Parallel EGR Coolers for Engine Packaging and Valve Protection
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Solution Overview
Problem
Existing exhaust systems with single large EGR coolers and multiple control valves are cumbersome, costly, and prone to premature failure due to extreme environments, limiting their packaging and control complexity.
Innovation Solution
The exhaust system features separate EGR passages and coolers for each bank of cylinders, with control valves and measuring devices located downstream of the coolers to regulate recirculation and reduce wear, and a compact design that includes coolers mounted at the sides of the engine block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single large EGR cooler is mounted to the top of the engine, then exhaust gas recirculation cooling function is achieved, but packaging space is consumed and installation becomes cumbersome
Solution Approach 1:
The patent divides the single EGR cooler into multiple separate coolers, with each cooler serving a specific bank of cylinders. This segmentation allows the cooling function to be distributed across multiple smaller components rather than requiring one large cooler, thereby reducing the space occupied at any single location and improving packaging efficiency.
Solution Approach 2:
The patent transitions from a vertical arrangement (single cooler mounted on top of the engine) to a horizontal/distributed arrangement (multiple coolers positioned at different locations along the engine block). This dimensional change allows the cooling system to be distributed across the engine rather than concentrated at a single point, improving packaging space utilization.
2Ease of operation
If control valves are located upstream of the EGR cooler, then EGR flow control is achieved, but the valves experience extreme heat and moisture environments causing excessive wear and premature failure
Solution Approach 1:
The patent introduces the EGR cooler as an intermediary component between the exhaust manifold and the control valves. The cooler condenses moisture and reduces temperature of the exhaust gases before they reach the control valves, thereby protecting the valves from the extreme heat and moisture environments that would cause excessive wear and premature failure.
Solution Approach 2:
The patent performs the cooling and moisture condensation action before the exhaust gases reach the control valves. By preparing the exhaust stream in advance through the cooler, the system prevents harmful thermal and moisture effects from reaching the valves, thereby extending their service life and improving reliability.
3Measurement precision
If multiple control valves are used to regulate EGR flow and bypass exhaust, then flow control precision is improved, but system cost and control complexity increase
Solution Approach 1:
The patent segments the EGR flow control into separate pathways with dedicated control valves for each bank of cylinders. This segmentation allows for independent control of exhaust recirculation to each bank, improving flow control precision while maintaining manageable system complexity through modular valve placement and dedicated control pathways.
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 configuration enhances packaging efficiency, reduces control complexity, and extends the life of components by creating a more temperate environment for valves and measuring devices, allowing for improved exhaust gas recirculation control and reduced emissions.
Implementation Method 1
a first cooler located in fluid communication with the first exhaust gas recirculation passage, and a second cooler located in fluid communication with the second exhaust gas recirculation passage
Data Source
AI summary
An exhaust system is disclosed for use with an engine. The exhaust system may have a first exhaust manifold associated with a first plurality of engine cylinders, and a second exhaust manifold associated with a second plurality of engine cylinders. The exhaust system may also have a first exhaust gas recirculation passage extending from the first exhaust manifold to the first plurality of engine cylinders, and a second exhaust gas recirculation passage extending from the first exhaust manifold to the second plurality of engine cylinders. The exhaust system may additionally have a first cooler located in fluid communication with the first exhaust gas recirculation passage, and a second cooler located in fluid communication with the second exhaust gas recirculation passage.