The present disclosure relates to engines associated with exhaust gas recirculation (EGR) systems. More particularly, the present disclosure relates to a multi-cylinder engine having a CAM timing associated with various CAM profiles like miller cycle, Atkinson cycle, and the like.
Internal combustion engines typically combust a mixture of air and fuel using one or more engine cylinders for generating mechanical power. Exhaust gases are emitted into atmosphere from each of the engine cylinders because of combustion process, The stream of exhaust gases may contain emissions such as unburned fuel, soot, nitrous oxide (NOx), carbon dioxide (CO2) and carbon monoxide (CO). Engines are required to meet stringent emission standards to limit the emissions that the engine may discharge into the atmosphere. Various engine manufacturers have been incorporating Exhaust Gas Recirculation (EGR) systems in engines to comply with the emission standards. The EGR system facilitates recirculation of a portion of the exhaust gases back into an intake manifold of the engine so that the recirculated exhaust gases mix with a fresh stream of air intake.
Where a multi-cylinder engine incorporates an EGR system, manufacturers typically designate one or more cylinders as “donor” cylinders, while the remaining cylinders are designated as “non-donor” cylinders. The donor cylinders donate at least some part of the exhaust gases to the EGR system for the purpose of recirculation. In contrast, the exhaust gases from the non-donor cylinders may be directed to a turbine of the turbocharger or an aftertreatment system, thereby bypassing the EGR system This prevents back-pressure in the non-donor cylinders, as most of the exhaust gases are expelled out of the non-donor cylinders.
Although the aforementioned setup may prevent high back-pressure from the exhaust gases in the non-donor cylinders, the donor cylinders would continue to experience high back-pressure. High back-pressure may force a portion of the exhaust gases to remain inside the donor cylinders. Presence of the back-pressure may reduce the air intake as a portion of the exhaust gases remain inside the donor cylinders. The high temperature of the residual exhaust gases in the cylinder combined with low temperature of the incoming fresh air increases the temperature of the mixture for the combustion during next cycle. Subsequently emissions are also increased. Due to the back-pressure, the donor cylinders consequently become pre-occupied, at least in part, by the exhaust gases remnant or left behind. The donor cylinders may therefore receive a lesser amount of fresh air as compared to the non-donor cylinders. This reduces the air fuel ratio required for combustion. In some cases, the donor cylinders may receive, for example. 10% to 15% lesser fresh air as compared to the non-donor cylinders. Thus, the donor cylinders may have higher emissions than the non-donor cylinders for same engine operating conditions.
In order to reduce the high emissions, tuning of the donor cylinders may be performed differently from that of the non-donor cylinders. Numerous electronic systems exist in the art to control an operation of the donor cylinders and the non-donor cylinders separate from one another. However, these electronic systems may be complex, unreliable, and expensive to implement. Hence, there is a need for an improved, simplified, reliable, and cost-effective method that overcomes the aforementioned shortcomings when used in conjunction with an EGR system.
In an aspect of the present disclosure, a multi-cylinder engine includes a donor cylinder, a non-donor cylinder, at least one intake manifold, and at least one camshaft. The donor cylinder includes an intake valve that operatively controls a flow of air into the donor cylinder. The donor cylinder fluidly communicates exhaust gases to an exhaust gas recirculation (EGR) system. The non-donor cylinder includes an intake valve that operatively controls a flow of air into the non-donor cylinder. The at least one intake manifold directs air into the donor cylinder and the non-donor cylinder. The at least one intake manifold is disposed in fluid communication with the EGR system. The at least one camshaft controls an opening and closing of the intake valve of the non-donor cylinder such that the intake valve of the non-donor cylinder is maintained open for a first intake duration. In addition, the at least one camshaft controls an opening and closing of the intake valve of the donor cylinder, The at least one intake valve of the donor cylinder is open for a second intake duration. The second intake duration is greater than the first intake duration associated with the opening of the non-donor cylinder.
Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
The disclosed engine system 10 may find particular applicability with locomotives that may typically be subject to large variations in load. In embodiments herein, it may he contemplated to embody the engine 12 in the form of a four-stroke diesel engine, a four-stroke gasoline engine, or four-stroke gaseous-fuel-powered engine. The engine 12 includes a first cylinder bank 18, a second cylinder bank 20, at least one camshaft 22, a first intake manifold 24, a second intake manifold 26, a first exhaust manifold 28, a second exhaust manifold 30, a turbocharger 32, a first aftercooler 34, and a second aftercooler 36.
