Efficiency and emissions improvements for natural gas conversions of EMD 2-cycle medium speed engines

Abstract

A prechamber assembly includes a cylinder head including a coolant cavity, a prechamber body located within the cylinder head, the prechamber body including a nozzle, and an annular sleeve radially surrounding a portion of the prechamber body. The sleeve includes a plurality of coolant inlet holes. A portion of the prechamber body is radially spaced from the sleeve to form a coolant sleeve annulus extending along a length of the prechamber body above the coolant inlet holes. The coolant cavity and the coolant sleeve annulus are in fluid communication through the plurality of coolant inlet holes.

Claims

1. A prechamber assembly comprising: a cylinder head including a coolant cavity; a prechamber body located within the cylinder head, the prechamber body including a nozzle and a coolant exit port; and an annular sleeve radially surrounding a portion of the prechamber body, the annular sleeve including a plurality of coolant inlet holes; wherein a portion of the prechamber body is radially spaced from the annular sleeve to form a coolant sleeve annulus extending along a length of the prechamber body above the coolant inlet holes; wherein the coolant cavity and the coolant sleeve annulus are in fluid communication through the plurality of coolant inlet holes; wherein the plurality of coolant inlet holes is positioned towards the end of the coolant sleeve annulus closest to the nozzle and the coolant exit port is positioned near a top of the prechamber body.

2. The prechamber assembly of claim 1 wherein the annular sleeve further includes a plurality of coolant outlet holes, wherein the plurality of coolant inlet holes is positioned towards the end of the coolant sleeve annulus closest to the nozzle.

3. The prechamber assembly of claim 2 wherein the coolant outlet holes are in fluid communication with a coolant return cavity.

4. The prechamber assembly of claim 1 further including a coolant comprising water.

5. The prechamber assembly of claim 1 wherein the prechamber body includes a feed groove distal from the nozzle and in fluid communication with the cooling cavity, wherein the coolant cavity spans from the feed groove to the plurality of coolant inlet holes.

6. The prechamber assembly of claim 1 further including a coolant comprising engine oil.

7. The prechamber assembly of claim 1 wherein the annular sleeve and the nozzle are integral.

8. A prechamber assembly comprising: a cylinder head including a coolant cavity; and a prechamber body located within the cylinder head, the prechamber body including a nozzle and a coolant exit port; wherein the nozzle includes a plurality of jets directing flow through the nozzle at an angle other than parallel or perpendicular relative to a longitudinal centerline axis of the nozzle, wherein the plurality of jets is clustered in groups radially spaced apart from each other around the longitudinal centerline axis of the nozzle; and wherein the coolant exit port is positioned near a top of the prechamber body.

9. The prechamber assembly of claim 8 wherein the groups of jets are equally spaced radially.

10. The prechamber assembly of claim 8 wherein flow through the jets of each group of jets converges at a distance from the nozzle.

11. The prechamber assembly of claim 8 wherein each group of jets comprises two jets.

12. The prechamber assembly of claim 8 wherein the nozzle further includes a centerline jet aligned along the centerline axis.

13. The prechamber assembly of claim 8 wherein the nozzle further includes a centerline group of jets aligned approximately parallel to the centerline axis.

14. The prechamber assembly of claim 8, wherein flow through the centerline group of jets converges at a distance from the nozzle.

15. A prechamber assembly comprising: a cylinder head including a coolant cavity; and a prechamber body located within the cylinder head, the prechamber body including a nozzle and a coolant exit port; wherein the nozzle includes a plurality of jets, each jet aligned along a respective axis that is offset from a centerline axis of the nozzle such that the jet axes do not intersect the centerline axis; wherein the coolant exit port is positioned near a top of the prechamber body.

16. The prechamber assembly of claim 14 wherein the nozzle includes a mixing area, and wherein each jet axis of the plurality of jets is offset an equal distance from the centerline axis such that flow through the plurality of jets causes a rotating flow about the centerline axis in the mixing area of the nozzle.

Description

DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a side view of a typical 16 cylinder EMD turbocharged engine as used in locomotives.

(2) FIG. 2 is a side view of the same engine in FIG. 1 except that the exhaust system has been revised to accommodate a single substrate OC system.

(3) FIG. 2A is an isometric view of a prior art exhaust runner.

(4) FIG. 2B is an isometric view of an embodiment of an exhaust runner of the engine of FIG. 2.

(5) FIG. 2C is an isometric view of an embodiment of an OC substrate of the engine of FIG. 2.

(6) FIG. 3 is a side view of the prior art Miratech preturbine V-Cat system.

(7) FIG. 4 is a side view of an EMD 16 cylinder illustrating the location of the Variable Inlet Guide Vane Unit.

(8) FIG. 5 is an isometric view of the turbocharger and the Variable Inlet Guide Vane Unit with its blades closed.

(9) FIG. 6 is an isometric view of a prior art Variable Inlet Guide Vane Unit with the blades partially open.

(10) FIG. 7 is an isometric view of an ECI manufactured gas inlet valve (GIV).

