Patent Application
20150047619
The present invention relates to an exhaust gas radiator for an exhaust gas system or for an exhaust gas recirculation system of an internal combustion engine. The invention also relates to an operating method for such an exhaust gas radiator.
Exhaust gas radiators can be used in an exhaust gas system to remove thermal energy from the exhaust gas in order to use it elsewhere, for example to heat a coolant of a cooling circuit or to evaporate a working medium of a Rankine circuit or for heating an air stream for the air conditioning of a passenger compartment during vehicle use. An exhaust gas radiator is used in an exhaust gas recirculation system to cool the recirculated exhaust gas. Cooling of the recirculated exhaust gas increases the mass flow and reduces the combustion temperatures in the combustion chambers of the internal combustion engine, which is advantageous in terms of emissions of pollutants, in particular NOx emissions.
An exhaust gas radiator usually comprises an exhaust gas path, which leads from an exhaust gas inlet to an exhaust gas outlet, and a coolant path, which is coupled thereto in a heat-transferring manner and leads from a coolant inlet to a coolant outlet.
In heat transfer media, what is known as “fouling” occurs, which means the contamination of heat-transferring components by constituents of the coolant used. For example, algae can form in the coolant circuit, which can lead to clogging of the coolant path. In the case of exhaust gas radiators, fouling on the exhaust gas side also means the accumulation of soot. Soot entrained in the exhaust gas can accumulate on the surfaces of the exhaust gas radiator and in this manner also lead to gradual clogging of the exhaust gas path.
The present invention is concerned with the problem of specifying an improved embodiment for an exhaust gas radiator of the type mentioned in the introduction, which in particular has a reduced risk of clogging of the exhaust gas path owing to soot particles.
This problem is solved according to the invention by the subject matter of the independent claim. Advantageous embodiments form the subject matter of the dependent claims.
The invention is based on the general concept of equipping the exhaust gas radiator on the exhaust side with at least three different cooling capacity regions, which follow each other, that is, are arranged in series, in the flow direction of the exhaust gas. Accordingly, an inlet region comprises the exhaust gas inlet and is designed for an inlet cooling capacity. Downstream of the inlet region, an intermediate region is situated, which is designed for an intermediate cooling capacity. Downstream of the intermediate region, an outlet region is provided, which comprises the exhaust gas outlet and is designed for an outlet cooling capacity. The exhaust gas radiator is then designed such that the intermediate cooling capacity is lower than the inlet cooling capacity and is lower than the outlet cooling capacity. This structure according to the invention is based on the finding that the tendency for soot accumulation is comparatively low at high exhaust gas temperatures, which occur in the inlet region of the exhaust gas path. Accordingly, a comparatively high inlet cooling capacity can be realised in the inlet region. At moderate exhaust gas temperatures, however, the tendency for soot accumulation increase greatly. This can be counteracted by a reduced intermediate cooling capacity. At low exhaust gas temperatures, as occur in the outlet region of the exhaust gas path, likewise relatively great accumulations can be observed, but they adhere less and therefore can in particular be flushed out. Accordingly, a higher outlet cooling capacity can be realised again in the outlet region. The exhaust gas radiator presented here thus has, in particular inside a common housing, at least three different structured regions, which follow each other in the exhaust gas path and which make possible different heat transfer capacities owing to their different structures.
“Cooling capacity” in this case means a flow of heat from the exhaust gas in the direction of the coolant per unit time.
An embodiment is preferred in which the exhaust gas radiator has a single housing, in which the whole exhaust gas path is accommodated and which has the exhaust gas inlet and the exhaust gas outlet. The three capacity regions are thus situated inside this common housing of the exhaust gas radiator, as a result of which a particularly compact structure can be realised.
Alternatively, an embodiment is also possible in which the exhaust gas radiator has two or three housings, to which the exhaust gas path is distributed and which are series-connected to each other by means of one or two connecting pipes. The exhaust gas inlet and the exhaust gas outlet are thus situated on different housings. The inlet region and the exhaust gas inlet are expediently situated in a first housing on the inlet side, while the outlet region and the exhaust gas outlet are situated in a second housing on the outlet side. The intermediate region can then be accommodated either in the housing on the inlet side or in the housing on the outlet side or else in a central, third housing.
An embodiment is advantageous in which only one single and thus common coolant path is provided, which is routed through the at least three cooling capacity regions preferably successively, that is, in series. Likewise preferred is a flow route for the single exhaust gas path and the single coolant path using the counterflow principle. In order to be able to realise different cooling capacities with a single exhaust gas path and a single coolant path, for example the dwell times of the exhaust gas and of the coolant can vary in the individual cooling capacity regions. The surfaces available for the heat transfer can likewise be varied, e.g. by the use of heat transfer structures and the configuration thereof. The flow conditions, such as the presence of turbulent or laminar flows and/or the thickness of the boundary layers produced, can also be varied by suitable measures, such as the use of turbulators and the configuration thereof.
