Patent Application
20250035074
This instant specification relates to exhaust gas recirculation (EGR) intercoolers, more particularly EGR intercoolers providing a fluidic diode function.
Internal combustion engine thermal efficiency is partially limited by an ability, or lack thereof, to increase exhaust gas recirculation (EGR) flow at peak torque condition without creating other system drawbacks. This is due to low pressure differences between the exhaust manifold and intake manifold. Because of this limitation, previous internal combustion engines (ICE) cannot be operated at higher brake thermal efficiencies (BTE).
In general, this document discusses exhaust gas recirculation (EGR) intercoolers that provide a fluidic diode function.
In a first example implementation, a heat exchanger apparatus includes a first fluid conduit defining a first fluid flow path for a first fluid and comprising a fluid diode that is at least partly fluidically diodic and formed of a thermally conductive material, the fluid diode having a first fluid inlet, a first fluid outlet, a first sub-conduit extending from the fluid inlet to the fluid outlet, and a second sub-conduit extending from the first sub-conduit proximal the fluid inlet to the first sub-conduit proximal the fluid outlet as a partial loop defining a cavity extending through the partial loop, and a second fluid conduit in thermal communication with the first fluid conduit and defining a second fluid flow path through the partial loop, fluidically isolated from the first fluid flow path, for a second fluid.
Various implementations can include some, all, or none of the following features. The fluid diode can partly define the second fluid conduit and the cavity can partly define the second fluid flow path. The second fluid conduit can be formed of another thermally conductive material and can extends through the cavity. The fluid diode can be a Tesla valve. The first sub-conduit can define the first fluid flow path as a substantially linear fluid flow path from the fluid inlet to the fluid outlet. The second sub-conduit can define the second fluid flow path as a substantially curved fluid flow path having a predetermined radius. The fluid inlet can include a third sub-conduit defining a first substantially linear fluid flow path, the first sub-conduit can define the first fluid flow path as a second substantially linear fluid flow path arranged at a first predetermined angle to the first substantially linear fluid flow path, the second sub-conduit can include a curved section in fluid communication with the first sub-conduit, extending away from the first sub-conduit at a second predetermined angle to the first sub-conduit and a linear section configured to fluidically connect the third sub-conduit and the curved section, the linear section defining a third substantially linear fluid flow path arranged substantially aligned with the first substantially linear fluid flow path. The linear section can have a predetermined length L, and the curved section can have a minimum radius of about
wherein α is the first predetermined angle. The first predetermined angle is in a range of about 10 degrees to about 80 degrees. The heat exchanger apparatus can include a first inlet manifold in fluidic communication with the first fluid inlet and configured to supply a first fluid to the first fluid conduit, a second inlet manifold in fluidic communication with a second inlet of the second fluid conduit and configured to supply a second fluid to the second fluid conduit, a first outlet manifold in fluidic communication with the first fluid outlet, and a second outlet manifold in fluidic communication with a second fluid outlet of the second fluid conduit.
In another example implementation, a heat exchanger apparatus includes a first fluid conduit defining a first fluid flow path and configured as a Tesla valve having at least one partial loop defining an annulus, and a second fluid conduit in thermal communication with the first fluid conduit and defining a second fluid flow path, different from the first fluid flow path, through the annulus.
Various implementations can include some, all, or none of the following features. The Tesla valve can have a plurality of the partial loops, fluidically interconnected and defining the first fluid flow path. The heat exchanger can include a first inlet manifold configured to supply a first fluid to the first fluid conduit, where the first fluid conduit can include another Tesla valve arranged fluidically parallel to the Tesla valve, a first outlet manifold configured to receive the first fluid from the first fluid conduit, a second inlet manifold configured to supply a second fluid to the second fluid conduit, where the second fluid conduit can include a plurality of the second fluid flow paths through one or more of the plurality of partial loops, and a second outlet manifold configured to receive the second fluid from the second fluid conduit. The first fluid can be combustion exhaust gases, and the second fluid can be a coolant fluid configured to absorb heat energy transferred away from the combustion exhaust gases.
In another example implementation, a method of heat exchange includes flowing a first fluid in a first direction through a first fluid conduit configured as a Tesla valve defining a first fluid flow path and comprising at least one partial loop defining an annulus, and flowing a second fluid, different from the first fluid, through a second fluid flow path, different from the first fluid flow path, at least partly defined by the annulus.