The first cylinder bank 18 includes six donor cylinders 38. Although,
Each of the donor cylinders 38 includes a cylinder head (not shown). The cylinder head (not shown) includes an intake valve 40 and an exhaust valve 42. The camshaft 22 mechanically actuates each of the intake valve 40 and the exhaust valve 42 to operate an open position and a closed position. The intake valve 40 operatively controls a flow of air into the donor cylinder 38. In the open position, the intake valve 40 allows the flow of air from the first intake manifold 24 to the associated donor cylinder 38. The air combusts with the fuel inside the donor cylinder 38 to produce exhaust gases. The exhaust gases are expelled through the exhaust valve 42 when the exhaust valve 42 is maintained in the open position by the camshaft 22. Downstream of the exhaust valve 42, the exhaust gases of the donor cylinder 38 flow to the first exhaust manifold 28. In the closed position, the intake valve 40 and the exhaust valve 42 block fluid communication of the donor cylinder 38 with the first intake manifold 24 and the first exhaust manifold 28 respectively.
The second cylinder bank 20 is located downstream of the second intake manifold 26 and upstream of the second exhaust manifold 30. The second cylinder bank 20 includes six non-donor cylinders 44. Although the disclosed embodiment of
Each of the non-donor cylinders 44 includes an intake valve 46 and an exhaust valve 48 to control flow of air and exhaust gases. The intake valve 46 operatively controls a flow of air into the non-donor cylinder 44. In the closed position, the intake valve 46 and the exhaust valve 48 block fluid communication of the non-donor cylinder 44 with the second intake manifold 26 and the second exhaust manifold 30 respectively. When maintained by the camshaft 22 in the open position, the intake valve 46 allows the flow of air from the second intake manifold 26 to the associated non-donor cylinder 44. This way, the exhaust gases produced during combustion can be expelled through the exhaust valve 48. Downstream of the exhaust valve 48, the exhaust gases of the non-donor cylinder 44 flow to the second exhaust manifold 30, and thereafter to the turbocharger 32.
The turbocharger 32 is disposed in fluid communication with the second exhaust manifold 30 and hence, receives the exhaust gases from the second exhaust manifold 30, The turbocharger 32 includes a turbine 52 and a compressor 54. The turbine 52 is rotatably coupled to the compressor 54. The exhaust gases exiting the second exhaust manifold 30 move downstream and expand in the turbine 52. Expansion of the exhaust gases in the turbine 52 rotates the turbine 52 and hence, rotatively drives the compressor 54 that is in fluid communication with the air intake system 16. Although the engine system 10 shows only one turbocharger in here, the engine system 10 may use multiple turbocharging system connected in series or parallel as per requirement.
The camshaft 22 mechanically actuates opening and closing of each of the intake valves 40, 46 and each of the exhaust valves 42, 48. The camshaft 22 may operatively engage a crankshaft (not shown) in any manner known to persons skilled in the art such that a rotation of the crankshaft causes a corresponding rotation of the camshaft 22. As disclosed in
In the disclosed camshaft 22, the donor intake lobe is configured to exhibit a different cam profile as compared to the cam profile of the non-donor intake lobe. When the camshaft 22 rotates, the non-donor intake lobe opens and closes the intake valve 46 of the non-donor cylinder 44, such that the intake valve 46 of the non-donor cylinder 44 is open for a first intake duration. The first intake duration may correspond to a conventional CAM timing for the non-donor cylinder 44. The donor intake lobe opens and closes the intake valve 40 of the donor cylinder 38, such that the intake valve 40 of the donor cylinder 38 is maintained open for a second intake duration. The camshaft 22 is designed to lift the intake valve 40 of the donor cylinder 38, for example, according to a late-closing CAM cycle. Based on the late-closing CAM cycle, the intake valve 40 of the donor cylinder 38 remains opens for the second intake duration which corresponds to a modified CAM timing in accordance with embodiments of this disclosure. The modified CAM timing associated with the donor cylinder 38 is longer in duration compared to the CAM timing for the non-donor cylinder 44. This implies that the second intake duration is greater the first intake duration. Hence, the intake valve 40 of the donor cylinder 38 is maintained open for a longer duration as compared to the intake valve 46 of the non-donor cylinder 44. This allows an increased amount of air to flow into the donor cylinder 38 as compared to the non-donor cylinder 44 such that both the donor cylinders 38 and the non-donor cylinders 44 receive a uniform amount of air.
