming processes
Solution Approach 2:
The integrally formed auxiliary cover structure performs multiple functions simultaneously: it provides the crankcase gas introduction passage for gas recirculation, the intake pipe for air intake, and the oil supply passage for lubrication. This multi-functionality in a single component reduces the overall system weight compared to having separate dedicated components for each function
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 design prevents inadvertent disengagement of pipes, improves lubricating oil separation from crankcase gas, and reduces the engine's size and weight by integrating the intake pipe and oil supply passage, while increasing rigidity and ensuring accurate gas recirculation.
Implementation Method 1
a gas-liquid separation passage (74) jointly with the head cover, the gas-liquid separation passage being communicated with a crankcase chamber (11) of the internal combustion engine, and configured to separate lubricating oil from a crankcase gas drawn from the crankcase chamber
Data Source
AI summary
A head cover structure (45) for an internal combustion engine (1) comprises a head cover (4) connected to a cylinder head (3), and an auxiliary cover (44) connected to the head cover and defining a gas-liquid separation passage (74) jointly with the head cover, the gas-liquid separation passage being communicated with a crankcase chamber (11) of the internal combustion engine, and configured to separate lubricating oil from a crankcase gas drawn from the crankcase chamber, wherein the auxiliary cover is integrally formed with an intake pipe (49) internally defining a part of an intake passage (20) of the internal combustion engine, and the auxiliary cover internally defines a crankcase gas introduction passage (63) communicating the gas-liquid separation passage with an interior of the intake pipe.