Various implementations can include some, all, or none of the following features. The method can include receiving combustion exhaust gases from an exhaust manifold of a combustion engine, providing the combustion exhaust gases as the first fluid, cooling the combustion exhaust gases by transferring thermal energy from the combustion exhaust gases to the second fluid, and providing the cooled combustion exhaust gases to an intake manifold of the combustion engine. Flowing the first fluid in the first direction through the first fluid conduit configured as the Tesla valve defining the first fluid flow path and having at least one partial loop defining the annulus can include flowing the first fluid along a first substantially straight portion of the first fluid flow path past an intersection with the partial loop, redirecting, by the first fluid conduit, the first fluid at a predetermined angle of about 10 degrees to about 80 degrees, and flowing the first fluid along a second substantially straight portion of the first fluid flow path. The method can include flowing the first fluid through the first fluid flow path in a second direction opposite the first fluid flow direction, and resisting, by the fluid flow path, fluid flow in the second direction. Flowing the first fluid through the first fluid flow path in the second direction opposite the first fluid flow direction can include flowing a first portion of the first fluid flow along a substantially straight portion of the first fluid flow path, flowing a second portion of the first fluid flow along a curved portion of the first fluid flow path toward an intersection of the curved portion and the substantially straight portion, and rejoining the a first portion of the first fluid flow and the second portion of the first fluid flow proximal the intersection, and resisting, by the fluid flow path, fluid flow in the second direction comprises fluidically interfering, by the second fluid flow and based on the rejoining, the first fluid flow. The substantially straight portion can have a predetermined length L, and the curved portion has a minimum radius of about
where α is a predetermined angle of the intersection.
The systems and techniques described here may provide one or more of the following advantages. First, a system can reduce engine fuel usage. Second, the system can reduce engine emissions. Third, the system can reduce exhaust back pressure. Fourth, the system can provide improved spark timing. Fifth, the system can reduce the cost of exhaust after-treatment. Sixth, the system can improve measurement of exhaust gas recirculation. Seventh, the system can smooth transient operation. Eighth, the system can improve accuracy of torque and/or speed control.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
This document describes systems and techniques for cooling exhaust gas recirculation (EGR) gases that increase EGR efficiency by preventing EGR backflow. In general, an EGR cooler is configured as a check valve or fluidic diode that permits gas flow in the forward direction (e.g., from exhaust, through an EGR cooler and toward an engine inlet such as an intake manifold) while resisting gas flow in the reverse direction (e.g., from intake, through an EGR cooler, and toward an exhaust manifold). Reliability and service life of the EGR cooler is increased through the use of a fluidic diode design that does not require the use of moving mechanical parts.
The example engine system 100 includes an engine body 102, an intake manifold 104, an exhaust manifold 106, an exhaust gas recirculation (EGR) valve 108, and an EGR cooler 110. The engine system 100 can include additional or different components and subsystems. The components of the engine system 100 can be configured as in the example shown in
The intake manifold 104 of the example system 100 receives air from an air intake system. In some example engine systems, the air intake system can include, for example, a turbocharger compressor, an intake air cooler, an air intake throttling valve and other components. The intake manifold 104 can also receive exhaust gas from the exhaust manifold 106. The EGR valve 108 can control the flow of exhaust gas into the intake manifold 104.
The EGR cooler 110 can cool the flow of combustion exhaust gases into the intake manifold 104. In some instances, there is no inflow of exhaust gas at the intake manifold 104. The intake manifold 104 can provide an air mixture to the engine body 102. The air mixture provided to the engine body 102 can include air from the air intake system, which may be mixed with cooled combustion exhaust gases from the exhaust manifold 106 and possibly other fluids. The intake manifold 104 can include various flow meters, valves, sensors, and other components that are not specifically shown in
The engine body 102 can include various features, components, and subsystems. For example, the engine body 102 can include a combustion chamber, a cylinder, a piston, an ignition system, a fuel injection system, and various other features. The engine body 102 can receive the air mixture (e.g., through an intake valve) from the intake manifold 104 and fuel from a fuel injection system. An ignition system can ignite the air-fuel mixture in the combustion chamber in the engine body 102, which moves the piston and produces the mechanical output of the engine body 102 (e.g., rotation of a crank shaft, etc.). The exhaust gas created by combustion of the air-fuel mixture in the engine body 102 can be directed (e.g., through an exhaust valve) to the exhaust manifold 106.