Referring to the first curve 56, the intake valve 46 of the non-donor cylinder 44 opens at a crank angle θ1 and closes at a crank angle θ2. A point 56a on the first curve 56 depicts a maximum valve lift of the intake valve 46 at a crank angle θ3. The intake valve 46 remains open between the crank angle θ1 and the crank angle θ2, thereby determining the first intake duration corresponding to the CAM timing. In reference with the second curve 57, the intake valve 40 of the donor cylinder 38 opens at the crank angle θ1, which is at a same time as that of the intake valve 46 of the non-donor cylinder 44. The intake valve 40 lifts and travels to reach a maximum valve lift at a crank angle θ4. The maximum valve lift of the intake valve 40 at the crank angle θ4 is depicted by a point 57a on the second curve 57. However, the intake valve 40 of the donor cylinder 38 closes at a crank angle θ5, which is in time ahead of the crank angle θ2 (at which the intake valve 46 of the non-donor cylinder 44 closes). The intake valve 40 remains open between the crank angle θ1 and the crank angle θ5, thereby determining the second intake duration corresponding to the modified CAM timing. As seen from the graph 55, the intake valve 40 of the donor cylinder 38 opens for a longer intake duration as compared to the intake duration of the intake valve 46 of the non-donor cylinder 44. Hence, the second intake duration for the intake valve 40 of the donor cylinder 38 is greater than the first intake duration for the intake valve 46 of the non-donor cylinder 44. This facilitates a uniform mass flow rate of air to each of the donor cylinder 38 and the non-donor cylinder 44.
In this disclosure, the donor intake lobe of the camshaft 22 is designed to open the intake valve 40 for the second intake duration which, as disclosed earlier herein, is longer in duration than the first intake duration associated with the non-donor cylinders 44. In general, the modified CAM timing for the intake valves 40 can be accomplished in any manner known to persons skilled in the art, including, but not limited to, the addition of devices and actuators that act on valve pushrods (not shown) to keep the respective intake valve open for a prolonged period. In an alternative embodiment, one or more actuators may be associated with the intake valves 40 of the donor cylinders 38. The actuators may be electrically actuated, hydraulically actuated, or may embody any type of device that is capable of acting on the valve pushrods to hold the respective intake valve open and vary a valve timing of the intake valve 40.
Referring to
Exhaust gases from the first cylinder bank 18 and the second cylinder bank 20 are discharged into the first exhaust manifold 28 and the second exhaust manifold 30 respectively. The first exhaust manifold 28 directs the stream of exhaust gases to the EGR system 14. Downstream of the first exhaust manifold 28, a portion of the exhaust gases from the first cylinder bank 18 may flow to the second exhaust manifold 30 via a flow restriction orifice 50 that is positioned between the first exhaust manifold 28 and the second exhaust manifold 30. The second exhaust manifold 30 receives the exhaust gases from the non-donor cylinders 44 and delivers the received exhaust gases to the turbine 52 of the turbocharger 32.
The EGR system 14 includes a first EGR circuit 58 and a second EGR circuit 59. Downstream of the first exhaust manifold 28, the exhaust gases split into a first portion and a second portion that flow to the first EGR circuit 58 and the second EGR circuit 59 respectively. The first EGR circuit 58 includes a first EGR cooler 60 and a first EGR valve 62. The first portion of the exhaust gases is cooled in the first EGR cooler 60 and thereafter, flows to the first intake manifold 24 via the first EGR valve 62. The second EGR circuit 59 includes a second EGR cooler 64 and a second EGR valve 66. The second portion of the exhaust gases is cooled in the second EGR cooler 64 and thereafter. flows to the second intake manifold 26 via the second EGR valve 66. It is contemplated that above mentioned configuration can be also applied for single or multiple path EGR systems.
The first intake manifold 24 and the second intake manifold 26 receive the exhaust gases from the EGR system 14. The exhaust gases mix with a fresh charge of air that is received from the air intake system 16 to result in an air-exhaust mixture in the first intake manifold 24 and the second intake manifold 26. The first intake manifold 24 and the second intake manifold 26 provide the air-exhaust mixture to the first cylinder bank 18 and the second cylinder bank 20 respectively during subsequent combustion cycles of the engine 12.
In operation, the camshaft 22 of the engine 12 controls actuation of the intake valves 40 of the donor cylinders 38 according to the late-closing CAM cycle. The present disclosure discloses the modified CAM tuning that is implemented for use in conjunction with each of the donor cylinders 38. The modified CAM timing of the intake valves 40 of the donor cylinders 38 is longer in duration as compared to the CAM timing of the intake valves 46 associated with the non-donor cylinders 44. The intake valves 40 of the donor cylinders 38 therefore remain open for a longer duration of time as compared to the intake valves 46 associated with the non-donor cylinders 44, thereby causing an increased amount of air to flow inside the donor cylinders 38 until both the cylinders banks 18, 20 receive a uniform amount of air. The modified CAM timing for the intake valves 40 of the donor cylinders 38 may be achieved by merely configuring the individual lobes of the camshaft 22 thus reducing cost and effort typically required to improve engine performance in reducing emissions. Further, this reduces a need for complex electronic control that would otherwise entail added costs to manufacturers of engines. The modified CAM timing of the intake valve 40 associated with the donor cylinder 38 also improves other operating parameters of the engine 12, explanation to which will be made in conjunction with
While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems, and methods without departing from the spirit and scope of the disclosure. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.