(11) FIG. 8 is cross section view of a conventional poppet valve in the open position of a prior art GIV.

(12) FIG. 9 is a cross section view of the revised poppet valve and valve seat insert to achieve sonic gas injection flow.

(13) FIG. 10A is a cross section view illustrating a dual stage hydraulic valve assembly in the closed state.

(14) FIG. 10B is a cross section view illustrating a dual stage hydraulic valve assembly in the fully open state.

(15) FIG. 10C is a cross section view illustrating a dual stage hydraulic valve assembly in the partially open state.

(16) FIG. 11 is a cross section view of an EMD cylinder head with a prechamber installed.

(17) FIG. 12A is an enlarged view of the prechamber body of the EMD cylinder head of FIG. 11.

(18) FIG. 12B is an enlarged, fragmentary view of the prechamber body of FIG. 12A.

(19) FIG. 13A is a Section View of a truck engine cylinder head with a prechamber assembly installed.

(20) FIG. 13B is an enlarged view of the XXX of the truck engine cylinder head of FIG. 13A.

(21) FIG. 14 is an exploded view of an OPOC engine Variable Compression Ratio system.

(22) FIG. 15A is a table illustrating the firing order variations for a 12 cylinder EMD 2-stroke engine.

(23) FIG. 15B is a table illustrating the firing order variations for a 16 cylinder EMD 2-stroke engine.

(24) FIG. 16A is a section view of a prechamber nozzle with grouped and offset TJI jets.

(25) FIG. 16B is an isometric view of a prechamber nozzle with a single axial TJI jet.

(26) FIGS. 17-22C illustrate additional views of nozzles including TJI jets.

DETAILED DESCRIPTION

(27) To facilitate an understanding of the present disclosure, a number of terms and phrases are defined below:

(28) Gaseous Fuel: The predominant gaseous fuel used in internal combustion engines is natural gas consisting mostly of methane, but with minor modifications these engines could consume any gaseous fuel including but not limited to propane, natural gas and hydrogen. In this document the term natural gas and gaseous fuel are used interchangeably.

(29) Hydrocarbon (HC): Emissions resulting from incomplete combustion.

(30) Main Charge: The air fuel mixture in the main combustion chamber space between the piston top and the cylinder head. If an opposed piston engine, this would be the space between the opposed piston faces.

(31) Particulate Matter (PM): Particulate matter is a criteria pollution emitted from many sources. In this document we will commonly refer to it simply as PM. It could include both diesel soot PM that is considered toxic in California or the type of PM created by the consumption and combustion of lube oil from an engine. While still considered PM as a criteria emission, the PM from lube oil consumption is considered less toxic than diesel soot.

(32) The first portion of the detailed description is most closely related to a single element preturbine oxidation catalyst element for EMD turbocharged engines using twisted exhaust runners. FIG. 1 is a side view of a typical 16 cylinder EMD turbocharged engine as used in locomotive and marine applications. In this prior art configuration Engine 2 has an exhaust system along the top of it. The exhaust system is composed of three exhaust collector segments 4 and one turbocharger adapter exhaust collector segment 8 that collect the exhaust gases from the 16 engine cylinders into one combined exhaust mass flow. Each one of these exhaust collector segments connects to 4 of the engines 16 cylinders, with exhaust gases flowing from an individual engine cylinder to an exhaust collector segment through an exhaust runner 6. The standard exhaust runner 6 is a 4 inch by 9 inch rectangular tube as illustrated in FIG. 2A. The longer 9 inch dimension is shown along FIG. 1 as going left to right and the four inch dimension is normal to FIG. 1. The exhaust gasses flow in a direction from the bottom of the Figure through an exhaust runner 6 up into an exhaust collector segment. Each exhaust collector segment has two pairs of exhaust runners 6, only one is visible as the second exhaust runner 6 of each pair is directly behind the first exhaust runner 6. In some version of the EMD engines, the pairs of exhaust runners 6 are combined together into one larger runner. Sometimes this larger runner would have a shared wall in between, keeping the exhaust gases from the two cylinders separate until they mixed with the combined exhaust flow in the exhaust collector segments. In other cases this was missing or removed and the exhaust gases from the pair of engine cylinders would mix in the combined exhaust runner 6 volume before mixing with the combined exhaust flow in the exhaust collector segments. This would appear the same in FIG. 1 and functionally does not affect this description of the prior art.

(33) The three exhaust collector segments 4 and one turbocharger adapter exhaust collector segment 8 are connected to each other by flexible bellows 5 at three places. The now combined exhaust gasses flow from the turbocharger adapter exhaust collector segment 8 thru debris screen housing 10 and small flexible bellows 12 into the turbocharger inlet 14. As the combined exhaust mass flows through the debris screen housing 10, it must pass through debris screen 16. Debris screen 16 is a metal plate installed in debris screen housing 10 with a large number of small holes that will allow the exhaust gases to flow through it, but will block any small solid parts from traveling with the exhaust gases into the turbocharger and damaging the turbine blades. This debris screen 16 does cause a small pressure drop in the exhaust system which reduces engine performance and efficiency, but it prevents damage to the turbocharger assembly in the case of a component failure elsewhere in the engine. This is a valuable trade off as the turbocharger is one of the most expensive parts of the engine.

