Turbine Dosing Module Mounting for Turbocharger Back-Pressure Reduction
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Solution Overview
Problem
Existing turbocharger systems face inefficiencies due to the need for large decomposition chambers that increase back-pressure and pumping work, leading to reduced engine efficiency and poor mixing of Diesel Exhaust Fluid (DEF) with exhaust gas.
Innovation Solution
A turbine dosing system is introduced, where a dosing module is mounted within the turbine outlet passage, specifically within 10 exducer diameters downstream of the turbine wheel, allowing for direct injection of aftertreatment fluid into the high-energy exhaust gas flow, thereby eliminating the need for a separate decomposition chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a large decomposition chamber is used to mix DEF with exhaust gas, then the mixing process is improved, but the back-pressure increases and pumping work increases
Solution Approach 1:
The patent merges the decomposition chamber function directly into the turbine outlet passage, eliminating the need for a separate large decomposition chamber. The dosing module is integrated into the turbine outlet passage structure, allowing DEF to be injected and decomposed in-situ where the exhaust gas flow provides both mixing and thermal energy for decomposition.
Solution Approach 2:
The patent extracts the decomposition chamber function from the traditional separate chamber design and relocates it to the turbine outlet passage. This extraction eliminates the need for a large separate chamber while maintaining the essential decomposition function through the integrated dosing module.
2Ease of operation
If a large decomposition chamber is used to mix DEF with exhaust gas, then the mixing process is improved, but the back-pressure increases
Solution Approach 1:
The patent combines the decomposition chamber with the turbine outlet passage, creating an integrated system where DEF is dosed and decomposed directly in the high-velocity exhaust gas flow. This merging eliminates the need for a separate large chamber that would create back-pressure, while the turbine outlet passage's existing geometry provides sufficient mixing through its high-energy flow characteristics.
3Productivity
If DEF is injected into a decomposition chamber, then the decomposition into reductants is achieved, but the mixing with exhaust gas is poor
Solution Approach 1:
The patent applies local quality by positioning the dosing module to inject DEF directly into a specific high-energy region of the exhaust gas flow within the turbine outlet passage. The local high-velocity flow and thermal energy at this specific location provide both rapid decomposition of DEF into reductants and effective mixing with the exhaust gas, simultaneously achieving both functions that were previously separate problems.
4Productivity
If a separate decomposition chamber is used, then the system can decompose DEF, but the overall system complexity increases
Solution Approach 1:
The patent merges the DEF decomposition function into the existing turbine outlet passage structure, eliminating the need for a separate decomposition chamber. The dosing module is integrated directly into the turbine outlet passage, combining multiple functions (exhaust gas transport, DEF dosing, decomposition, and mixing) into a single integrated system, thereby reducing overall system complexity.
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 the decomposition of aftertreatment fluid into reductants, improves mixing with exhaust gas, and reduces back-pressure, leading to increased engine efficiency and effective emission control.
Implementation Method 1
Exhaust gas leaving the internal combustion engine passes through the turbine, causing the turbine wheel to rotate. The rotation of the turbine wheel drives the compressor wheel, which acts to compress the intake air as it is delivered to the intake manifold.
Implementation Method 2
In the decomposition chamber, heat is exchanged from the exhaust gas to the DEF which causes the water within the DEF to evaporate and the urea to thermally decompose into the reductants ammonia (NH3) and Isocyanic Acid (HNCO) which are required to support the SCR reaction.
Implementation Method 3
the urea to thermally decompose into the reductants ammonia (NH3) and Isocyanic Acid (HNCO) which are required to support the SCR reaction.
Data Source
AI summary
There is disclosed a turbine dosing system for a turbocharger. The turbine dosing system comprises a turbine inlet passage (112), a turbine wheel chamber and a turbine outlet passage (116). The turbine inlet passage is configured to receive exhaust gas from an internal combustion engine. The turbine wheel chamber is configured to receive exhaust gas from the turbine inlet passage. The turbine wheel chamber contains a turbine wheel supported for rotation about a turbine wheel axis. The turbine wheel comprises an exducer defining an exducer diameter. The turbine outlet passage is downstream of the turbine wheel chamber and is configured to receive exhaust gas from the turbine wheel chamber. The turbine outlet passage is at least partly defined by a structure which comprises a dosing module mount (122) configured to receive a dosing module (32). The turbine outlet passage defines a flow axis which extends from a downstream end of the turbine wheel. The dosing module mount is located within around 10 exducer diameters, along the flow axis, downstream of the downstream end of the turbine wheel.