Integrated EGR Valve With Linear Bypass and Flow Dosing Control
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Solution Overview
Problem
Existing exhaust gas recirculation (EGR) systems require complex and costly solutions for precise regulation of gas flow, with a need for a more economic and robust valve that can efficiently control and bypass gas flow in vehicle engines to minimize emissions.
Innovation Solution
A valve with an axially movable shaft and dual valve body elements that can block or unblock gas inlets and outlets, combining the functions of a bypass valve and dosing unit, allowing for adjustable gas flow and space-saving design, with a default position for safety in case of malfunction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a complex valve system with multiple separate components is used for precise gas flow regulation, then measurement precision and control accuracy are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the bypass valve and dosing unit into a single integrated valve body with a unified actuator system. The valve body contains multiple outlets (first outlet for EGR flow, second outlet for bypass flow) controlled by a single axially movable shaft with corresponding valve elements, eliminating the need for separate valves while maintaining precise flow regulation capability
Solution Approach 2:
The single valve body performs multiple functions simultaneously: it acts as both a bypass valve (diverting flow through the second outlet) and a dosing unit (controlling EGR flow through the first outlet). The axially movable shaft provides universal control over all flow paths, allowing one component to replace multiple specialized components
2Adaptability or versatility
If multiple separate valves are used for bypass and dosing functions, then functional versatility is improved, but weight and space requirements increase
Solution Approach 1:
The patent merges the bypass valve and dosing unit into one physical assembly, where a single valve body houses both the first outlet (EGR) and second outlet (bypass) pathways. The shared actuator mechanism controls both functions, significantly reducing the total weight compared to using two separate valves with independent actuators
Solution Approach 2:
The valve body is designed as a multi-functional component that simultaneously provides bypass capability (through the second outlet) and EGR dosing capability (through the first outlet). The axially movable shaft provides universal control over all flow paths, allowing one component to replace multiple specialized components, thereby reducing overall assembly weight
3Measurement precision
If a complex valve system with multiple separate components is used, then flow control precision is improved, but the number of parts and maintenance requirements increase
Solution Approach 1:
The patent combines multiple valve functions into a single integrated assembly with fewer discrete parts. The unified valve body and shared actuator system reduce the total component count compared to separate bypass and dosing valves, simplifying installation and reducing the number of potential failure points that require maintenance
Solution Approach 2:
The valve body serves as a universal housing for both bypass and EGR control functions, with the axially movable shaft providing centralized control. This multi-functional design means that a single maintenance intervention can address both bypass and dosing pathways, rather than requiring separate maintenance procedures for each function
Data Source
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AI summary
Valve (1) for controlling gas flow, comprising a housing (7) with at least one gas inlet (50); at least one first gas outlet (51) and one second gas outlet (52); a valve device adapted for blocking or unblocking the first gas outlet (51) and/or the second gas outlet (52) and/or the gas inlet (50); the valve device comprising an axially movable shaft (3) driven by an actuator (2), a valve body (4) comprising a first valve body element (40) and a second valve body element (41) and being arranged on the axially movable shaft (3); the first valve body element (40) being adapted for blocking or unblocking the gas inlet (50); the second valve body element (41) being adapted for blocking or unblocking the first gas outlet (51) or the second gas outlet (52); the first valve body element (40) and the second valve body element (41) being fixedly connected to each other; wherein the valve body (4) is adapted to block or unblock the gas inlet (50), the first gas outlet (51) and the second gas outlet (52) via linear movement along a longitudinal axis L of the shaft (3).