The exhaust manifold 106 receives exhaust gas from the engine body 102. The exhaust manifold 106 can communicate the exhaust gas to a component of the exhaust system or another subsystem of the engine system 100. In some implementations, the exhaust manifold 106 directs the exhaust gas through a turbocharger exhaust turbine. From the turbocharger, in such implementations, the exhaust gas can be communicated from the engine system 100, for example, to an external environment. The exhaust manifold 106 can communicate exhaust gas through the EGR cooler 110 and the EGR valve 108. The exhaust manifold 106 can include various flow meters, valves, sensors, and other components that are not specifically shown in
The EGR valve 108 controls the flow of exhaust gas from the exhaust manifold 106 to the intake manifold 104. For example, the EGR valve 108 can control flow by manipulating (e.g., opening, closing, constricting, dilating, etc.) an exhaust flow path. In the example shown in
The EGR cooler 110 is configured as a heat exchanger apparatus that cools the flow of exhaust gas from the exhaust manifold 106 to the intake manifold 104. For example, the EGR cooler 110 can cool flow by transferring heat from exhaust gases in an exhaust flow path to a coolant in a coolant flow path. In the example shown in
Although not specifically shown in the example engine system 100, in some embodiments there may also be a valve for metering the flow into the intake manifold 104 as well as an intake throttle valve to further improve the pressure difference from the exhaust manifold 106 to the intake manifold 104.
In some implementations, exhaust gas pressure generated by the engine system 100 applies a force to the EGR valve 108. For example, the EGR valve 108 can include a throttle valve assembly in fluid communication with the exhaust ports of the engine body 102 and the inlet of a turbocharger exhaust turbine. The throttle valve can experience severe fluid force fluctuations, for example, due to unsteady engine exhaust processes in the exhaust manifold 106. In these and other contexts, exhaust gas can impart an unsteady aerodynamic torque loading on the EGR valve shaft, which can displace the EGR valve from the desired valve position. In some cases, the unsteady loading on the EGR valve can cause the valve to hit its end-of-travel stop repeatedly, which may cause mechanical instability or failure of the EGR valve.
In some embodiments, a controller can control operation of the EGR valve 108. In some examples, the controller can generate an EGR valve control signal configured to achieve a desired EGR valve position. The controller can generate the EGR valve control signal based on data stored in memory, data received from the EGR valve 108, engine operating condition data from sensors installed in the engine system 100, or a combination of these and other data. The controller can send the EGR valve control signal to the EGR valve 108 to control the position of the EGR valve 108.
In previous designs where an EGR valve is arranged downstream from a previously known EGR cooler, the previously known EGR cooler can significantly damp out useful (e.g., forward-flowing) pulsations. To reduce or eliminate valve position disturbance created by unsteady exhaust gas pressure on the EGR valve 108 while permitting useful pulsations and preventing backflow, the EGR cooler 110 acts as a check valve. For example, the EGR cooler 110 can permit pulses to flow forward (e.g., away from exhaust and toward intake) substantially unimpeded, and can substantially block or resist reverse flow.
The sensors in the engine system 100 can include, for example, pressure sensors, temperature sensors, accelerometers, position sensors, etc. In some implementations, one or more pressure sensors in the intake manifold 104 provide data that indicate the engine load; one or more engine revolution sensors in the engine body 102 provide data that indicate the engine speed (e.g., based on the revolution speed of a crank shaft, etc.); and one or more position sensors in the engine body 102 provide data that indicate engine position (e.g., based on the position of a piston, etc.). In some implementations, one or more position sensors in the EGR valve 108 provide data that indicate the position of the EGR valve shaft or the EGR valve actuator, etc.
The EGR cooler 200 includes a coolant port 206 (e.g., a coolant fluid inlet configured to supply another, different fluid to the EGR cooler 200) that is in fluidic communication with a coolant port 208 (e.g., a coolant fluid outlet). The EGR cooler 200 has an internal configuration, which will be described in more detail below, that functions as a heat exchanger in which heat energy of EGR gases is transferred to a coolant fluid flow between the coolant port 206 and the coolant port 208 (or a coolant flow between the coolant port 208 and the coolant port 206).
In general, each of the fluid diodes 400a-400d defines a fluid conduit 402 comprising a thermally conductive material configured as a Tesla valve having a number of at least partial loops 410 having an annulus 420 (e.g., eye). As will be described in more detail below, in such a configuration, fluid can flow in one fluid flow direction (e.g., from the EGR port 202 to the EGR port 204) substantially unimpeded, while fluid flow in the opposite fluid flow direction (e.g., from the EGR port 204 toward the EGR port 202) will subdivide the flow into two or more sub-conduits and redirect the flow against itself, resisting and/or substantially blocking reverse flow. The fluid diodes 400a-400d are configured to provide such diodic or check valve function substantially without the use of moving or mechanical parts. In some embodiments, other types of check valves and/or fluid diodes can be used (e.g., ball check valves, tilting disk valves, swing check valves).
The EGR cooler 200 includes a number of intercooler cells 450.
In the illustrated example of
The EGR cooler 200 includes a collection of lateral interior diverter walls 710a and a collection of lateral interior diverter walls 710b. The lateral interior diverter walls 710a that extend from the longitudinal wall 712a part way to the longitudinal wall 712b, defining passages 716a between the longitudinal wall 712a and the lateral interior diverter wall 710a. The lateral interior diverter walls 710b that extend from the longitudinal wall 712b part way to the longitudinal wall 712a, defining passages 716b between the longitudinal wall 712b and the lateral interior diverter wall 710b.
In the illustrated example, a coolant fluid flow 701 generally flows from the coolant port 206 to the coolant port 208. Coolant flows in through the coolant port 206 to the passage 714b, then through the fluid conduits 530 to the longitudinal fluid channel 714a, as partly redirected by the lateral interior diverter wall 710a. As the coolant flows through the fluid conduits 530, thermal energy is absorbed from EGR gases (or other fluid) flowing through the fluid diodes 410a-410d through the conduit walls 510.
Coolant fluid flow along the longitudinal fluid channel 714a flows around the lateral interior diverter wall 710b through the passage 716a to the next intercooler cell 450. Coolant flows to the longitudinal fluid channel 714a, then through the fluid conduits 530 to the passage 714b, as partly redirected by the lateral interior diverter wall 710b. As the coolant flows through the fluid conduits 530, additional thermal energy is absorbed from EGR gases (or other fluid) flowing through the fluid diodes 410a-410d through the conduit walls 510.
Coolant continues to flow back-and-forth through the serpentine labyrinth formed by the fluid conduits 530 to the coolant port 208, where the heated coolant exits the EGR cooler 200. In some embodiments, the heated coolant can be cooled actively and/or passively. For example, the coolant can be passed through another heat exchanger (e.g., a radiator, geothermal reservoir) to dissipate thermal energy to the ambient environment. In another example, the coolant can be processed through a refrigeration cycle configured to remove heat energy from the coolant.
The design of the EGR cooler 200 as illustrated is one example of various designs that can be implemented. The size, shape, flow directions, flow paths, flow patterns, and/or other structural details of the EGR 200 can be configured based on various target implementations (e.g., the design can be made application-specific).
The fluid diode 800 includes an inlet port 802 configured to receive a fluid (e.g., EGR gases) that is fluidically connected to an outlet port 804. The fluid diode 800 includes three major sections, including an inlet manifold 810 that includes the inlet port 802, an outlet manifold 812 that includes the outlet port 804, and a fluid diode portion 820 configured to fluidically connect the inlet manifold 810 to the outlet manifold 812 and define a fluid path there between.
In general, the fluid diode portion 820 defines the fluid conduit 830 as a Tesla valve having a number of loops 840 and linear sections 842. Previously known Tesla valve designs are substantially rectangular in cross-section, in which the fluid conduits are formed as rectangular tubular conduit that bends and turns longitudinally while being substantially straight laterally. Unlike such previous designs, the fluid diode portion 820 is substantially revolute, in which the fluid conduit 830 is formed as a substantially cylindrical cavity defined between a cylindrical outer housing 850, and a cylindrical inner housing 852. The loops 840 are further defined by rings 854 that are arranged between the cylindrical outer housing 850 and a cylindrical inner housing 852.
The revolute, three-dimensional, cylindrical configuration of the fluid conduit 830 is capable of providing performance characteristics that differ from linear and/or rectangular Tesla valve type fluid diodes. For example, in rectangular configurations, the flowable cross-sectional areas of loops are substantially equal to the flowable cross-sectional areas of linear portions. By contrast the flowable cross-sectional areas of the loops 840 and the linear sections 842 is proportional to their predetermined radius/radii. For example, the radially outermost parts of the loops 840 have a relatively larger radius and therefore a relatively larger flowable area than their relatively smaller radiused linear sections 842.
During reverse flow, the flowable area available to the fluid increases as it flows into the outermost portions of the loops 840. As the area increases, the fluid velocity drops. As the fluid flows around the loops 840, the flow is redirected radially inward, forcing the fluid into a relatively smaller area that creates additional resistive, diodic backpressure not generally found in rectangular designs.
