Stackable Gas Mixer Segments for Internal Combustion Engines
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Solution Overview
Problem
Existing gas mixers for internal combustion engines become increasingly complex and costly as the number of gases to be mixed with air increases, leading to overproportional increases in production, installation, and maintenance costs.
Innovation Solution
A modular gas mixer design featuring stackable duct segments with tube and cone sections, allowing for the formation of a main gas conduit and separate admix gas conduits, which can be easily expanded by adding additional duct segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of gases to be mixed with air increases, then the mixing capability is improved, but the device complexity and costs increase overproportionately
Solution Approach 1:
The gas mixer is divided into multiple stackable duct segments, each capable of forming separate conduits for different gases. This segmentation allows the system to handle multiple gases without requiring a completely complex integrated structure, as each segment can be independently designed and assembled.
Solution Approach 2:
The duct segments are designed to be nested within each other when stacked, with inner surfaces of one segment forming conduits within the structure of another segment. This nesting approach allows multiple gas conduits to be integrated within a compact arrangement, improving mixing capability without proportionally increasing overall complexity.
2Adaptability or versatility
If the number of gases to be mixed with air increases, then the mixing capability is improved, but the production, installation and maintenance costs increase overproportionately
Solution Approach 1:
By segmenting the gas mixer into standardized duct segments, each segment can be manufactured using similar processes and designs, reducing the overall production complexity and cost. The modular nature allows for easier assembly compared to manufacturing a single complex integrated unit.
Solution Approach 2:
The duct segments are designed with universal features that allow them to serve multiple functions - forming different types of conduits (main gas conduit, admix gas conduits) depending on their position and configuration in the stack. This multi-functionality reduces the need for specialized components for each gas type, thereby reducing production and installation costs.
3Adaptability or versatility
If the number of gases to be mixed with air increases, then the mixing capability is improved, but the maintenance costs increase overproportionately
Solution Approach 1:
The modular segmented design allows for easier maintenance and repair compared to a monolithic structure. If a problem arises in one segment, only that segment needs to be accessed or replaced, rather than disassembling the entire gas mixer. This segmentation directly reduces maintenance time and costs.
Solution Approach 2:
The stackable and modular nature of the duct segments provides flexibility in maintenance operations, allowing segments to be independently removed, inspected, or replaced without affecting the entire system. This dynamic accessibility improves ease of maintenance significantly compared to fixed integrated designs.
Data Source
AI summary
The present invention pertains to a gas mixer for an internal combustion engine for mixing air with at least one admix gas, comprising a first duct segment having a first tube section and a first cone section, and a second duct segment having a second tube section and a second cone section. The first and second duct segments are stackable such that in a stacked state, a main gas conduit is formed by the first and second tube sections and an admix gas conduit is formed between the first cone section and the second duct segment. The present disclosure also pertains to a method for producing a gas mixer, comprising the steps of: for a predetermined mass flow of a gas to be admixed to air, calculating a flow cross section; machining at least one inner surface of an admix gas conduit such that at any position, the admix gas conduit comprises at least the calculated flow cross section; stacking two duct segments to provide the gas mixer. The present disclosure also pertains to a duct segment for being used in the gas mixer.