(34) FIG. 2 is a side view of the same engine in FIG. 1 with a revised exhaust system to include a single substrate OC system. Engine 2′ has similar components in its exhaust system upstream of turbocharger adapter exhaust collector segment 8′ and downstream of debris screen housing 10′. The primary difference is the deletion of the debris screen 16 and the addition of the OC substrate 18 into modified turbocharger adapter exhaust collector segment 8′.

(35) Turbocharger adapter exhaust collector segment 8′ has been modified to allow the OC substrate 18 as shown in FIG. 2C to slide into it. The primary modification to make this possible is the reshaping of exhaust runner 6′. Where exhaust runner 6 had a consistent 9 inch by 4 inch rectangular shape along its path as shown in FIG. 2A, the cross section of exhaust runner 6′ will change along its length as shown in FIG. 2B. It will start with the same 9 inch by 4 inch shape at the engine cylinder port, but as it travels towards the turbocharger adapter exhaust collector segment 8′ its shape will transform as depicted in FIGS. 2 and 2C. The goal is to have a similar cross section area along the exhaust flow path of exhaust runner 6′, but have the length and width dimension transition from 9 inches by 4 inches at a runner first end 6′-a to something close to 4 inches by 9 inches at a runner second end 6′-b. This will allow the creation of a cylindrical pocket that allows OC substrate 18 to slide in. The pocket does not need to be cylindrical, but the changing cross section of the exhaust runners 6′ is what allows a single OC substrate 18 to fit between the exhaust runner 6′ and the small flexible bellows 12.

(36) Referring to FIG. 2C, the OC substrate 18 is likely to be a round metallic substrate approximately 18″ in diameter and 5″ thick. These sizes and substrate material composition will vary depending on system design. OC substrate 18 may slide all the way into either turbocharger adapter exhaust collector segment 8′ or into debris screen housing 10′, but is most likely to protrude partially into each. Other shapes of substrate and pockets to fit it in may not be cylindrical, but may be oval or rectangular.

(37) In this embodiment it is designed that the OC substrate 18 slides into a pocket created in turbocharger adapter exhaust collector segment 8′ and is retained in that pocket by debris screen housing 10′. In another embodiment, turbocharger adapter exhaust collector segment 8′ and debris screen housing 10′ may be combined into one assembly with OC substrate 18 sliding into this assembly from direction normal or close to normal to the axis of exhaust gas flow. This would require some kind of cover plate to be used to cover the pocket opening similar to the cover plates used in the Miratech V-Cat design.

(38) FIG. 3 is a side view of the prior art V-Cat system 80 patented and manufactured by Miratech. The V-Cat system 80 comprises four exhaust collector segments 82 which replace the three exhaust collector segments 4 and one turbocharger adapter exhaust collector segment 8 from FIG. 1. In each exhaust collector segment 82 are four individual OC substrates to service the exhaust gases of four engine cylinders. A pair of OC substrates is captured on each side of a exhaust collector segment 82 by a cover 84. Each exhaust collector segment 82 has four exhaust runners 86 similar to the exhaust runners 6 in FIG. 8 and FIG. 9.

(39) It is a cover similar to cover 84 that could be used to retain a single OC substrate 18 into a combined turbocharger adapter exhaust collector segment 8′ and debris screen housing 10′.

(40) The second portion of the detailed description is most closely related to adjustable inlet guide vanes for improved emissions in EMD locomotives.

(41) FIG. 4 is a side view of a 16 cylinder EMD engine 2. Turbocharger 15 is mounted to engine 2. Variable inlet guide vane unit 6 is mounted to the compressor inlet of turbocharger 4. Even with as much value and performance that the variable inlet guide vane units adds, FIG. 4 illustrates what a small and easy to package system the variable inlet guide vane unit is. No parts on the engine need to be replaced, only the intake pipe bringing in outside air to the turbocharger compressor inlet. On the other hand this unit may allow the simplification and cost reduction of the ECI conversion kit by eliminating the waste gate assembly the aftercooler diverter valve and its extra plumbing.

(42) FIG. 5 is an isometric view of the engine turbocharger 24 and the variable inlet guide vane unit 26. In this view the guide vanes 28 are in the fully closed position, this leaves a small flow area 30 formed by the blade tips. In the prior art version of this device the valve was either fully open or fully closed, manipulation of this state was done by actuator 32.

(43) New embodiments of this system will have actuator 32 upgraded to have variable positions. In one embodiment a 90 degree variable position actuator may be used and the fully closed position will not have the guide vanes 28 rotated so far that they touch. This now allows the vanes when rotated 90 to have traveled past neutral and be positioned at an angle to cause increased boost at notch 6 or act as a waste gate limiting turbine rpm at notch 8.