In such a configuration, fluid can flow in one direction (e.g., from the inlet port 802 to the outlet port 804) substantially unimpeded, while fluid flow in the opposite direction (e.g., from the outlet port 804 toward the inlet port 802) will subdivide the flow and redirect the flow against itself, resisting and/or substantially blocking reverse flow. The fluid diode portion 820 is configured to provide such diodic or check valve function substantially without the use of moving or mechanical parts.
In some implementations, diodicity can be given as:
If Di>1, then the conduit in question has diodic behavior, where:
Where ΔP is the applied pressure difference between two ends of the conduit, and Q is the flow rate. Di is found to be inversely proportional to R.
The performance and behavior of a Tesla valve type fluid conduit can be modified by varying various dimensional parameters of its design (e.g., to configure the design to meet one or more predetermined performance parameters). In the illustrated example, the fluid diode configuration 1200 includes a linear (e.g., straight) portion 1210 having a predetermined length L1 and defining a linear fluid flow path, a linear portion 1220 having a length L and defining a linear fluid flow path, a linear portion 1230 having a predetermined length L2 and defining a linear fluid flow path a linear portion 1240 having a predetermined width W and defining a linear fluid flow path, and a curved portion 1250 having a predetermined radius R. The linear portion 1240 branches away from the linear portion 1220 at a predetermined angle α, and the curved portion 1250 intersects the linear portion 1240 at a predetermined tangent angle β.
The relationships between various ones of the dimensions of the fluid diode configuration 1200 can affect the diodicity of fluid diode configuration 1200. The angle α can be selected to be between about 10 degrees to about 80 degrees. Larger angles of β can reduce the amount of flow entering the curved portion 1250 in the direction of forward flow. Larger angles of β can increase the resistive or blocking action of reverse flow through the curved portion 1250.
At 1310, a first fluid is flowed in a first direction through a first fluid conduit configured as a Tesla valve defining a first fluid flow path and comprising at least one partial loop defining an annulus. For example, an EGR gas can be supplied to the fluid port 202 to flow through the fluid conduits 402 to the fluid port 204.
At 1320, a second fluid, different from the first fluid, is flowed through a second fluid flow path, different from the first fluid flow path, at least partly defined by the annulus. For example, coolant can be provided to the fluid port 206 to flow through the annuli 420 to the fluid port 208.
In some implementations, the process 1300 can include receiving combustion exhaust gases from an exhaust manifold of a combustion engine, providing the combustion exhaust gases as the first fluid, cooling the combustion exhaust gases by transferring thermal energy from the combustion exhaust gases to the second fluid, and providing the cooled combustion exhaust gases to an intake manifold of the combustion engine. For example, heat energy from hot EGR gases can be transferred through the walls of the fluid conduits 402 to coolant flowing through the annuli 420.
In some implementations, the process 1300 can include flowing the first fluid along a first substantially straight portion of the first fluid flow path past an intersection with the partial loop, redirecting, by the first fluid conduit, the first fluid at a predetermined angle of about 10 degrees to about 80 degrees, and flowing the first fluid along a second substantially straight portion of the first fluid flow path. For example, EGR gases can flow in a forward direction as discussed in the description of
In some implementations, the process 1300 can include flowing the first fluid through the first fluid flow path in a second direction opposite the first fluid flow direction, and resisting, by the fluid flow path, fluid flow in the second direction. In some implementations, flowing the first fluid through the first fluid flow path in the second direction opposite the first fluid flow direction can include flowing a first portion of the first fluid flow along a substantially straight portion of the first fluid flow path, flowing a second portion of the first fluid flow along a curved portion of the first fluid flow path toward an intersection of the curved portion and the substantially straight portion, and rejoining the a first portion of the first fluid flow and the second portion of the first fluid flow proximal the intersection, and resisting, by the fluid flow path, fluid flow in the second direction comprises fluidically interfering, by the second fluid flow and based on the rejoining, the first fluid flow. For example, EGR gases flowing in a reverse direction can be resisted or blocked as discussed in the description of
In some implementations, the substantially straight portion can have a predetermined length L, and the curved portion can have a minimum radius of about
wherein α can be a predetermined angle of the intersection. For example, the fluid diode 200 can be configured as discussed in the description of the example fluid diode configuration 1200 of
Although a few implementations have been described in detail above, other modifications are possible. For example, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other implementations are within the scope of the following claims.
