Intake Camshaft Mode Switching for Engine Brake Efficiency

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Solution Overview

Problem

Existing engine brake devices for commercial vehicles are not cost-effective and efficient in providing high engine braking power, as they require additional actuators that increase complexity and fuel consumption.

Innovation Solution

The engine brake device incorporates an intake camshaft with firing and braking cams, utilizing the torque and rotational movement to switch between firing and braking modes without additional actuators, thereby increasing efficiency and reducing fuel consumption by allowing two intake strokes per cycle and eliminating the need for separate actuators for mode switching.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If additional actuators are used to switch between firing mode and braking mode, then the engine braking power can be increased, but the device complexity and fuel consumption increase

Engineering Contradiction:
Improveengine braking powerVSAvoidcomplexity of actuators
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The intake camshaft is designed to perform multiple functions: it drives both the firing mode operation and the braking mode operation. The same camshaft structure is used to actuate intake valves during both normal combustion cycles and engine braking cycles, eliminating the need for separate actuators dedicated solely to mode switching. This multi-functionality approach allows the camshaft to directly utilize the engine's own rotational movement to control valve timing in both modes.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The engine brake device utilizes the engine's own torque and rotational movement to switch between firing mode and braking mode. The intake camshaft leverages the existing rotational energy of the engine to actuate the intake valves during braking cycles without requiring external power sources or additional actuators. The system essentially serves itself by using the engine's operational characteristics to control its own braking function.

Inventive Principle:
Principle #25Self-service

2Power

If additional actuators are used to switch between firing mode and braking mode, then the engine braking power can be increased, but the fuel consumption increases

Engineering Contradiction:
Improveengine braking powerVSAvoidfuel consumption
Core Design Contradiction:
PowerVSUse of energy by moving object

Solution Approach 1:

The intake camshaft utilizes the engine's own rotational movement and torque to control valve actuation during both firing and braking modes. By leveraging the existing mechanical energy already present in the engine's operation, the system avoids the need for additional powered actuators that would consume extra fuel. The camshaft's design allows it to automatically transition between modes using the engine's natural operational cycles.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The invention extracts and utilizes the existing torque and rotational movement from the engine's normal operation to power the mode switching function. Instead of adding independent actuation systems that would require separate energy inputs, the design captures and repurposes the mechanical energy already generated by the engine during its combustion cycles to control the intake valve timing for both firing and braking modes.

Inventive Principle:
Principle #2Taking out (Extraction)

3Measurement precision

If separate actuators are provided for each camshaft, then the control precision can be improved, but the device complexity and cost increase

Engineering Contradiction:
Improvecontrol precisionVSAvoidcomplexity of actuators
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The intake camshaft is designed as a universal actuating mechanism that serves both firing mode and braking mode operations. The same camshaft structure, with its specifically designed cam profiles, controls the intake valve timing for both normal combustion cycles and engine braking cycles. This eliminates the need for separate actuators for each mode while maintaining precise control through the camshaft's geometric design.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the actuation functions for firing mode and braking mode into a single intake camshaft mechanism. By combining the control of intake valves for both operational modes into one camshaft system, the design reduces the total number of actuators required while maintaining the ability to precisely control valve timing through the camshaft's profile design and rotational positioning.

Inventive Principle:
Principle #5Merging (Combining)

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 provides a cost-effective and space-saving engine brake device with enhanced engine braking power by leveraging the intake camshaft's torque and rotational movement to switch between modes, reducing the number of actuators and improving efficiency, leading to lower fuel consumption.

Implementation Method 1

a switchover device that is assigned to the intake camshaft and provided for the purpose of translating a torque of the intake camshaft into a force for switching between the firing mode and the braking mode

Methodology Applied
Scientific EffectTorque: Torque

Data Source

PatentUS10731526B2Engine brake device for an internal combustion engine
Publication Date: 2020.08.04 DAIMLER TRUCK AG
  • US10731526B2 patent drawing
  • US10731526B2 patent drawing
  • US10731526B2 patent drawing

AI summary

An engine brake device is disclosed. The engine brake device includes at least one intake camshaft which includes at least one intake cam group having at least one firing cam and at least one braking cam, at least one intake cam follower that is assigned to the firing cam and is provided for actuating at least one intake valve in a firing mode, at least one braking intake cam follower that is assigned to the braking cam and is provided for actuating the at least one intake valve in a braking mode, and a switchover device that is assigned to the intake camshaft and is provided for the purpose of translating a torque of the intake camshaft into a force for switching between the firing mode and the braking mode.