The present application claims priority to German Application 102012200014.3, filed on Jan. 2, 2012, the entire contents of which are hereby incorporated by reference for all purposes.
The multi-cylinder internal combustion engines of motor vehicles often include at least one cylinder head connected to the mounting face of a cylinder block and four cylinders arranged in line along the longitudinal axis of the cylinder head, wherein each cylinder is equipped with ignition devices to initiate external ignition. Each cylinder generally contains at least one exhaust port to discharge the exhaust gasses from the cylinder via the exhaust gas discharge system, wherein each exhaust gas pipe is connected at each exhaust port. In the context of the following specification the term “engine,” in particular, comprises petrol engines equipped with external ignition. Engines have at least one cylinder head and one cylinder block which are connected together at their mounting faces to form the individual cylinders referred to as combustion chambers.
The cylinder head frequently serves to hold the valve actuating mechanism called the valve gear to control the charge change. In charge change, combustion gasses are expelled via the exhaust ports and a fresh mixture or fresh air is drawn in via the inlet ports, filling the combustion chamber. Reciprocating valves are often used as charge change control elements during operation of the engine to open and close the inlet and exhaust ports, wherein the aim is rapid opening of a flow cross-section large enough to keep choke losses low and maximize the fill of the cylinders. Therefore, cylinders are frequently fitted with two or more inlet or exhaust ports. Downstream of the manifold the exhaust gasses may then be sent to a turbine of the exhaust turbocharger and/or to one or more exhaust post-treatment systems. Power released by combustion is adjusted by changing the fill of the combustion chamber by adjusting the pressure in the aspirated air and varying the aspirated air mass. Lower loads rely upon a higher choking, so charge change losses are increased the low load region.
One approach for dechoking the working process of the petrol engine lies in the use of a variable valve gear with which the stroke of the valves and/or the control times can be varied to a greater or lesser extent. Varying the control times of the valves is achieved by use of a camshaft adjustment device with which the camshaft can be twisted through a certain angle in relation to the crankshaft allowing control times to be advanced or retarded without varying the opening duration of the valves. In this method of variable valve control, valve overlap depends on the crank angle range in which the exhaust is not yet closed while the inlet remains open. During valve overlap at high loads “flushing losses” can occur, wherein part of the aspirated fresh air flows through the cylinder without participating in the subsequent combustion. A variable valve control allows decreasing the valve overlap in response to increased rotation speed. For engines charged by means of exhaust turbocharging, at low rotation speeds a large valve overlap is suitable for raising the maximum torque and improving the unstable operating behavior. A pressure fall present at low rotation speeds between the inlet side and exhaust side supports an effective flushing of the cylinders with fresh air and ensures greater cylinder filling and hence higher power. A large valve overlap, possibly from late closure of the at least one exhaust valve, is also suitable for reducing the pumping and the resulting charge change losses.
Charge change has proved problematic for the exhaust pipes of the cylinders. Degradation can occur from the respective exhaust port through to the collection point in the exhaust gas discharge system at which the exhaust pipes merge into a common exhaust pipe and the hot exhaust gas from the cylinders is collected, this is compounded by the increasingly shorter exhaust pipe designs in modern engines. Increasingly often, the exhaust gas discharge system is integrated, at least partly, in the cylinder head in order to participate in the cooling provided in the cylinder head and reduce the need for expensive thermally heavy duty materials. Short exhaust pipes can lead to a mutual disadvantage of the cylinders of the engine on the effect on charge change, in particular, the effect achieved by residual gas flushing may be decreased. Thus in an in-line engine operated in a combustion sequence, the charge change of a cylinder can have a disadvantageous effect on the cylinder immediately preceding it in the ignition sequence due to different mechanisms competing to evacuate exhaust gas.
For example, exhaust gas emerging from the one cylinder entering another cylinder before its exhaust valves close resulting in two different mechanisms competing to evacuate combustion gasses from the fourth cylinder. Various approaches may be used to combat the problem arising from the short exhaust pipes, these approaches include shortening the opening duration of the exhaust valves by opening a valve later or closing a valve sooner. Use of large valve overlap is often heightened at low engine speeds by opening the valve later while maintaining closing time, this measure maintains engine torque at low engine rotation speeds; however, power disadvantages arise from shortened valve duration at high engine rotation speeds from the reduction in pumping in the low load range to reduce fuel consumption.