According to an advantageous embodiment, the exhaust gas radiator can be designed for a predefined operating state of the exhaust gas radiator such that a hydrocarbon dew point lies in the region of a transition from the inlet region to the intermediate region, while the water dew point lies in the region of a transition from the intermediate region to the outlet region. The hydrocarbons are the molecules of the respective fuel supplied to the internal combustion engine for combustion, which have not been reacted or have not been completely reacted in the respective combustion chamber. These are therefore predominantly long-chain hydrocarbons based on diesel, biodiesel, petrol, biopetrol and other, usually liquid combustible substances. This specific design of the exhaust gas radiator with regard to the three cooling capacity regions is based on the finding that water vapour and uncombusted, vaporous hydrocarbons are entrained in the exhaust gas in addition to soot. At high exhaust gas temperatures above the dew points of water and the relevant hydrocarbons, the soot accumulation is deposited comparatively little on the heat-transferring surfaces in the exhaust gas path. Accordingly, this temperature range is assigned to the inlet region with the comparatively high inlet cooling capacity. In a temperature range that lies below the dew point temperature of the hydrocarbons and above the dew point temperature of water, the soot accumulation is extremely critical, since the soot can combine with the condensing hydrocarbons to form a sticky mass that can only be removed with comparative difficulty. Accordingly, this temperature range is assigned to the intermediate region with the reduced intermediate cooling capacity. However, if the exhaust gas temperature has also fallen below the dew point of water, the condensing water can flush out the accumulating soot, so an increased cooling capacity can be realised again in this temperature range. Accordingly, this lower temperature range is assigned to the outlet region with the increased outlet cooling capacity.
The predefined operating state can for example be defined by a predefined exhaust gas volumetric flow and/or a predefined exhaust gas temperature at the exhaust gas inlet and/or a predefined coolant volumetric flow and/or a predefined coolant temperature at the coolant inlet.
According to a further advantageous embodiment, the outlet region of the exhaust gas path can then be configured to discharge condensate. As explained above, condensation of water occurs primarily in the outlet region. The condensate produced can be discharged in a targeted manner by the proposed configuration of the outlet region. The condensate can carry away flushed out soot accumulations in the process.
An embodiment in which the inlet cooling capacity is greater than the outlet cooling capacity is particularly advantageous. In this case it is taken into account that the tendency for soot formation is much lower in the inlet region than in the outlet region.
According to a particularly advantageous embodiment, the cooling capacity can be defined by the surface area available for heat transfer in the exhaust gas path. This means that said heat transfer surface is selected to be much larger in the inlet region than in the intermediate region and that the outlet region has a larger heat transfer surface than the intermediate region. The more surface area is available for heat transfer, the more surface area is also available for the accumulation of soot. If the heat transfer surface is accordingly significantly reduced in the intermediate region, there is also a much smaller surface area available to the soot carried in the exhaust gas for accumulation, which results in a reduction in soot accumulation in the intermediate region.
According to another advantageous embodiment, the cooling capacity can be defined by the density of heat transfer means in the exhaust gas path. The density of the heat transfer means is the number of heat transfer means per unit volume in the exhaust gas path. The higher the density of the heat transfer means, the greater the available heat transfer surface and the higher the cooling capacity. Applied to the exhaust gas radiator presented here, this means that the density of the heat transfer means in the inlet region is greater than in the intermediate region and is greater in the outlet region than in the intermediate region.
According to an expedient development, such heat transfer means can for example be formed by ribs and/or turbulators and/or flow obstacles, what are known as winglets, and/or by lamellae and the like, which are arranged in the exhaust gas path. Accordingly, the density of the heat transfer means or the heat transfer surface can for example be defined by the rib density, that is, by the number of ribs per unit volume in the exhaust gas path. The rib density would then be lower in the intermediate region than in the inlet region and lower than in the outlet region. In particular, it can be provided for ribs to be provided only in the inlet region and in the outlet region and for the intermediate region to be without ribs.
According to another advantageous embodiment, the cooling capacity can be defined by the cross section of the exhaust gas path through which flow can pass and/or by the flow resistance in the exhaust gas path. The flow resistance is produced by the density of the heat transfer means on the one hand and by the cross section through which flow can pass on the other. The larger the cross section through which flow can pass, the lower the flow resistance. It has been found that the tendency for soot accumulation is greatly reduced in regions with low flow resistance and a large cross section through which flow can pass. Accordingly, in the case of the exhaust gas radiator proposed here, the flow resistance in the exhaust gas path is preferably lower in the intermediate region than in the inlet region and lower than in the outlet region. Additionally or alternatively, the cross section of the exhaust gas path through which flow can pass in larger in the intermediate region than in the inlet region and than in the outlet region.