(44) A further embodiment will have an actuator like the Delphi Smart Remote Actuator that has 120 degrees of travel. With this variable actuator, the guide vanes 28 can be rotated fully closed and still have the range to rotate 30 degrees past neutral well into the range where notch 6 boost is increased.

(45) FIG. 6 is an isometric view of a prior art inlet guide vane unit 26′ with the guide vanes 28′ partially open.

(46) The third portion of the detailed description is most closely related to a sonic and dual stage gas inlet valve that could also be used for continuous water injection.

(47) FIG. 7 is an isometric view of a standard ECI GIV assembly 40. It illustrates the relationship between the GIV body 41 the valve seat insert 42 and the poppet valve 43. In this view the poppet valve is in the fully extended position. This particular valve assembly is designed to inject natural gas into and EMD 2 Stroke natural gas engine on the compression stroke. It is possible to use this direct injection valve design and any embodiment of the current invention in any reciprocating engine using any gaseous fuel. This GIV could also be used for direct and continuous water injection. Gaseous fuel is supplied to the GIV at natural gas inlet 46, secondary inlet 47 is where a supplemental water injector could be located. The mixed gaseous fuel and water mist could then exit the GIV into the combustion chamber at natural gas exit 48

(48) FIG. 8 is a cross section view of the prior art GIV assembly 40 from FIG. 7. FIG. 8 illustrates the poppet valve 43 and valve seat insert 42 when the poppet valve is fully extended. This valve is typical in construction to the exhaust and intake valves in most reciprocating piston engines. The valve seat area 44 is around 0.065″ wide and the valve seat angle is 60 degrees from the valve axis. The intent of this valve system is specifically to allow the most airflow to pass through it with the minimal amount of pressure drop during the time is has available to be open. There is minimal consideration as to what the characteristics the exiting airflow has and the pressure drop across these valves is typically under 2:1 for conventional engine intake and exhaust valves and up to 4:1 for the GIV units used on turbocharged EMD engines with a natural gas feed pressure of 80 psi.

(49) FIG. 9 is a cross section of the new poppet valve 43′ and valve seat insert 42′ design. Just the modification of these two parts converts ECI's standard GIV into a version that creates a sonic cone of injected gaseous fuel. The view on the left shows the valve in the closed position. Significantly different from FIG. 8 is that the flow cone angle is 50 degrees instead of 120. The valve seat angle is actually 25 degrees from the axis of poppet valve 43′ instead of 60 degrees in the prior art design. The cone angle could be more or less than and 50 degrees. The narrower this angle is, the further into the cylinder bore that the gaseous fuel travels before it impinges on the cylinder wall for improved mixing.

(50) FIG. 10A is a cross section view of a hydraulic actuator for the GIV assembly 40 with two discrete open positions. This view illustrates the GIV assembly 40 in the closed position. In this view the plunger 51 is inside of the plunger body 50, and it is the plunger 51 that the hydraulic fluid pushes down on to open up the poppet valve 43. These two parts are consistent with the standard prior art version of GIV assembly 40. What is added in this embodiment is the plunger follower 52, the plunger stop body 55 and the movable plunger stop 54.

(51) FIG. 10B the GIV assembly 40 is in the full open position. The plunger 51 was forced down by the hydraulic fluid until it contacted the movable plunger stop 54. The movable plunger stop 54 is resting on the top surface of the plunger stop body 55. When the plunger 51 started to move in the downward direction, it contacted, pushed down on and moved the plunger follower 52. The plunger follower 52 was in contact with the top of the poppet valve 43 and pushed it down also. All three parts continued to move downward until the plunger motion 51 was stopped as it contacted the movable plunger stop 54.

(52) FIG. 10C illustrates the GIV assembly 40 in the partially open position. To stop the poppet valve 43 in this position, pressurized hydraulic fluid is fed into the plunger stop hydraulic port 53. This pressurizes the plunger stop hydraulic cavity 57 and this pressure forces the movable plunger stop 54 to move up until it contacts the bottom of the plunger body 50. With the movable plunger stop 54 in this position, the plunger 51 now travels a shorter distance before contacting the movable plunger stop 54 which will now limit the poppet valve 43 opening to a reduced stroke in the partially open position. The movable plunger stop 54 is able to keep the plunger 51 from moving it down because it has more surface area exposed to the hydraulic fluid pressure in the plunger stop hydraulic cavity 57.

(53) This system could be designed to have more than one movable stop by multiplying certain features in this design.

(54) The standard way to operate an ECI low pressure direct injection EMD conversion is to have the valves stay open for set amount of time for each piston stroke. This time period is set by the amount of time available at high RPM to inject gas after the intake ports are closed. After this time period is set, the engine load is controlled by adjusting the gas supply pressure to the injectors. As the load and RPM decreases and less fuel is required, the supply pressure is decreased. It would be possible to maintain a constant pressure and then reduce the injection time as fuel demand decreased, but that may decrease the amount of air and fuel mixing because the high velocity fuel gas was injected for a shorter period of time.

