Integrated Short Path EGR System with Cylinder Head Cooler
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Solution Overview
Problem
Conventional EGR systems are inefficient, bulky, and complex, leading to reduced engine performance and increased NOx emissions due to long recirculation paths, which negatively impact fuel efficiency and response time.
Innovation Solution
A compact EGR system utilizing a low-profile cooler with engine oil as a coolant, mounted between the valve cover and valve train, with a short recirculation path and an EGR distribution assembly that evenly distributes cooled exhaust gas across the engine cylinders, along with an oil cooler and bypass valve for selective oil cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional EGR systems with long recirculation paths are used, then NOx emissions are reduced, but engine response time deteriorates and system complexity increases
Solution Approach 1:
The patent extracts the EGR cooler from the traditional long recirculation path and relocates it to mount directly on the cylinder head. This extraction of the cooling function to a new location enables a short-path recirculation configuration, allowing exhaust gas to be cooled and recirculated quickly without traversing long external passages, thereby maintaining NOx reduction while improving engine response time.
Solution Approach 2:
The patent merges the EGR cooler mounting location with the cylinder head structure itself. By integrating the cooler directly onto the cylinder head and utilizing the cylinder head's coolant passages, the system combines multiple functions (cooling, structural support, fluid distribution) into a single integrated assembly, eliminating the need for separate long recirculation paths and reducing system complexity.
2Object-generated harmful factors
If conventional EGR systems with long recirculation paths are used, then NOx emissions are reduced, but device complexity and size increase
Solution Approach 1:
The patent merges the EGR cooler mounting location with the cylinder head structure itself. By integrating the cooler directly onto the cylinder head and utilizing the cylinder head's coolant passages, the system combines multiple functions (cooling, structural support, fluid distribution) into a single integrated assembly, eliminating the need for separate long recirculation paths and reducing system complexity.
Solution Approach 2:
The patent employs multi-functionality by using the cylinder head's existing coolant passages for dual purposes: both engine cooling and EGR gas cooling. The cylinder head structure serves multiple functions including structural support, coolant distribution, and EGR cooler mounting. This universal use of existing components reduces the need for additional dedicated parts, thereby reducing overall system complexity.
3Object-generated harmful factors
If conventional EGR systems with long recirculation paths are used, then NOx emissions are reduced, but fuel efficiency deteriorates
Solution Approach 1:
The patent extracts the EGR cooler from the traditional long recirculation path and relocates it to mount directly on the cylinder head. This extraction of the cooling function to a new location enables a short-path recirculation configuration, allowing exhaust gas to be cooled and recirculated quickly without traversing long external passages, thereby maintaining NOx reduction while improving engine response time.
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
The system achieves improved fuel efficiency, reduced engine friction, and faster response times by using engine oil as a coolant and distributing cooled exhaust gas efficiently across the engine, thereby reducing NOx emissions and enhancing engine performance.
Implementation Method 1
an EGR cooler that cools recirculated engine exhaust gas... The EGR cooler may use engine oil as a coolant for the recirculated exhaust gas
Implementation Method 2
At least a portion of the engine oil used as a coolant may be splashed onto the EGR cooler by the valve train itself
Implementation Method 3
an oil cooler that selectively cools the engine oil
Data Source
AI summary
In one embodiment, an exhaust gas recirculation (EGR) system for an engine is disclosed. The EGR system includes an EGR cooler that cools recirculated engine exhaust gas and is mounted between a valve cover and valve train of a cylinder head in the engine.