In another advantageous embodiment, the coolant path can lead from a coolant inlet to a coolant outlet, the coolant inlet being arranged at the outlet region and the coolant outlet being arranged at the inlet region, as a result of which the exhaust gas and the coolant flow through the exhaust gas radiator according to the counterflow principle. It is likewise possible for the coolant inlet to be arranged at the inlet region and the coolant outlet to be arranged at the outlet region, as a result of which exhaust gas and coolant flows through the exhaust gas radiator according to the co-flow principle. In each case the coolant path leads through all three regions of the exhaust gas path successively, that is, in series. The structural integration of the three cooling capacity regions into a single exhaust gas radiator is supported in this manner.
In another advantageous embodiment, the exhaust gas radiator can be configured as a ribbed tubular heat exchanger in which a plurality of coolant pipes extends through the exhaust gas path, which conduct the coolant on the inside and bear ribs on the outside, at least in the inlet region and in the outlet region. The different cooling capacities in the different regions of the exhaust gas path can then be changed particularly easily by varying the rib size and/or rib number and/or rib density.
In a particularly advantageous embodiment, the coolant path comprises an inlet chamber, a plurality of deflecting chambers and an outlet chamber. Overall, at least four chambers are provided, which are formed in the coolant path or along the coolant path, in particular in a common housing of the exhaust gas radiator. The common housing of the exhaust gas radiator that may be provided thus encloses the three cooling capacity regions on the side of the exhaust gas path and the above-mentioned at least four chambers on the side of the coolant path.
In a preferred embodiment, exactly four deflection chambers can be provided, so the coolant path then comprises exactly six chambers. The inlet chamber expediently has a coolant inlet and is fluid-connected to the first deflection chamber via a first group of coolant pipes, which lead through the exhaust gas path. The first deflection chamber can then be fluid-connected to the second deflection chamber via a second group of coolant pipes, which lead through the exhaust gas path. The second deflection chamber can be fluid-connected to the third deflection chamber via a third group of coolant pipes, which lead through the exhaust gas path. The third deflection chamber can be fluid-connected to the fourth deflection chamber via a fourth group of coolant pipes, which lead through the exhaust gas path. Finally, the fourth deflection chamber can be fluid-connected to the outlet chamber, which has a coolant outlet, via a fifth group of coolant pipes, which lead through the exhaust gas path. Owing to this structure, the coolant flows through the six chambers of the coolant path successively, so they form a series connection. If there is a different number of deflection chambers, there is also a correspondingly different number of groups of coolant pipes leading through the exhaust gas path.
According to an advantageous development, the coolant pipes of the first group and of the second group can run in the outlet region and the coolant pipes of the fourth group and of the fifth group can run in the inlet region (with the counterflow principle) or vice versa (with the co-flow principle). In contrast thereto, the coolant pipes of the third group run in the intermediate region.
Another embodiment proceeds from the exhaust gas radiator being configured as a bundled tubular heat exchanger, in which a plurality of exhaust gas pipes extend from the exhaust gas inlet to the exhaust gas outlet through the coolant path, conduct the exhaust gas on the inside and are exposed to the coolant on the outside. According to an advantageous development, heat transfer means can then be arranged in the exhaust gas pipes in the inlet region and in the outlet region. These heat transfer means then define the cooling capacity of the respective region of the exhaust gas path by their dimensions and/or number and/or density.
In another embodiment, flow-directing elements or flow obstacles can be arranged in the exhaust gas pipes at least in the inlet region and in the outlet region. Such flow-directing elements or flow obstacles can be realised particularly simply as “winglets” in a bundled tubular heat exchanger configured as a flat tubular heat exchanger. These are generally raised and depressed stamped portions that are produced by forming on the mutually facing longitudinal sides of the individual flat tubes. The heat transfer capacity in the exhaust gas path can be defined by the geometry and/or number and/or density and/or distribution of these winglets.
An inventive method for operating an exhaust gas radiator that has at least three regions in the exhaust gas path, namely an inlet region, an intermediate region and an outlet region, is characterised in that different cooling capacities are realised in the at least three regions, namely an inlet cooling capacity, an intermediate cooling capacity and an outlet cooling capacity, the intermediate cooling capacity being lower than the inlet cooling capacity and lower than the outlet cooling capacity.
Particularly advantageous in this case too is an embodiment in which the exhaust gas is cooled at least to a hydrocarbon dew point in the exhaust gas radiator upstream of the intermediate region and the exhaust gas is cooled at least to a water dew point in the exhaust gas radiator downstream of the intermediate region.
According to a preferred development, it can also be provided in this case for the hydrocarbon dew point to be reached in the region of a transition from the inlet region to the intermediate region and/or for the water dew point to be reached in the region of a transition from the intermediate region to the outlet region.