(55) On a fuel system using standard poppet valves that achieve sonic flow at the valve periphery this would be a measurable effect.

(56) This is the primary advantage of the GIV with multiple valve stroke settings. It reduces the total amount of injector feed pressure, instead of reducing the pressure for all 8 throttle notches in a locomotive. The pressure could be reduced incrementally for Notches 7 and 6, and then Notch 5 will have the GIV assembly 40 operate at reduced poppet valve 43 lift and a slightly longer valve open time because the RPM is now lower. From this point both the valve open time and gas supply pressure will be reduced incrementally down to the minimum flow needed at idle. The goal is to have the GIV fuel gas feed pressure remain high enough that good mixing is maintained, but balance that with manipulation of the valve open time to maximize the amount of time the high velocity injected gas is mixing with the air in the combustion chamber.

(57) As an example, instead of having a constant 80 milliseconds of injection time starting at a pressure of 300 and dropping to 100 at notch 1, now the highest 3 throttle notches will have an 80 ms injection time and pressure will drop to 250 in notch 6. At throttle notch 5 the injection time is raised to 115 ms, the poppet valve 43 lift is 40% of full open and the injector feed pressure is raised back to 300. By notch 3 the injection time has be lowered back to 80 ms and pressure feed pressure has only been reduce down to 275. By throttle notch 1, the pressure has been further reduced to 220. By ending at a 220 psi supply pressure instead of 100 psi, the exit velocity of the gas leaving the GIV should still be sonic. If it had dropped down to 100 psi, it would likely have become subsonic in the GIV.

(58) An interesting further use of this concept would be in large ship engines. Both 2 stroke and 4 stroke engines that are diesel pilot ignited would benefit from added swirl in the combustion chamber. Any number of these GIV's could be placed offset from the engine cylinder axis and tilted at an angle to induce a swirl to the air in the combustion chamber. If more than one supersonic GIV is used, they should have a similar angle in reference to the engine cylinder axis so that they induce swirl in the same direction. This swirl of air around the engine cylinder axis in the combustion chamber improves the combustion of the diesel pilot helping to lower PM or NOx emissions. This is because the swirl improves the air utilization during mixing controlled combustion as the surface of the diesel fuel jet is in contact with more air molecules than it would be if the air was stationary.

(59) Another interesting possibility will be the incorporation of sonic flow GIV's with an opposed piston engine. If only one sonic GIV was used per cylinder there would be the risk of the gas flow impinging on the opposite cylinder wall. This may or may not have detrimental effects such as a colder spot at the cylinder wall with possible lubrication or thermal stress issues. If cylinder wall impingement is to be avoided or for improved mixing, two of these sonic GIV's could be placed directly opposite of each other across the combustion chamber, in this case the two cone shape flows would collide in the middle of the chamber causing a great amount of turbulence and entraining significantly more intake air in the cylinder before the cold gases reach the cylinder walls.

(60) The fourth portion of this detailed description is most closely related to prechamber cooling sleeves including single and double pass variations.

(61) FIG. 11 is a cross section of a cylinder head 58 illustrating the placement of the prechamber 59 in relation to the cylinder head 58 and the piston 70′. The o-ring 61 at the top creates a cavity between the prechamber 59 outer surface and the cylinder head 58 pocket wall, this cavity is sealed at the bottom where the lower tapered section of the prechamber 59 is forced against the bottom of the cylinder head 58 pocket. This seal at the bottom is designed to resisted blow by of combustion gasses when the engine is operating so it will not have an issue keeping the prechamber coolant out of the engine cylinder.

(62) At the top of the prechamber 59 is the cooling fluid inlet 60. Pressurized Cooling fluid is injected here and an internal passage brings the cooling fluid to an exit port on the outer surface of the prechamber below the o-ring 61. The prechamber cooling fluid can be many different fluids including water, but in this preferred embodiment it would be engine oil to eliminate the need for return plumbing to a separate cooling fluid reservoir.

(63) In this embodiment, the cooling fluid is injected into a feed groove 67 around the prechamber 59. This feed groove 67 acts as a manifold and helps distribute the cooling fluid around the entire circumference of the prechamber body 59 before it starts to flow through the narrow cavity between the prechamber body 59 and cylinder head 58 wall. This is considered the first pass of the coolant in a double pass prechamber cooling system.

(64) In this prechamber embodiment is a diesel injector, this prechamber configuration uses a micropilot of diesel fuel to start ignition. This invention would work in a similar fashion with a spark plug ignited prechamber with or without additional fuel being added to the prechamber 59.

(65) Another embodiment not depicted could replace the single feed groove 67 around the prechamber body 59 with a spiral groove. The upper portion of the prechamber body 59 has a thicker wall section and in this area of the prechamber body a spiral groove could be cut into the outer surface of the prechamber. Possibly 10 to 15 turns, it would appear similar to an acme square thread except the eternal thread feature would be thin compared to the size of the passage. This spiral passage would slow the cooling fluid down allowing it more time to absorb heat from the prechamber body. The spiral groove feature could also give the cooling fluid more than twice the surface area to transfer heat.

