Variable Speed Air Pump and Gated Check Valve for Dual-Bank Engine Emissions
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Solution Overview
Problem
Conventional secondary air systems in vehicles lack control over airflow and pressure, leading to inefficiencies in emissions control and diagnostics, particularly in dual bank engines, and require multiple check valves and sensors, which can cause air leakage and complexity.
Innovation Solution
A secondary air system incorporating a variable speed air pump and a multi-position gated check valve with delta pressure feedback sensors, allowing for precise control of airflow between engine banks, eliminating the need for mass air flow sensors and reducing system complexity by enabling full or partial opening/closing of airflow, and using PWM signals for pump control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional secondary air systems use simple electrical/mechanical air pumps and one-way reed valves, then the system structure is simple, but the system lacks control over airflow and pressure leading to inefficiencies in emissions control
Solution Approach 1:
The patent applies a variable speed air pump instead of a fixed-speed pump, allowing the system to dynamically adjust airflow based on engine operating conditions. This dynamic control enables precise management of secondary air injection, improving emissions control efficiency while maintaining reasonable system complexity through electronic control.
Solution Approach 2:
The patent incorporates pressure sensors that provide feedback on exhaust pressure and airflow conditions. This feedback mechanism allows the control system to adjust pump speed and valve positioning in real-time, ensuring optimal emissions control efficiency by adapting to varying engine loads and operating conditions.
2Adaptability or versatility
If dual bank engines use multiple check valves to control airflow to each bank, then airflow control to individual banks is achieved, but system complexity increases and air leakage risks increase
Solution Approach 1:
The patent combines multiple check valve functions into a single multi-position gated check valve that can direct airflow to bank 1, bank 2, both banks, or neither bank. This consolidation reduces the number of components, simplifies the system structure, and maintains the ability to independently control airflow to each engine bank, thereby reducing air leakage risks while preserving adaptability.
Solution Approach 2:
The gated check valve is designed with multi-functionality, serving as a universal component that can perform multiple airflow routing functions (directing air to bank 1 only, bank 2 only, both banks, or shutting off completely) that would traditionally require multiple separate check valves. This universal component approach reduces system complexity while maintaining full adaptability for dual bank engine configurations.
3Use of energy by moving object
If secondary air systems operate only at startup to help burn rich air-to-fuel mixture, then the system is simple and energy-efficient, but emissions control is limited to cold start conditions
Solution Approach 1:
The variable speed air pump enables the secondary air system to operate dynamically across multiple operating conditions, not just at cold startup. The pump speed can be adjusted based on engine load, temperature, and emissions requirements, allowing the system to provide effective emissions control during both cold start and warm operating conditions, thereby expanding adaptability while managing energy consumption through selective operation.
Solution Approach 2:
The system utilizes parameter changes in pump speed and airflow rate to adapt to different operating conditions. By varying these parameters, the system can optimize emissions control for cold start conditions when the catalytic converter is not yet hot, and continue to provide beneficial emissions reduction during warm operation, thus expanding the operational envelope without excessive energy consumption.
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 solution enhances emissions control and diagnostics by providing consistent air injection and fuel control, improving cold start performance and reducing variability, while simplifying the system by eliminating redundant components and sensors, thus achieving better compliance with emissions and testing requirements.
Implementation Method 1
a fan motor contained within housing and being operable to be driven by a controller at a variable speed to draw air in from an input port and direct it towards an output port
Implementation Method 2
a multi-position gated check valve with delta pressure feedback sensors, allowing for precise control of airflow between engine banks
Implementation Method 3
at least one delta pressure feedback sensor positioned between a junction point where the variable speed air pump and gated check valve are connected, and one of the output ports of the gated check valve
Data Source
AI summary
A secondary air system comprising a variable speed air pump and a gated check valve connected between the variable speed air pump and an IC engine. The gated check valve has two ports, and generally, a first of the two ports is connected to a first bank of engine cylinders, and a second of the two ports is connected to a second bank of engine cylinders. The system further comprises a controller for controlling the speed of the variable speed air pump, and the positioning of the gated check valve. The gated check valve is operable to fully close air flow to both ports, fully open air flow to one of the two ports, or variably split air flow between the two ports.