Further important features and advantages of the invention can be found in the subclaims, the drawings and the associated description of the figures using the drawings.
It is self-evident that the above-mentioned features and those still to be explained below can be used not only in the combination given in each case but also in other combinations or alone without departing from the scope of the present invention.
Preferred exemplary embodiments of the invention are shown in the drawings and are explained in more detail in the description below, the same reference symbols referring to the same or similar or functionally equivalent components.
In the figures,
According to
In the examples of
The exhaust gas path 5 has an inlet region 13 indicated by a curly bracket, downstream thereof an intermediate region 14 indicated by a curly bracket and downstream thereof an outlet region 15 indicated by a curly bracket. The inlet region 13 comprises the exhaust gas inlet 7. The outlet region 15 comprises the exhaust gas outlet 8. The intermediate region 14 is arranged in the flow direction of the exhaust gas between the inlet region 13 and the outlet region 15. The intermediate region 14 is thus arranged distally to the exhaust gas inlet 7 and distally to the exhaust gas outlet 8.
The inlet region 13 is designed for an inlet cooling capacity. The intermediate region 14 is designed for an intermediate cooling capacity. The outlet region 15 is designed for an outlet cooling capacity. The intermediate cooling capacity is lower than the inlet cooling capacity and lower than the outlet cooling capacity. The outlet cooling capacity is preferably also lower than the inlet cooling capacity. Accordingly, the cooling capacity in the inlet region 13 is greater than in the intermediate region 14 and greater than in the outlet region 15. However, the cooling capacity is greater in the outlet region 15 than in the intermediate region 14. The cooling capacity is lower in the intermediate region 14 than in the inlet region 14 and lower than in the outlet region 15.
For a predefined operating state of the exhaust gas radiator 1 or of the internal combustion engine equipped therewith, the exhaust gas radiator 1 is expediently designed in such a manner that a dew point of hydrocarbons THC lies in a region 16, indicated by a curly bracket, of a transition from the inlet region 13 to the intermediate region 14. The exhaust gas radiator 1 is expediently designed for the predefined operating state in such a manner that a dew point of water TH2O lies in a region 17, indicated by a curly bracket, of a transition from the intermediate region 14 to the outlet region 15.
According to
In the embodiment shown in
In the embodiment shown in
In the embodiment shown in
According to
a-3c each show a plan view of an exhaust gas pipe 35 configured as a flat pipe. It can be seen that these exhaust gas pipes 35 are provided with raised and depressed stamped portions that form flow-directing elements 37 or flow obstacles. The depressed stamped portions project into the exhaust-gas-conducting interior of the respective exhaust gas pipe 35. The raised stamped portions however project into the coolant path 9. In a stack of such flat pipes 35, adjacent exhaust gas pipes 35 can be supported on each other or spaced apart from each other by means of such stamped flow-directing elements 37. The heat transfer capacity in the respective capacity region of the exhaust gas path 5 can in turn be defined by the shape, number, distribution and size of the flow-directing elements 37 extending into the interior of the respective exhaust gas pipe 35.
The manner in which the exhaust gas radiator 1 functions is explained in more detail below using
During operation of the exhaust gas radiator 1 and of the internal combustion engine equipped therewith, hot exhaust gas flows through the exhaust gas inlet 7 into the inlet region 13. The inlet region 13 is dimensioned such that the hydrocarbon dew point THC is situated at the end of the inlet region 13, that is, in the transition region 16. Since a soot accumulation is not critical or hardly takes place above the hydrocarbon dew point temperature THC, a particularly high cooling capacity can be realised here, which is realised by the large heat transfer area with the aid of the high rib density in
The exhaust gas radiator 1 presented here can characterised in summary in that it has a cooling capacity that is adapted to the exhaust gas temperature, which decreases along the exhaust gas path 5, in such a manner that a significantly reduced cooling capacity is realised in the intermediate region 14, in which hydrocarbon condensation but no water condensation takes place. In this manner, the accumulation of soot particles can be much reduced in this intermediate region 14 in which the hydrocarbon condensation takes place, which reduces the risk of clogging and blockage of the exhaust gas path 5 in the exhaust gas radiator 1. Soot accumulation is taken into account in the outlet region 15 but can be flushed out by the water condensation.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102012205026.4 | Mar 2012 | DE | national |
| 102012208742.7 | May 2012 | DE | national |
This application claims priority to German Patent Application No. 10 2012 205 026.4, filed Mar. 28, 2012, German Patent Application No. 10 2012 208 742.7, filed May 24, 2012, and International Patent Application No. PCT/EP2013/056542, filed Mar. 27, 2013, all of which are hereby incorporated by reference in their entireties.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2013/056542 | 3/27/2013 | WO | 00 |
