Rotatable Air Intake Elbow with Upstream Compressor Passage

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Solution Overview

Problem

Internal combustion engines using exhaust gas recirculation (EGR) face issues where EGR gases are ingested into air compressors, reducing their service life, and existing solutions restrict the rotation of air compressor inlet elbows due to extended tubes, which are costly and inflexible with varying engine configurations.

Innovation Solution

An air intake assembly with a rotatable elbow featuring a first passage for mixing EGR gas and a second passage for the air compressor, allowing the air compressor supply port to be located further upstream and maintaining full rotation flexibility by centering the passage within the elbow, thus minimizing EGR gas ingestion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If the air compressor supply port is moved upstream away from EGR gas entry, then EGR gas ingestion is reduced, but the elbow rotation flexibility is restricted

Engineering Contradiction:

ImproveEGR gas ingestionVSAvoidelbow rotation flexibility

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The air intake connector is divided into separate functional passages: a first passage for EGR gas mixing and a second passage for air compressor supply. This segmentation allows each passage to be optimized independently - the second passage can be positioned upstream to reduce EGR ingestion while the elbow maintains full rotation capability for different engine configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a three-dimensional passage configuration within the elbow where the second passage extends through the elbow body in a direction that provides upstream positioning. This spatial arrangement achieves separation from EGR gas entry while preserving rotational freedom, effectively using dimensional positioning to resolve the contradiction.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Object-affected harmful factors

If a tube is inserted into the elbow to extend the air supply port upstream, then EGR gas ingestion is reduced, but the elbow rotation is limited

Engineering Contradiction:

ImproveEGR gas ingestionVSAvoidelbow rotation

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The invention merges the air supply port function directly into the elbow structure through an integrated second passage. This eliminates the need for a separate extensible tube that would restrict rotation, while achieving the same upstream positioning effect. The passage is formed as part of the elbow body, combining structural integrity with rotational freedom.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If the air compressor supply port is positioned further upstream, then separation from EGR gas is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

ImproveEGR gas ingestionVSAvoidintake connector structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The air intake connector is designed as a universal component with multiple internal passages that can accommodate different engine configurations. The second passage provides upstream positioning for air compressor supply while the centered connection to the elbow allows full rotation. This multi-functional design achieves EGR separation without requiring configuration-specific modifications, reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution effectively separates EGR gases from the air compressor intake, allowing maximum rotation of the elbow and accommodating various engine configurations while extending the air compressor supply port further upstream, thereby reducing EGR gas ingestion and maintaining operational flexibility.

Implementation Method 1

a first passage for routing a first portion of the air to the air intake connector to be mixed with the EGR gas

Methodology Applied

Scientific EffectFluid mixing:

Implementation Method 2

a second passage for routing a second portion of the air to the air intake connector and out an exit port of the air intake connector to an air compressor

Methodology Applied

Scientific EffectFluid flow:

Data Source

PatentUS8096289B2Apparatus and method for separating air compressor supply port from the EGR gas

Publication Date: 2012.01.17 CUMMINS INTELLECTUAL PROPERTY INC

AI summary

Separation of an air compression supply port from exhaust gas recirculation (EGR) in internal combustion engines. In one aspect, an air intake connector includes an entry port for an EGR gas, and an air intake elbow is connected to the air intake connector, the elbow receiving air. The elbow includes a first passage for routing a first portion of the air to the air intake connector to be mixed with the EGR gas, and a second passage for routing a second portion of the air to the air intake connector and out an exit port to an air compressor. The second passage is attached to the elbow and extends through a bend in the elbow.