(66) FIG. 12A is a close up cross section of the lower half of the prechamber body 59. FIG. 12B is a detail view of FIG. 12A. Clearly visible is the prechamber nozzle 68 that slides over the prechamber body 59 from the bottom. The prechamber nozzle 68 is designed to contact the prechamber body 59 at two points with press fit pilots. There is a press fit pilot at the top of the prechamber nozzle 68; this pilot is in a low stress area and only seals against the cooling fluid going from the coolant first pass straight to the coolant collection groove. This is also the area that the prechamber nozzle 68 and the prechamber body 59 could be optionally welded together.

(67) If the prechamber body 59 upper half was equipped with an optional spiral coolant groove it would end before the optional weld area.

(68) The second contact point between the prechamber nozzle 68 and the prechamber body 59 is the press fit at the bottom of the prechamber nozzle 68. This press fit is important as it seals the prechamber combustion area from the coolant cavity around the prechamber 59. The thermal expansion stress from the prechamber body 59 heating up and the forces of combustion both enhance the sealing capacity.

(69) With or without the optional spiral cooling groove, the coolant first pass 64 starts at the point the cooling fluid is first injected at feed groove 67 on the exterior of the prechamber 59 and continues down the length of the outer surface of both the prechamber body 59 and prechamber nozzle 68. As the cooling fluid moves along the coolant first pass 64, it will be simultaneously absorbing heat from the prechamber 59 and prechamber nozzle 68 and transferring that excess heat to the cylinder head 58 surface.

(70) Just before the contact point where the prechamber nozzle 68 seals to the cylinder head 58, there is a ring of radial coolant inlet holes 66. These radial coolant inlet holes 66 are at the end of the coolant first pass 64 and the start of the cooling sleeve annulus 65. These radial coolant inlet holes 66 are equally spaced small holes around the prechamber nozzle 68 and the pressure drop that the cooling fluid experiences as it transitions these radial coolant inlet holes 66 equalizes the flow around the perimeter of the prechamber nozzle 68. This encourages the flow before and after the radial coolant inlet holes 66 to be more evenly distributed even if the thickness of the first and second coolant passes may vary slightly due to machining tolerances of the prechamber 59 or the head 58.

(71) Once the cooling fluid enters the cooling sleeve annulus 65, it will flow upwards around the outside of the prechamber 59 and the inside surface of the prechamber nozzle 68. This cooling fluid ends up collecting in coolant return groove 62 and exiting prechamber 59 through coolant exit port 63. This cavity for cooling sleeve annulus 65 should be thinner than that of coolant first pass 64 so that the cooling fluid travels faster and picks up less heat. The goal is to absorb only the amount of heat required out of the prechamber 59 body, but not so much that it can over heat the cooling fluid or over cool the prechamber body. When the coolant fluid is oil, overheating will result in the oil coking in this area and the corresponding overheating and failure of the prechamber due to lack of cooling fluid. A slower velocity along the outside of the prechamber nozzle 68 in the coolant first pass 64 will allow the cooling fluid to absorb more heat from the prechamber nozzle 68 and transfer it to the cylinder head 59 wall.

(72) There are three general goals of prechamber cooling; keeping the spark plug from overheating, keeping the prechamber nozzle 68 from getting hot enough to cause pre-ignition, while keeping the prechamber 59 inner combustion chamber walls hot enough to insure easy and rapid combustion internally.

(73) The coolant first pass around the top of the prechamber 59 is the area that will control spark plug temperature. The optional spiral cooling groove could enhance that cooling if needed. Prechamber nozzle 68 will get cooling from both coolant passes and will transfer some heat to the cylinder head 58 at its contact point. The heat transfer between contacting metal surfaces can be an order of magnitude less than the heat transfer through conduction of the base metal. Although the prechamber nozzle 68 to cylinder head contact 58 point is a cooling path, it is likely that significantly more heat from the nozzle is conducted up through the nozzle and absorbed by the cooling fluid that passes by two surfaces on the nozzle. The prechamber 59 wall around the prechamber combustion chamber is left as thick as possible to reduce the heat conduction rate and it is only cooled by a single pass of the cooling fluid.

(74) By the time the coolant has gotten to the end of the second pass in a double pass cooling sleeve, it may have gotten too hot to be effective. This will cause the lower part of the prechamber to be cooled more effectively and the cooling fluid could actually be over heated by the time it reaches the end of the cooling sleeve annulus 65.

(75) In another embodiment a second set second radial inlet coolant holes 65 would function as bypass coolant holes that could allow some coolant to bypass the bottom of the prechamber body and start further up the coolant sleeve annulus 65. These holes would allow some coolant to travel an abbreviated distance through the coolant sleeve annulus 65 of the nozzle 68, therefor increasing the total amount of coolant fluid mass and decreasing the average temperature of the coolant that is used in last sections of the cooling sleeve annulus 65 of the double pass system. This also would slightly raise the temperature of the material at the start of the second pass as there would be less coolant going by.

