Intake Manifold Temperature Control for Plastic EGR Systems
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Solution Overview
Problem
The use of temperature-sensitive components in internal combustion engine intake manifolds with exhaust recirculation poses a challenge due to high temperatures, which necessitates expensive and heavy metal alloys, while economical plastics are not suitable, leading to a trade-off between fuel efficiency and material costs.
Innovation Solution
A process and device that measure and compute temperature in the intake area using sensors and computational models to set the amount of recirculated exhaust gas, ensuring the temperature does not exceed a maximum value, allowing for the use of economical plastic manifolds without overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If exhaust gas recirculation is used to reduce fuel consumption and emissions, then fuel efficiency is improved, but the intake manifold temperature rises excessively
Solution Approach 1:
The patent implements a feedback control system where a temperature sensor continuously monitors the intake manifold temperature and feeds this information back to the control unit. The control unit adjusts the exhaust gas recirculation amount dynamically based on the measured temperature to maintain it below a predetermined threshold, thus resolving the contradiction between fuel efficiency and temperature control.
Solution Approach 2:
The patent changes the operational parameters of the exhaust gas recirculation system by dynamically adjusting the recirculation amount based on temperature measurements. When temperature approaches the threshold, the system reduces the recirculation amount, thereby changing the thermal parameters of the intake manifold while maintaining fuel efficiency optimization.
2Temperature
If expensive temperature-resistant metal alloys are used for the intake manifold, then temperature resistance is improved, but manufacturing cost and weight increase
Solution Approach 1:
The patent enables the use of cheaper plastic materials for the intake manifold by implementing active temperature control through exhaust gas recirculation management. The control system ensures the manifold temperature remains below the thermal degradation threshold of plastic materials, allowing the use of cost-effective plastic instead of expensive metal alloys without compromising durability.
Solution Approach 2:
The patent changes the thermal environment parameters of the intake manifold by controlling the exhaust gas recirculation amount. This parameter control ensures the temperature remains within the safe operating range of plastic materials, enabling the substitution of metal alloys with plastic and thereby reducing manufacturing cost and weight.
3Ease of manufacture
If plastic intake manifolds are used to reduce cost, then manufacturing cost is reduced, but the manifold cannot withstand high temperatures from exhaust gas recirculation
Solution Approach 1:
The patent uses a feedback control mechanism where the temperature sensor monitors the manifold temperature and the control unit adjusts the exhaust gas recirculation amount in real-time to prevent temperature from exceeding the plastic material's thermal tolerance, thus enabling the use of cost-effective plastic manifolds.
Solution Approach 2:
The patent makes economical plastic materials suitable for high-temperature exhaust gas recirculation applications by implementing active temperature management, allowing the use of cheap plastic instead of expensive temperature-resistant metals without sacrificing thermal withstand capability.
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 approach enables the use of cost-effective plastic intake manifolds while minimizing fuel consumption and maintaining material integrity by adjusting exhaust gas recirculation to prevent temperature exceedance, thereby optimizing operating conditions.
Implementation Method 1
the temperature is measured at at least one definable point in the intake area
Implementation Method 2
computation of the temperature prevailing at at least one definable point in the intake area is done by means of a computational model
Implementation Method 3
the intake manifold is supplied with hot exhaust gases, it can be greatly heated
Implementation Method 4
the intake manifold is supplied with hot exhaust gases, it can be greatly heated
Data Source
AI summary
A method of diminishing the thermal effects of the exhaust gas recirculation in an internal combustion engine of a motor vehicle generally consisting of sensing the temperature of the gas at a selected point along the flow thereof, comparing the sensed temperature with a selected temperature and adjusting the supply of the gas responsive to a selected deviation of the sensed temperature from the selected temperature.