The inventors herein recognized this problem inherent in shortened exhaust pipes and recognized that some of the issues addressed above by providing some degree of isolation of the exhaust pipes of cylinders adjacent in the ignition sequence. Further, this method would alleviate the problems of mutual influence of adjacent cylinders on charge change while maintaining the benefits of a large valve overlap or long exhaust opening duration o minimize the power disadvantages arising with at high rotation speeds and/or with regard to the reduction of pumping in low load operation.
In an engine, the cylinder head frequently serves to hold the valve gear. To control the charge change, an engine often utilizes control elements and actuation devices to activate the control elements. In the context of the charge change, combustion gasses are expelled via the exhaust ports and a fresh mixture or fresh air is drawn in via the inlet ports, filling the combustion chamber. To control charge change reciprocating valves are used as control elements, almost exclusively in four stroke engines. The reciprocating valves execute an oscillating reciprocal motion during operation of the engine and thus open and close the inlet and exhaust ports. A valve gear is a valve actuating mechanism able to move the valves. A valve actuating device frequently comprises a camshaft on which multiple cams are arranged.
The function of the valve gear is to open and close the inlet and exhaust ports of the cylinders at the correct time, wherein the aim is rapid opening of a flow cross-section large enough to keep choke losses low in the gas inflow and outflow to maximize the possible fill of the cylinders with fresh mixture and the corresponding discharge of exhaust gasses. Therefore, cylinders are frequently fitted with two or more inlet or exhaust ports.
The four cylinders arranged in line of the at least one cylinder head of the engine which is the subject of the present disclosure have at least one exhaust port to discharge the exhaust gasses via the exhaust gas discharge system. The exhaust pipes of the cylinders are merged into a common exhaust pipe in stages, forming an exhaust gas discharge system. Downstream of the manifold the exhaust gasses are then where applicable sent to a turbine of the exhaust turbocharger and/or to one or more exhaust post-treatment systems.
Power released by combustion is adjusted by changing the fill of the combustion chamber, the resulting quantity regulation can result in higher fuel consumption and lower efficiency in the petrol engine than in its diesel counterpart. The load control usually takes place by adjusting the pressure in the aspirated air and varying the aspirated air mass via the throttle valve in the intake track. Lower loads utilize higher choking, so charge change losses are increased the low load region.
In a four-cylinder in-line engine, the cylinders of which may be operated by a control system with instructions to ignite in the sequence 1-3-4-2, the charge change of a cylinder may have a disadvantageous effect on the cylinder preceding it in the ignition sequence. For example, the exhaust gas emerging from the fourth cylinder may enter the third cylinder before its exhaust valves close resulting in two different mechanisms competing to evacuate combustion gasses from the fourth cylinder. If an exhaust valve, for instance, opens at the start of charge change, the high pressure level predominating in the cylinder towards the end of combustion creates a high pressure difference between the combustion chamber and the exhaust gas system resulting in combustion gasses flowing at high speed through the exhaust port into the exhaust pipe. Presence of exhaust gasses from the fourth cylinder in the third cylinder along with the heightened exhaust lead pulse can cause degradation in the exhaust pipe system. Ignition of the cylinders in sequence 1-3-4-2 is advantageous because the exhaust gas discharge system according to the specification has been optimized with regard to this ignition sequence, whereby the desired positive effect is achieved in particular in connection with said ignition sequence.
This pressure-driven flow process is stronger the higher the torque emitted, and is accompanied by a high pressure peak—also called an exhaust lead pulse—which propagates along the exhaust pipe. Further along the course of the charge change, the pressures in the cylinder and in the exhaust pipe largely balance out so that the combustion gasses are now expelled as a result of the piston movement. However, the initial presence of exhaust gasses from the fourth cylinder in the third cylinder along with the heightened exhaust lead pulse can cause degradation in the exhaust pipe system.
This problem can be reduced by employing a cylinder head in which the exhaust gas pipes of the cylinders merge in stages into a common exhaust gas pipe, and the exhaust gas discharge system emerges at outside of the cylinder head as shown in
In the embodiment in
Embodiments of the engine may have at least one charging device. A charging device can, for example, be an exhaust turbocharger and/or a compressor. In particular, embodiments of the engine are advantageous with at least one exhaust turbocharger comprising a turbine 124, wherein the turbine is arranged in the exhaust gas discharge system and comprises an inlet region to supply the exhaust gasses.
Further embodiments of a turbocharger may comprise a compressor and a turbine which are arranged on the same shaft (not shown). The hot exhaust gas flow may be supplied to the turbine and expand, emitting energy to the turbine and setting the shaft in rotation. The energy emitted by the exhaust gas flow at the turbine and finally at the shaft may be used to drive the compressor which may also be arranged on the shaft. Cylinder charging occurs upon the compressor delivering and compressing the charge air supplied to it. If applicable, charge air cooling may be provided with which the compressed combustion air is cooled before entering the cylinders by charge air cooler 136. This charging serves primarily to increase the performance of the engine. By compressing the air for the combustion process, a greater air mass can be supplied to each cylinder per working stroke. As a result, the fuel mass and hence the average pressure can be increased thus increasing the power of an engine without changing capacity and inducing more favorable performance measurements. Therefore, the load collective can be shifted towards higher loads at which the specific fuel consumption is lower for the same vehicle peripheral conditions. Embodiments may also utilize an exhaust gas recirculation system. Further embodiments may not have a turbocharger nor an exhaust gas recirculation system.
The exhaust gas discharge system 100 is connected at a mounting face with a cylinder block (not shown) comprising four cylinders arranged in line along the longitudinal axis 112 of the cylinder head 144. Each cylinder has at least one exhaust port 150 to discharge the exhaust gasses from the cylinder via the exhaust gas discharge system, for which an exhaust pipe 110 and 106 is connected at each exhaust port.
Embodiments of the engine may be advantageous in which each cylinder has at least two exhaust ports to discharge the exhaust gasses from the cylinder. During the charge change a rapid release of as large a flow cross-section as possible is desired, in order to keep the choke losses on the out flowing exhaust gasses as low as possible and guarantee effective discharge of the exhaust gasses. It is therefore advantageous to equip the cylinders with two or more exhaust ports.
In the present case each cylinder (A, B, C, D) has two emerging exhaust ports 150 that merge into 4 separate exhaust pipes: innermost exhaust pipes 106 emerging from cylinder B and C, respectively, and outermost exhaust pipe 110 emerging from cylinder A and D, respectively, that are themselves merged in stages. The exhaust pipes for each respective cylinder exhaust port emerge inside the cylinder head 144, other embodiments may have a single exhaust pipe per cylinder or a multiplicity of exhaust pipes per cylinder. The innermost exhaust pipes 106 of the two internal cylinders (B and C) are merged at a first junction 116 into a part exhaust pipe 122 within the cylinder head 144. The part exhaust pipe 122 is then merged with the exhaust pipes of the two outermost cylinders (A and D) into a single common exhaust pipe 126 at a collection point 120. In
In either embodiment, shortening of opening duration to suppress the mutual influencing of the cylinders on charge change can be reduced as the merging of the exhaust pipes from cylinders adjacent in the ignition sequence minimize exhaust gasses from one cylinder enter the cylinder previously ignited. Further, the benefits of a large valve overlap or long exhaust opening duration can be utilized, without two cylinders adjacent in the ignition sequence hindering each other on charge change.
Accordingly, one outermost exhaust pipe 110 is separated from the two innermost exhaust pipes 106 by an outer wall segment 146. The outermost exhaust pipe 110 is separated from the two innermost exhaust pipes 106 by an outer wall segment 146. The two innermost exhaust pipes 106 are separated for a distance within the cylinder head and inner wall segment 148 that ends at a first junction 116 to form the part exhaust pipe 122.
An embodiment may also be arranged to accommodate engines that have two cylinder heads if, for example, the cylinders are divided into two cylinder banks The merging of the exhaust pipes in the method described herein similarly leads to an improvement in charge change and an improvement in torque provision. This embodiment is beneficial because the inner wall segment 148 ending within the cylinder head 144 is at s distance of Δd>0 from the cylinder head outer wall 118.
Engine embodiments may also utilize an inner wall segment protruding into the exhaust gas discharge system that have a latitudinal distance from the outside of the cylinder head as shown in
Increasing the distance Δd and decreasing the length of the inner wall segment may allow for a more compact cylinder head design. A shorter inner wall segment allows a steeper merging of the two outer most exhaust pipes within the part exhaust pipe and thus the collection point to occur a shorter latitudinal distance from the cylinders.
In some embodiments of the engine, it may be advantageous for the outer wall segments to extend further than the inner wall segment in the latitudinal direction of the outside of the cylinder head by a distance Δs, wherein Δs≧5 mm. Particular embodiments may utilize a value of Δs≧10 mm. In particular embodiments of the engine are advantageous in which Δs≧10 mm.
Computer-supported simulations show that in individual cases a satisfactory torque characteristic can be achieved even when the outer wall segment extends 5 mm or more beyond the inner wall segment in the direction of the outside of the at least one cylinder head, wherein the distance Δs is measured perpendicular to the longitudinal axis of the at least one cylinder head and as a reference point, the point on the wall segment is taken which protrudes furthest into the exhaust gas discharge system in the direction of the outside.
A greater length of protrusion of the outer wall segments beyond the inner wall segment will have a more pronounced travel distance separation of the exhaust pipes and a more perceptible resulting effect. Namely, cylinders ignited successively on charge change will exert less mutual influence and hindrance.
Therefore, embodiments of the engine may be advantageous in which the exhaust pipes of the cylinder merge into a common exhaust pipe inside the cylinder head to form an integrated exhaust manifold (not shown) and will retain all of the advantages which come from an exhaust gas discharge system fully integrated in the cylinder head.
Nonetheless, embodiments of the engine can be advantageous in which the part exhaust pipe of the two innermost cylinders and the exhaust pipes of the two outermost cylinders merge into a common exhaust pipe outside the cylinder head, such as
Further, with a common exhaust pipe 126 formed outside the cylinder head 144, embodiments of the engine can be advantageous in which the outer wall segments 146 which protrude into the exhaust gas discharge system extend beyond the outside of the cylinder head 144. According to this embodiment the exhaust flows of the two outermost and part exhaust pipe 122, and 110 are separated from each other by the outer wall segments 146 even after leaving the cylinder head. In this embodiment of the engine, the exhaust gas discharge system also emerges from the cylinder head in the form of three outlet openings (
The common feature of the two embodiments described above is that the exhaust gas discharge system is designed modular and comprises a manifold segment integrated in the cylinder head and an external manifold or manifold segment. The external manifold segment can also be formed by a component arranged in the exhaust gas discharge system, for example the inlet housing of a turbine or an external manifold.
As in
For this, the two outer wall segments 146 which each, in portions, separate from each other the two outermost exhaust pipes 110 of outermost cylinders (A and D) and the two innermost exhaust pipes 106 of the adjacent innermost cylinder (B and C) and protrude into the exhaust gas discharge system 100, extend further in the direction of the outside 108 of the cylinder head than the inner wall segment 146 which, in portions, separates from each other the innermost exhaust pipes 106 of the two innermost cylinders (B and C) and protrudes into the exhaust gas discharge system.
In this embodiment, the innermost exhaust pipes 106 the two innermost cylinders (B and C) merge within the cylinder head into a part exhaust pipe 122, wherein the inner wall segment 148 protruding into the exhaust gas discharge system has a latitudinal distance Δd from the cylinder head outer wall 118. The outer wall segments 146 which protrude into the exhaust gas discharge system 100, however, extend beyond the cylinder head outer wall 118 of the cylinder head, so that the part exhaust pipe 122 of the two innermost cylinders (B and C) and the outermost exhaust pipes 110 of the two outermost cylinders (A and D) merge into a common exhaust pipe 126 outside the cylinder head to form collection point 120.
In the embodiment shown in
To this extent the exhaust gas discharge system 100 is partly integrated in the cylinder head, wherein a manifold segment 162 lying inside the cylinder head is supplemented by a manifold segment 160 lying outside the cylinder head 144, including an external manifold segment 160.
With regard embodiments such as those in
The center part exhaust pipe 122 of the two innermost cylinders and the laterally adjacent two outermost exhaust pipes 106 and 110 cylinders, on outlet from the cylinder head into the outside, form line cross-sections which lie on a line and have an equal distance from the mounting face 166.
The cylinder head may be equipped with a coolant jacket for liquid cooling and may comprise a lower coolant jacket 168 arranged between the exhaust pipes and the mounting face 166 of the cylinder head, and an upper coolant jacket 170 which may be arranged on the side of the exhaust pipes lying opposite the lower coolant jacket 168. Spaced between the exhaust pipes may be connecting channels 172 that are provided between the lower coolant jacket 168 and the upper coolant jacket 170 which serve for the passage of coolant.
The line route described above allows the compact construction of the cylinder head, in particular the formation of a cylinder head of low height, wherein the height of the head is measured perpendicular to the mounting face. This will lead to reduced head volume and consequently, reduced weight and cost.
With outer wall segments extending beyond the outside of the cylinder head, the outer wall segments can be formed of one piece with the at least one cylinder head, wherein the wall segments in not mounted state of the engine protrude from the cylinder head and project outwards. Alternately, the outer wall segments can also be constructed modular. Embodiments may also have the outer wall segments constructed modular in which the cylinder head forms one part segment and an external manifold or manifold segment forms a further part segment.
Embodiments of the engine may be further advantageous if the outer wall segments are constructed modular and in each case the cylinder head forms one part segment and the inlet region of a turbine forms a further part segment.
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