(76) In another embodiment, the addition bypass coolant holes can be at multiple axial distances from the first radial cooling inlet holes 66 for even more even distribution of coolant temperature along the cooling sleeve annulus.

(77) Although nozzle 68 in this embodiment is pictured with an integrated cooling sleeve, alternate embodiments could have the cooling sleeve manufactured as a separate part from nozzle 68 with minimal change in the performance of the prechamber cooling system.

(78) FIG. 13A is a preferred embodiment of a prechamber 59′ for installation into a Detroit Diesel Series 60 diesel truck cylinder head 58′ instead of an EMD locomotive engine. In cylinder head 58′ there is a coolant cavity 92 that contains jacket water coolant for cooling the cylinder head. Typically this coolant will be a mixture of glycol and water. There are also two fuel return cavities 91 that would have been used to supply and return fuel for the diesel fuel injectors. In this embodiment those diesel injectors have been replaced by prechamber 59′. In this embodiment, it will be jacket water coolant instead of oil that will be used to cool the prechambers, and this coolant will have to be captured and returned to the engine cooling system. In this embodiment fuel return cavities 91 are used for the collection and transfer of prechamber cooling fluid out of the engine back to the jacket water cooling radiator system.

(79) FIG. 13B is a detail view of FIG. 13A and illustrates a prechamber cooling system that has a separate nozzle 68′ and cooling sleeve 93. In this case the coolant is in a single pass configuration starting from the coolant cavity 92, flowing through the radial coolant inlet holes 66′, up through the coolant sleeve annulus 65′ and exiting the prechamber 59′ through radial coolant exit holes 94 into fuel return cavity 91′.

(80) The fifth portion of this detailed description is most closely related to a variable compression ratio mechanism for an OPOC engine. This variable compression ratio system would operate on the outer pistons in the OPOC design.

(81) FIG. 14 is an exploded view of the VCR system. The outer wrist pin 71 slides into the piston 70. There is an offset hole in the outer wrist pin 71 that the inner wrist pin (not shown) would be captured by. It is by rotating this outer wrist pin 71 around the inner wrist pin that the compression ratio is varied. The outer wrist pin 71 has a set of teeth machined into it and these teeth match the teeth cut into the rack gear 72. The rack gear is free to slide axially along a bored hole in the piston 70, as the rack gear 72 moves relative to the piston 70 it rotates the outer wrist pin 71 adjusting the compression ratio. The rack gear 72 has a female threads cut into it and the rack gear threaded insert 73 has a matching male thread on its OD that interfaces with the rack gear 72 internal thread. The rack gear threaded insert 73 is axially restrained in the piston 70 between a boss inside and the threaded insert retainer 74 that bolts to the back of the piston. It is the rack gear threaded insert 73 that positions the rack gear 72 axially in the piston 70 to set the compression ratio. The VCR actuator 75 is attached to the engine end cover and is fixed in place relative to the reciprocating motion of piston 70. It has a male splined shaft 76 that interfaces with the female internal splines inside the rack gear threaded insert 73. As the piston reciprocates inside its cylinder, the rack gear threaded insert 73 slides back and forth over the VCR actuator male splined shaft 76. It is the VRC actuator that sets the compression ratio in each cylinder. In this embodiment there is an actuator for each cylinder in the engine. It would be possible to belt drive multiple spline rod assemblies with one actuator.

(82) In this design both the VCR actuator 75 male splined shaft 76 and the rack gear threaded insert 73 can be replaced as service items without disassembling the engine.

(83) The sixth portion of this detailed description is most closely related to grouped cylinder deactivation on prechamber ignited EMD 2 stroke engines.

(84) FIG. 15A illustrates the firing order of a 12 cylinder EMD 2-stroke engine. The top table is for firing all of the cylinders, the lower table illustrates just one bank firing. In the lower table the engine is broken down into two half engine banks with a top half and bottom half with either half being able to be deactivated leaving behind the rest of the engine to operate on cylinder to cylinder engine timing as even as the full engine was operating. If the top half of the engine operated by itself the firing order would be 1, 7, 3, 9, 2, 8 with degrees between firings 45, 75, 45, 75, 45, 75. Additionally, 9 of the cylinders could be deactivated leaving three cylinders still firing with 120 degree spacing if the three firing cylinders were all from the same quadrant of the engine, either 1, 2, 3 or 4, 5, 6 or 7, 8, 9, or 10, 11, 12.

(85) FIG. 15B is a similar set of engine firing order tables, except for a 16 cylinder engine. In this case, when operating either the top half or bottom half of the engine, the cylinder firing spacing is an even 45 degrees. When only 4 cylinders in one quadrant are operated the cylinder spacing is still even at 90 degrees.

(86) By being able to operate only 25% of the engine or 50% of the engine cylinders, the engine can be tuned to operate at more optimum air fuel ratios all the way down to idle and the prechambers can be turned off in banks with a simple isolation valve for each group of cylinders.

