Passive pumping for recirculating exhaust gas
11293382 · 2022-04-05
Assignee
Inventors
Cpc classification
F02M26/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M35/10262
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/19
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/09
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M21/047
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M35/10222
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02M26/19
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/09
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Multiple convergent nozzles define multiple flow passages in a flow path from an air inlet of the mixer to an outlet of the mixer. The convergent nozzles each converge toward the outlet of the mixer. An exhaust gas housing includes an exhaust gas inlet leading into an interior of the exhaust gas housing. Multiple convergent-divergent nozzles each correspond to one of the plurality of convergent nozzles. The convergent-divergent nozzles each include an air-exhaust gas inlet in fluid communication to receive fluid flow from a corresponding convergent nozzle and the interior of the exhaust gas housing.
Claims
1. An engine exhaust gas recirculation mixer, the mixer comprising: a plurality of convergent nozzles defining a plurality of flow passages that extend alongside one another in a flow path from an engine intake air inlet of the mixer to an outlet of the mixer, the plurality of convergent nozzles each converging toward the outlet of the mixer; an exhaust gas receiver housing comprising an exhaust gas inlet into an interior of the exhaust gas housing; and a plurality of convergent-divergent nozzles in the flow path each corresponding to one of the plurality of convergent nozzles, the plurality of convergent-divergent nozzles extending alongside one another, the plurality of convergent-divergent nozzles each comprising an air-exhaust gas inlet in fluid communication to receive fluid flow from a corresponding convergent nozzle and the interior of the exhaust gas housing, where each one of the air-exhaust gas inlets is upstream of a corresponding outlet of one the plurality of convergent nozzles.
2. The engine exhaust gas recirculation mixer of claim 1, wherein inlets of each of the convergent nozzles being in a same, first plane perpendicular to the flow path, and corresponding outlets of the convergent nozzles being in a same, second plane perpendicular to the flow path.
3. The engine exhaust gas recirculation mixer of claim 1, wherein the air-exhaust gas inlet of each of the convergent-divergent nozzles being in a same, third plane perpendicular to the flow path, and the corresponding outlet of each of the convergent-divergent nozzles being in a same, fourth plane perpendicular to the flow path.
4. The engine exhaust gas recirculation mixer of claim 1, where each of the convergent-divergent nozzles are aligned on a same center axis as a corresponding convergent nozzle.
5. The engine exhaust gas recirculation mixer of claim 1, where the plurality of convergent nozzles extend within the exhaust gas housing.
6. The engine exhaust gas recirculation mixer of claim 1, where each of the air-exhaust gas inlets has a greater area than the corresponding outlet of the corresponding one of the plurality of convergent nozzles.
7. The engine exhaust gas recirculation mixer of claim 1, where the plurality of convergent nozzles comprise four convergent nozzles and the plurality of convergent-divergent nozzles comprise four corresponding convergent-divergent nozzles.
8. The engine exhaust gas recirculation mixer of claim 1, where a divergent portion of the convergent-divergent nozzle diverges no more than 7°.
9. An engine exhaust gas recirculation mixer, the mixer comprising: a plurality of convergent nozzles defining a plurality of flow passages that extend alongside one another in a flow path from an engine intake air inlet of the mixer to an outlet of the mixer, the plurality of convergent nozzles each converging toward the outlet of the mixer; a fuel supply port positioned downstream of an inlet to the plurality of convergent nozzles; an exhaust gas housing comprising an exhaust gas inlet into an interior of the exhaust gas housing; and a plurality of convergent-divergent nozzles in the flow path each corresponding to one of the plurality of convergent nozzles, the plurality of convergent-divergent nozzles extending alongside one another, the plurality of convergent-divergent nozzles each comprising an air-exhaust gas inlet in fluid communication to receive fluid flow from a corresponding convergent nozzle and the interior of the exhaust gas housing, where the air-exhaust gas inlet of each of the plurality of convergent-divergent nozzles is an air-fuel-exhaust gas inlet in communication with the fuel supply port into the mixer.
10. The engine exhaust gas recirculation mixer of claim 9, where the fuel supply comprises: the fuel supply port positioned upstream of the convergent-divergent nozzle.
11. The engine exhaust gas recirculation mixer of claim 10, where the fuel supply port comprises a gaseous fuel supply port.
12. An engine exhaust gas recirculation mixer, the mixer comprising: a plurality of convergent nozzles defining a plurality of flow passages that extend alongside one another in a flow path from an engine intake air inlet of the mixer to an outlet of the mixer, the plurality of convergent nozzles each converging toward the outlet of the mixer; an exhaust gas receiver housing comprising an exhaust gas inlet into an interior of the exhaust gas housing; and a plurality of convergent-divergent nozzles in the flow path each corresponding to one of the plurality of convergent nozzles, the plurality of convergent-divergent nozzles extending alongside one another, the plurality of convergent-divergent nozzles each comprising an air-exhaust gas inlet in fluid communication to receive fluid flow from a corresponding convergent nozzle and the interior of the exhaust gas housing; a plurality of pressure ports at a convergent end of each of the plurality of convergent nozzles.
13. A method comprising: increasing a velocity and decreasing a pressure of an engine intake air flow using a first plurality of convergent nozzles to form a plurality of free jets exiting a corresponding one of the plurality of converging nozzles; drawing an engine exhaust flow, in response to the decreased pressure of each of the plurality of free jets, downstream of the first plurality of convergent nozzles; mixing, using a second plurality of convergent nozzles downstream of the first plurality of convergent nozzles, the each of the plurality of free jets and the exhaust flow to form a plurality of mixed flows corresponding to the plurality of free jets, each of the second plurality of convergent nozzles corresponding with a different one of the first plurality of convergent nozzles, where each one of the air-exhaust gas inlets is upstream of a corresponding outlet of one the plurality of convergent nozzles; and increasing a pressure and reducing a velocity of the plurality of mixed flows using a plurality of divergent nozzles each corresponding to a different one of the second plurality of convergent nozzles.
14. The method of claim 13, where mixing one of the plurality of free jets and the exhaust flow to form one of the pluralities of mixed flows comprises mixing a portion of the air flow, a portion of the exhaust flow, and a portion of a fuel flow, to form a combustion mixture.
15. The method of claim 14, comprising supplying the fuel flow upstream of the convergent ends of the first plurality of convergent nozzles.
16. The method of claim 14, where the fuel flow comprises a gaseous fuel flow.
17. The method of claim 13, comprising directing the exhaust flow from an exhaust manifold to a point downstream of the first plurality of convergent nozzles.
18. An engine system comprising: an engine intake manifold configured to receive a combustible mixture configured to be combusted within an engine combustion chamber; a throttle upstream of the intake manifold, the throttle configured to regulate an air flow into the intake manifold; an exhaust manifold configured to receive combustion products from the combustion chamber; and an exhaust gas recirculation mixer downstream of the throttle and upstream of the intake manifold, the exhaust gas recirculation mixer comprising: a plurality of convergent nozzles that extend alongside one another defining a plurality of flow passages in a flow path from an engine air intake air inlet of the mixer to an outlet of the mixer, the plurality of convergent nozzles each converging toward the outlet of the mixer; an exhaust gas receiver housing comprising an exhaust gas inlet into an interior of the exhaust gas housing; and a plurality of convergent-divergent nozzles in the flow path each corresponding to one of the plurality of convergent nozzles, the plurality of convergent-divergent nozzles extending alongside one another, the plurality of convergent-divergent nozzles each comprising an air-exhaust gas inlet in fluid communication to receive fluid flow from a corresponding convergent nozzle and the interior of the exhaust gas housing where each one of the air-exhaust gas inlets is upstream of a corresponding outlet of one the plurality of convergent nozzles.
19. The engine system of claim 18, comprising a compressor upstream of the throttle, the compressor configured to increase a pressure within the flow path.
20. The engine system of claim 19, comprising a turbine downstream of the exhaust manifold, the turbine being coupled to the compressor and configured to rotate the compressor.
21. The engine system of claim 19, comprising an exhaust gas cooler positioned within a flow path between the exhaust manifold and the exhaust gas recirculation mixer, the exhaust gas cooler configured to lower a temperature of the exhaust gas prior to the exhaust gas recirculation mixer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
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(6) Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
(7) Exhaust gas recirculation (EGR) can have parasitic effects on an engine system, that is, it can reduce the effective power output of an engine system as energy is required to move exhaust gas from an exhaust manifold and into an intake manifold. This is especially problematic on forced induction engines where the intake manifold pressure can be higher than the exhaust manifold pressure. Ironically, EGR is most needed when the intake manifold pressure is high, such as when the engine is running at high load. In the case of a turbo-charged engine, increased back-pressure within the exhaust manifold can also contribute to knock under high loads.
(8) The concepts herein relate to an EGR system that can be used on an internal combustion engine, including a forced induction internal combustion engine. A set of jet pumps arranged in parallel is added to the air intake system of the engine between the throttle and the intake manifold. If a compressor is provided in the intake system, the jet pumps can be placed downstream of the compressor (although it could alternatively be placed upstream of the compressor, too). Air, the primary fluid, flows through a central flow passage of each of the jet pumps from the throttle towards the intake manifold. In a low pressure receiver region within each jet pump, recirculated exhaust gas is added to each air stream from the exhaust manifold. The lower effective pressure in each receiver region allows for a pressure differential to form between the exhaust manifold and the receiver. The reverse Bernoulli Effect recovers the pressure by slowing down the high velocity/low pressure gas to create a pressure in the intake manifold that is equal to or higher than the exhaust manifold. So, at the system level, the jet pumps enable the exhaust gas to flow from the exhaust manifold to the intake manifold even when the exhaust manifold is at a lower pressure. Fuel can be added to the air stream upstream of the convergent end of the convergent nozzles. Turbulence is produced within the jet pumps and downstream of the jet pumps leading to a well-mixed, combustible mixture flowing into the manifold.
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(10) A throttle 112 is positioned upstream of the intake manifold 104. The throttle 112 is configured to at least partially or entirely regulate an air flow into the intake manifold from the ambient environment 116, for example, by changing a cross-sectional area of a flow passage going through the throttle 112. In some implementations, the throttle 112 can include a butterfly valve or a disc valve. Reducing the cross-sectional area of the flow passage through the throttle 112 reduces the flowrate of air flowing through the throttle 112 towards the intake manifold 104.
(11) An exhaust manifold 106 is configured to receive combustion products (exhaust) from a combustion chamber of the engine 102. That is, the exhaust manifold 106 is fluidically coupled to an outlet of the combustion chamber. An EGR flow passage 108 or conduit fluidically connects the exhaust manifold 106 and the intake manifold 104. In the illustrated implementation, an EGR throttle valve 126 is located within the EGR flow passage 108 between the exhaust manifold 106 and the intake manifold 104 and is used to regulate the EGR flow. The EGR throttle valve 126 regulates the EGR flow by adjusting a cross-sectional area of the EGR flow passage 108 going through the EGR throttle valve 126. In some implementations, the EGR throttle valve 126 can include a butterfly valve, a disc valve, a needle valve, a globe valve, or another style of valve.
(12) The EGR flow passage 108 feeds into an EGR mixer 114 that is located downstream of a throttle 112 and upstream of the intake manifold 104 in the illustrated implementation. The EGR mixer 114 is in the engine intake system, fluidically connected to the throttle 112, the intake manifold 104, and the EGR flow passage 108. The fluid connections can be made with conduits containing flow passages that allow fluid flow. In some implementations, the EGR mixer 114 can be included within a conduit connecting the intake manifold 104 to the throttle 112, within the intake manifold 104 itself, within the EGR flow passage 108, integrated within the throttle 112, or integrated into the EGR throttle valve 126. Details about an example EGR mixer are described throughout this disclosure.
(13) In some implementations, an exhaust gas cooler 110 is positioned in the EGR flow passage 108 between the exhaust manifold 106 and the EGR mixer 114. The exhaust gas cooler 110 can operate to lower a temperature of the exhaust gas prior to the EGR mixer 114. The exhaust gas cooler 110 is a heat exchanger, such as an air-air exchanger or an air-water exchanger. In some implementations, the exhaust gas cooler 110 is not included.
(14) In some implementations, the engine system 100 includes a compressor 118 upstream of the throttle 112. In an engine with a compressor 118 but no throttle, such as an un-throttled diesel engine, the throttle is not needed and the mixer can be down stream of the compressor. The compressor 118 can include a centrifugal compressor, a positive displacement compressor, or another type of compressor for increasing a pressure within the intake manifold 104 during engine operation. In some implementations, the engine system 100 can include an intercooler 120 that is configured to cool the compressed air prior to the air entering the manifold. In the illustrated implementation, the compressor 118 is a part of a turbocharger. That is, a turbine 122 is located downstream of the exhaust manifold 106 and rotates as the exhaust gas expands through the turbine 122. The turbine 122 is coupled to the compressor 118, for example, via a shaft 124, and imparts rotation on the compressor 118. In the illustrated implementation, the turbine 122 also increases a back-pressure within the exhaust manifold 106, thereby increasing the pressure within the EGR flow passage 108. While the illustrated implementation utilizes a turbocharger to increase the pressure within the intake manifold 104, other methods of compression can be used, for example an electric or engine powered compressor (e.g., supercharger). In some implementations, a separate controller 130 or engine control unit (ECU) is used to control various aspects of the system operation. For example, the controller 130 can adjust air-fuel ratios, spark timing, and EGR flow rates based on current operating conditions.
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(17) The EGR mixer 114 is made up of one or more housings or casings. Openings in the end walls of the casings define an air inlet 204 and an outlet 206 of multiple interior flow passages 222, defined by each of the barrels 200. The interior flow passages 222 direct flow from the air inlet 204 to the outlet 206 to allow flow through the EGR mixer 114. Within a casing(s) 224, the EGR mixer 114 includes multiple convergent nozzles 202, each associated with a barrel 200, that define interior flow passages 222 in a flow path from an air inlet 204 of the EGR mixer 114 to an outlet 206 of the EGR mixer 114. The convergent nozzles 202 each converge toward the outlet of the EGR mixer 114. That is, each of the convergent nozzles 202 converge in the direction of flow toward a convergent end 208. That is, the downstream end (outlet) of the convergent nozzle 202 has a smaller cross-sectional area, i.e., a smaller flow area, than the upstream end (inlet) 226 of the convergent nozzle 202. In some implementations, the inlets 226 of the convergent nozzles 202 are in a same, first plane 402, and corresponding outlets of the convergent nozzles 202 are in a same, second plane 404. In other words, the components of each barrel 200 are aligned in parallel such that each component receives fluid flow in parallel with one-another within standard manufacturing tolerances.
(18) The EGR mixer 114 includes an exhaust gas receiver housing 210 and the exhaust gas receiver housing 210 includes one or more exhaust gas inlets 212 fed from and fluidically connected to the EGR flow passages 108, and into an interior receiver cavity 228 of the exhaust gas receiver housing 210. In the illustrated implementation, the exhaust gas receiver housing 210 surrounds the convergent nozzles 202, such that a portion of the convergent nozzle 202 is within the interior receiver cavity 228. In some implementations, convergent-divergent nozzles 214 of each barrel 200 can be within the interior receiver cavity 228 as well. The convergent nozzles 202 are positioned to each form a free jet of gas out of the convergent end 208 of each nozzle 202. Also, the exhaust gas inlet 212 is upstream of an outlet 209, of each convergent nozzle 202. While the illustrated implementation shows an outlet 209 separate from a convergent end 208, other arrangements can be used, for example, the outlet 209 and the convergent end 208 can both be in the second plane 404 in some implementations. While the illustrated implementation shows the outlet 209 to extend (at least partially or entirely) within the exhaust gas receiver housing 210, other designs can be utilized. In some implementations, the air inlet 204 and the outlet 206 are provided with attachments or fittings to enable connection to the intake manifold 104 of the engine 102 and/or the EGR mixer 114. In some instances, the convergent nozzles 202 can be modularly interchangeable with convergent nozzles of different the inlet area 226 and convergent area 208, making the system readily changeable to fit multiple engine sizes. For example, the nozzles 202 can be provided with threads or another form of removable attachment to the remainder of the mixer casing 224. In some implementation, the convergent nozzles 202 can be integrated into the mixer casing 224 as a single, unitary piece.
(19) Within each barrel 200, a convergent-divergent nozzle 214 is downstream of the convergent end 208 of a corresponding convergent nozzle 202 and is fluidically coupled to receive fluid flow from the outlet 206, the exhaust gas inlet 212, and, in certain instances, a fuel supply 216. In other words, the convergent-divergent nozzle 214 can act as an air-fuel-exhaust gas inlet for the intake manifold 104 (
(20) In some implementations, the convergent nozzles 202 and the convergent-divergent nozzles 214 within each barrel 200 to be aligned at a same center axis 220, but in some implementations, the center axis 220 of the convergent nozzle 202 and the convergent-divergent nozzle 214 within each barrel 200 might not be aligned or parallel. For example, space constraints may require the EGR mixer 114 to have an angle between the axis of each of the convergent nozzles 202 and their corresponding convergent-divergent nozzles 214. In some implementations, rather than having a substantially straight flow passage as shown in
(21) In some implementations, the fuel supply 216 includes a fuel manifold 219 and fuel supply ports 218 upstream of each of the convergent ends 208 of the convergent nozzles 202 within the air flow path. Each fuel supply port 218 is configured to supply fuel into the air flow path and upstream of a corresponding convergent nozzle 202. In some implementations, the fuel supply port 218 can be a gaseous fuel supply port, coupled to a source of gaseous fuel; however, the fuel delivered by the fuel supply port 218 can include any combustible fluid, such as natural gas, gasoline, or diesel. The fuel supply port 218 supplies a fuel flow 306 from a fuel manifold 219. Though illustrated with a single fuel port 218 within each barrel supplied by the common fuel manifold 219, separate, discrete fuel supplies with separate, discrete ports can be used with similar effect. While shown as a single port within each barrel, the fuel supply ports 218 can be configured in other ways, for example, as multiple fuel supply ports along the perimeter of each barrel, or in another manner. While the illustrated implementation shows a fuel supply port 218 configured to inject fuel upstream of the convergent end 208 of the convergent nozzle 202, fuel can also be added with a fuel supply port 218 upstream of the exhaust gas inlet 212. Such a port can include a gaseous fuel supply port.
(22) A pressure port 356 is positioned downstream the convergent portion 203 of each of the convergent nozzles 202. The pressure port 356 provides a location to sense pressure downstream of a convergent end 208 of each of the convergent nozzles 202 by allowing fluid communication between the interior flow passage 222 and a common pressure sensing manifold 354. A pressure sensor 352 senses a pressure within the common pressure sensing manifold 354 and sends a signal to the controller 130 indicative of the pressure within the common pressure sensing manifold 354. Though illustrated with a single sensor on a common manifold, separate, discrete sensors with separate, discrete ports can be used with similar effect. Alternatively or in addition, a virtual sensor can be used in lieu of a discrete sensor. That is, the pressure can be calculated based on the known geometry of the convergent nozzles and other information received from various sensors throughout the system.
(23) The pressure sensed by the pressure sensor 352 can be compared to a sensed pressure elsewhere either upstream or downstream of the EGR mixer 114 to determine a differential pressure. The determined differential pressure can be used to determine a mass air-flow (MAF) rate passing through the EGR mixer 114. In certain instances, such a calculation can be performed by the controller 130 (
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(25) The illustrated implementation operates as follows. The first set of convergent nozzles 202 each increase a velocity and decrease a pressure of a portion of an air flow 302 in the EGR mixer 114 to form multiple free jets exiting a corresponding convergent nozzle 202. An exhaust flow 304 is drawn into the EGR mixer 114 through the exhaust gas inlet 212 in response to (e.g., because of) the decreased pressure of each of the free jet air flows 302 exiting the convergent nozzles 202. The exhaust flow 304 is directed from the exhaust manifold 106 eventually to the point downstream of the convergent nozzles 202. The air flow 302, the exhaust flow 304, and a fuel flow 306 are mixed to form multiple mixed flows 308 that act as a combustion mixture. The mixed flows 308 are mixed with a second set of convergent nozzles 214a positioned downstream of the corresponding first convergent nozzles 202. Each of the second set of convergent nozzles 214a corresponds to a different one of the first set of convergent nozzles 202. A pressure of each of the mixed flows is increased, and a velocity of each of the mixed flows 308 is reduced with a set divergent nozzles 214b each corresponding to a different one of the second of convergent nozzles 214a. While each of the second set of convergent nozzles 214a and each of the set of divergent nozzles 214b are illustrated as unitary convergent-divergent nozzles 214, each of the second set of convergent nozzles 214a and each of the set of divergent nozzles 214b can be separate and distinct parts.
(26) In the illustrated implementation, the fuel flow 306 is supplied into the air flow 302 with a fuel supply port 218 located on the side of each of the convergent nozzles 202. The fuel flow 306 is supplied upstream of the convergent end 208. In some implementations, the fuel flow 306 is supplied into the exhaust flow 304 with a fuel supply port 218. Regardless of the implementation used, the fuel flow 306 can include a gaseous fuel flow.
(27) While this disclosure contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
(28) Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.
(29) Thus, particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results.