Rotary Valve Module Integrating EGR and Heat Recovery

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Solution Overview

Problem

The complexity and cost of manufacturing multiple valves to control gases in motor vehicle engine exhaust gas recirculation (EGR) and Exhaust Heat Recovery (EHR) systems are high, necessitating a more efficient and cost-effective solution.

Innovation Solution

A single rotary valve module with a rotary flap and bypass circuit, including a heat exchanger, that controls gas flow from the engine outlet to the intake, allowing selective diversion of gas to the environment or intake, thereby integrating EGR and EHR functions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple valves are used to control gases in EGR and EHR systems, then gas flow control capability is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvegas flow control capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple valve functions (EGR valve, EHR valve, and bypass valve) into a single integrated rotary valve assembly. The rotary flap mechanism provides multiple sealing positions that can direct exhaust gas flow to different paths (EGR recirculation, EHR heat recovery, or direct bypass to atmosphere), eliminating the need for separate valves for each function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single rotary valve assembly performs multiple functions simultaneously: it controls exhaust gas recirculation (EGR), manages exhaust heat recovery (EHR), and provides a bypass path to atmosphere. The rotary flap can be positioned to achieve different flow configurations, making one component universal for multiple gas control tasks.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple valves are used to control gases in EGR and EHR systems, then gas flow control capability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvegas flow control capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If a single rotary valve is used to control gases, then manufacturing complexity is reduced, but gas flow control precision may be compromised

Engineering Contradiction:

Improvemanufacturing complexityVSAvoidgas flow control precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The rotary flap is segmented with distinct sealing edges and positioning features that engage with corresponding seats in the valve body. This segmentation allows precise control of gas flow paths at different rotational positions, ensuring accurate diversion of exhaust gas to the required destination (EGR, EHR, or bypass).

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a rotary flap mechanism that can be actuated by various means (manual, electric motor, or electronic control system) to replace complex multi-valve mechanical assemblies. The rotary mechanism provides precise angular positioning capability for controlling gas flow distribution.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 single rotary valve module simplifies manufacturing, reduces costs, and achieves efficient gas control across various vehicle modes, eliminating the need for multiple valves and minimizing maintenance, while facilitating heat transfer and gas distribution.

Implementation Method 1

The bypass circuit has a heat exchanger disposed therein

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS10458313B2Multifunctional rotary valve module

Publication Date: 2019.10.29 HANON SYST CO LTD

AI summary

An engine exhaust gas circuit includes a primary circuit in fluid communication with an intake of an engine and an outlet of the engine. The primary circuit conveys a gas from the outlet of the engine to the inlet of the engine. The primary circuit including a valve body having a rotary flap rotatably disposed in the valve body. A bypass circuit extends from a branch point intermediate the outlet of the engine and the valve body to the valve body.