(87) Programming the ECU to not fire the GIV's in the deactivated cylinders is only a matter of software changes. Turning off the prechamber fuel feed to the opposing banks requires some additional hardware, but that can be as simple as two or four electrically controlled valves, one for the fuel supply to each bank of prechambers.

(88) As more advanced systems are proposed to get even lower emissions from these conversion systems, it will be likely that the prechamber supply pressure will not be constant. When the increased complexity of prechamber fuel pressure control is added, that would be a good time to institute this additional layer of control and hardware needed to turn on and off different prechamber feeds.

(89) For simplicity of control or in early deactivation systems, all of the spark plugs can be fired, even those in deactivated cylinders. In more advanced systems it is likely that the spark plugs would not be fired when the cylinders are deactivated to extend the spark plug service lives. When turning on and off the prechamber fuel supply, it may be beneficial to turn the spark plugs on a few cycles early, and when turning off the prechamber fuel supply it would be beneficial to fire the spark plugs a few cycles later.

(90) FIGS. 16A, 17, 18A-18C, 19A-19C, 20, 21, and 22A-22B illustrate a new prechamber nozzle 69″ design that uses 6 radial located groups of three 0.050 TJI jets 96 to replace one set of 6 individual larger orifice jets. These three TJI jets 96 in each group converge together at a point some distance, possibly ¾ of an inch, away from the nozzle. This new concept is likely to have both the quenching effect and good combustion chamber penetration. Because the three jets converge they will penetrate further into the combustion chamber similar to a larger single jet. It is likely that the efficiency of the group of jets with regard to penetration would be slightly less than a single larger jet of either the same effective area or combined flow rate. This seeming negative could have a silver lining in that it has the needed penetration, all of the burning gases quenched and at the same time a more concentrated pocket of partially burned combustion radicals to stimulate very rapid combustion throughout the chamber once ignition is started.

(91) FIG. 16A the Nozzle 69″ is illustrated with groups of 3 TJI jets 96 converging into a combined jet. In practice good results could be attained with only two TJI jets 96 in each group or four or more if needed. The concept is to have as many orifice jets as needed converge into a single flow to achieve the required penetration and local combustion intensity.

(92) In another embodiment, it is proposed to have some or all of the TJI jets 96 be offset from the centerline axis of nozzle 69″. If a set of jets enters the nozzle throat with the same offset they will give the flow entering the prechamber through the nozzle throat 97 a rotational flow along with the axial flow component. This swirling effect will have multiple benefits.

(93) The first and most intuitive benefit of the swirling flow be improved mixing at the top of the prechamber combustion chamber reducing the stratification of the air and fuel around the spark plug.

(94) Another non-intuitive benefit of the swirling flow entering the prechamber combustion chamber will be the larger effective volume of the flow as it has an axial velocity component and a rotational velocity component. This will require an increase of the mixing throat 97 diameter to have the same effective pressure drop and flow accelerating capability as a smaller throat diameter with a purely axial flow. On the other hand, after combustion when the rotational flow component is much less, the pressure drop across the throat will be less insuring more pressure drop across the jet orifices and higher velocity, mass flow and penetration of the jets. Essentially the mixing throat 97 will now effectively be less restrictive in the most beneficial direction.

(95) A potential issue being explored with multiple small jets in a prechamber nozzle designed for Turbulent Jet ignition is that complete quenching of the burning gasses as they exit may sometimes cause a misfire. At high loads where the in cylinder main chamber temperatures are higher because the gasses have less time to transfer heat to the surrounding metal, the TJI prechambers may exhibit stable combustion.

(96) Proposed is to have TJI jets in both a smaller diameter and a larger diameter. FIG. 16B illustrates one embodiment with groups of smaller diameter TJI jets 96 around the nozzle and then one larger diameter axial TJI jet 98 in the center. In this case the intent is that the axial TJI jet 98 is large enough in diameter to start combustion on its own, and the smaller TJI jets 96 discharged quenched air and fuel forming areas of ready to burn pockets. When the main combustion event is initiated by the larger torch nozzles, these pockets will subsequently ignite providing more rapid heat release. Pure TJI with all quenched jets would offer even higher heat release rates by delaying combustion even further, but could suffer from misfire. This system would overcome some misfire potential at some difficult engine operating points such as very low power. Also in some engines pure TJI may have heat release rates that are too rapid. This system could be used to mitigate that giving some of the benefit of TJI without the excessive heat release rate.

(97) In another embodiment, is to the single axial TJI jet 98 is eliminated and one of the quenched TJI jets 96 in one or several of the radial groups has a larger diameter so as to lose the quenching effect and act as a torch jet.

(98) In another embodiment, the axial jet 98 could be replaced by a set of group of smaller diameter axial jets 98 similar to the radial groupings of TJI jets 96. These axial jets 98 could remain parallel to each other in the axial direction of each be angled slightly off axis to converge.

(99) A second significant benefit of the axial jets 98 is to improve mixing internal to the prechamber. By adjusting the number and diameter of these axial jets 98 both the mixing benefit and the torch effect can be optimized.

(100) It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages.