Patent Grant
6883468
This invention relates generally to a method and apparatus for injecting fuel and gas into a combustion chamber of a compression ignition engine and, more particularly, to a method and apparatus for premixing fuel and gas during injection into the combustion chamber.
Compression ignition engines, for example diesel engines, operate by combustion of fuel and gas mixtures caused by compression of the mixtures, usually within a combustion chamber during a compression stroke. Compression engines offer the advantage of high output power for the amount of fuel used.
The combustion process, however, results in some amounts of emission by-products, such as NOx, HC, soot, and the like, being generated. The amount of emissions may be increased under certain conditions. For example, incomplete mixing of the fuel and gas results in higher temperature regions within the combustion envelope, thus resulting in increased levels of NOx. Higher temperatures overall within the combustion chamber also cause increased amounts of NOx.
Attempts to control various engine parameters and thus reduce emissions have met with limited success. One such strategy which shows promise is the use of homogeneous charge compression ignition (HCCI) technology. HCCI attempts to thoroughly mix the fuel and air within the combustion chamber to provide for uniform combustion temperatures. However, it has proven to be extremely difficult to achieve true HCCI operations and maintain control over the combustion process.
In U.S. Pat. No. 4,860,699, Rocklein discloses a two-cycle engine which delivers a mixture of fuel and air to the combustion chamber through a baffle, i.e., a series of mixing vanes, to promote mixing of the fuel and air. The air is obtained from an accumulator which stores compressed air from some source, such as a crankcase compressor, an external compressor, or a supercharger. The compressed air is always being delivered to the combustion chamber of the two-stroke engine, either to scavenge exhaust gases during the exhaust stroke or to deliver fuel and air during the intake stroke. The fuel is injected into the stream of compressed air prior to entry into the baffle. The fuel and air mixture, however, must be delivered to the combustion chamber for combustion by standard methods, i.e., either spark ignition or compression ignition. Thus, the disclosed engine of Rocklein merely establishes a means to deliver fuel and air to the combustion chamber and does not control combustion in any manner designed to resolve emission issues.
The present invention is directed to overcoming one or more of the problems as set forth above.
In one aspect of the present invention a method for delivering a mixture of fuel and gas to a combustion chamber of a compression ignition engine is disclosed. The method includes the steps of compressing a gas to a pressure sufficient to initiate combustion of a fuel, delivering a stream of the gas toward the combustion chamber, injecting a quantity of fuel into the stream of gas to create a near homogeneous fuel and gas mixture, and delivering the fuel and gas mixture to the combustion chamber such that combustion occurs substantially within the combustion chamber.
In another aspect of the present invention an apparatus for delivering a mixture of fuel and gas to a combustion chamber of a compression ignition engine is disclosed. The apparatus includes a compressor, an accumulator for storing a quantity of gas compressed by the compressor at a pressure sufficient to initiate combustion of a fuel, a passageway from the accumulator to the combustion chamber for delivering a quantity of compressed gas to the combustion chamber at a desired velocity, and a fuel injector located in the passageway for injecting a quantity of fuel into the quantity of compressed gas.
In yet another aspect of the present invention an apparatus for delivering a mixture of fuel and gas to a combustion chamber of a compression ignition engine is disclosed. The apparatus includes an intake valve providing an inlet for air to the combustion chamber, an exhaust valve providing an outlet for exhaust gas from the combustion chamber, an outlet port from the combustion chamber having a check valve located therein, an accumulator connected to the outlet port for receiving at least one of compressed air and exhaust gas from the combustion chamber, and a passageway from the accumulator to the combustion chamber for delivering a mixture of compressed gas and fuel to the combustion chamber.
In yet another aspect of the present invention an apparatus for delivering a mixture of fuel and gas to a combustion chamber of a compression ignition engine is disclosed. The apparatus includes a first combustion chamber for receiving a mixture of fuel and gas, combusting the mixture, and creating a resultant exhaust gas, a second combustion chamber, and a passageway located between the first and second combustion chambers for delivering a mixture of fuel and the exhaust gas to the second combustion chamber.
In still another aspect of the present invention an apparatus for delivering a mixture of fuel and gas to a combustion chamber of a compression ignition engine is disclosed. The apparatus includes a first cylinder having a piston movable therein and defining a compressor, an intake valve for providing an inlet for air to the compressor, an outlet port having a check valve located therein and for delivering compressed air from the compressor, an accumulator for receiving the compressed air at a pressure sufficient to initiate combustion of a fuel, a second cylinder having a piston movable therein and defining a combustion chamber, and a passageway for delivering a mixture of fuel and compressed air from the accumulator to the combustion chamber at a velocity sufficient for combustion to occur substantially within the combustion chamber.
In still another aspect of the present invention an apparatus for delivering a mixture of fuel and gas to a combustion chamber of a compression ignition engine is disclosed. The apparatus includes a first cylinder having a piston movable therein and defining a compressor, a first accumulator for receiving compressed uncooled gas from the compressor, a cooler for receiving a portion of the compressed uncooled gas and creating compressed cooled gas, a second accumulator for receiving the compressed cooled gas, a first valve actuator located in the first accumulator, a second valve actuator located in the second accumulator, and a second cylinder having a piston movable therein and defining a combustion chamber, and for receiving at least one of a quantity of compressed uncooled gas and a quantity of compressed cooled gas.
a is a diagrammatic illustration of a passageway;
b is a diagrammatic illustration of an alternate version of the passageway;
c is a diagrammatic illustration of yet another version of the passageway;
a is a diagrammatic illustration of the passageway having a fuel injector located therein;
b is a diagrammatic illustration of another configuration of the passageway and fuel injector;
a is a top view of the embodiment of
b is a top view of another version of the
c is a top view of yet another version of the
Referring to the drawings, a method and apparatus 100 for delivering a mixture of fuel and gas to a combustion chamber 104 of a compression ignition engine 102 is shown. The fuel may be any type suited for compression ignition engines, for example diesel fuel. The gas may be any type of fluid suited for performance as an oxidant, for example fresh air, recirculated exhaust gas, or a combination thereof.
Referring particularly to
A fuel injector 118 located in the passageway 110 provides controlled injection of fuel into a stream of compressed gas flowing through the passageway 110 toward the combustion chamber 104. Preferably, the fuel injector 118 is located in the passageway 110 at a distance d from the combustion chamber 104. The distance d may be chosen such that combustion of the fuel and gas mixture occurs substantially within the combustion chamber 104. The distance d may be a function of a velocity v of the gas moving through the passageway 110 and an ignition delay characteristic i of the fuel. For example, d may be defined as
d≦v*i (Eq. 1)
It may be desired for combustion of the fuel and gas mixture to take place completely within the combustion chamber 104. However, it may also be desired for combustion to begin occurring as the fuel and gas mixture approaches the combustion chamber 104, for example, within a 5 to 10 percent portion of the passageway 110 adjacent the combustion chamber 104. It is noted that both mixing of the fuel and gas and the combustion process initiate as the fuel is injected into the compressed stream of gas. However, the distance d and the velocity v of the stream of gas are such that combustion of the fuel and gas mixture is delayed until the mixture is substantially within the combustion chamber 104.
Referring to
An outlet port 202 from the combustion chamber 104 provides fluid communication with the accumulator 112. For example, exhaust gas may be controllably delivered from the combustion chamber 104 to the accumulator 112 under pressure sufficient to initiate combustion of the fuel. A check valve 204 may be used to provide further control of the delivery of compressed exhaust gas. As an example of operation, the exhaust valve 208 may open during a portion of an exhaust stroke of the engine 102, and may be closed prior to completion of the exhaust stroke. The remaining exhaust gas is compressed as the piston 106 continues to move toward top dead center until the pressure of the exhaust gas exceeds the force of the check valve 204. The check valve 204 then opens, allowing compressed exhaust gas to enter the accumulator 112 by way of the outlet port 202.
It is noted that, in the present embodiment as well as embodiments described below, any device functioning to compress gas may be defined as a compressor, although the principle function of that device may be for other purposes, such as combustion. For example, in the present embodiment, the combustion chamber 104, outlet port 202, check valve 204, and exhaust valve 208 may function together as a compressor during a portion of engine operation.
Referring to
In
The converging and diverging portions 302,304 provide control over the velocity of the compressed gas and may define a velocity profile for the gas along the length of the passageway 110. The velocity profile may help determine where combustion of the fuel and gas mixture begins. Furthermore, flow losses along the length of the passageway 110 may be minimized by design of the converging and diverging portions 302,304. It is noted that variations of the passageway 110 having a converging portion 302 and a diverging portion 304 may be used. For example, an additional converging portion (not shown) may be included downstream of the diverging portion 304.
c illustrates another variation of the passageway 110. A perforated inner wall 306 is surrounded by a solid outer wall 308. A portion of the compressed gas flows within the space between the inner and outer walls 306,308 and travels through the perforations along the length of the passageway 110, thus enhancing the mixing of the fuel with the compressed gas. In a variation of this embodiment, the pressure of the gas within the space between the inner and outer walls 306,308 may differ from the pressure of the gas flowing through the passageway 110. For example, the pressure of the gas flowing within the space between the inner and outer walls 306,308 may be greater than the pressure of the gas flowing through the passageway 110, thus preventing fuel from contacting the walls 306,308 of the passageway 110.
It is noted that the embodiments of the passageway 110 shown in
Referring to
Referring to
A second piston 510 and a second cylinder 512 define a second combustion chamber 508. The second combustion chamber may include a second intake valve 518 and a second exhaust valve 520. Preferably, the second piston 510 moves in tandem with the first piston 504, i.e., the first and second pistons 504,510 reach top dead center at substantially the same time.
A passageway 110 provides fluid communication between the first and second combustion chambers 502,508. More particularly, as the first combustion chamber 502 combusts a fuel and gas mixture, the highly pressurized exhaust gas is in fluid communication from the first combustion chamber 502 to the second combustion chamber 508 by way of the passageway 110. As the compressed exhaust gas travels through the passageway 110, a fuel injector 118 may inject a quantity of fuel into the stream of gas such that the fuel and gas mixture travels to the second combustion chamber 508 and combusts substantially within the second combustion chamber 508.
Referring to
b shows two passageways 110 from the first to the second combustion chambers 502,508, such that the fuel and gas mixture enters the second combustion chamber 508 from opposite sides, thus causing the mixture to collide within the second combustion chamber 508 and promote more thorough mixing of the fuel and compressed exhaust gas.
Referring to
The compressed air may be delivered to a cooler 720, for example an aftercooler. The cooled air may then be delivered from the cooler 720 to an accumulator 112 by way of a cooler output conduit 722. The cooler 720 may be omitted if desired. In this case, the compressed air may be delivered from the compressor 702 directly to the accumulator 112. Furthermore, it is noted that a cooler may be used in any of the previously described embodiments, for example in any of FIG. 1,2, or 5.
A second piston 710 and a second cylinder 712 define a combustion chamber 708. A passageway 110 provides fluid communication between the accumulator 112 and the combustion chamber 708, preferably from the accumulator 112 to the combustion chamber 708. A valve 114 and actuator 116 provide controlled flow of the compressed gas, as is described above. A fuel injector 118 controllably injects fuel into the passageway 110 such that fuel and gas are mixed and combust as the mixture substantially arrives at the combustion chamber 708.
Referring to
Referring to
Another portion of the compressed air is delivered to a cooler 720, e.g., an aftercooler, by way of a cooler input conduit 810. The cooled compressed air is delivered from the cooler 720 to a second accumulator 812 by way of a cooler output conduit 722, in which that portion of the compressed air is stored as cooled gas.
A second piston 710 and a second cylinder 712 define a combustion chamber 708. A first passageway 808 provides fluid communication between the first accumulator 802 and the combustion chamber 708. Preferably, the first passageway 808 provides fluid communication for compressed uncooled gas from the first accumulator 802 to the combustion chamber 708. Delivery of the compressed uncooled gas may be controlled by a first valve 804 and a first actuator 806, for example a hydraulic valve actuator.
A second passageway 818 provides fluid communication between the second accumulator 812 and the combustion chamber 708. Preferably, the second passageway 818 provides fluid communication for the compressed cooled gas from the second accumulator 812 to the combustion chamber 708. Delivery of the compressed cooled gas may be controlled by a second valve 814 and a second actuator 816, for example a hydraulic valve actuator. A fuel injector 118, located in the second passageway 818, provides controlled injection of fuel into the stream of compressed cooled gas such that a fuel and gas mixture is created which is designed to combust when the fuel and gas mixture substantially arrives at the combustion chamber 708.
Under normal engine operating conditions, the combustion chamber 708 may receive a supply of mixed fuel and gas from the second accumulator 812 only. However, during periods of time when additional bursts of torque may be needed, the combustion chamber 708 may also receive a quantity of compressed uncooled gas from the first accumulator 802.
Referring to
During a first stroke A, fresh air is drawn into the combustion chamber 104 as the piston 106 moves toward bottom dead center. For purposes of ease of explanation, operation of intake and exhaust valves, and other intake or output ports are not shown nor described, although it is understood that such operation is necessary for proper operation.
During a second stroke B, the fresh air is compressed as the piston 106 moves toward top dead center. In addition, the compressed fresh air is delivered to an accumulator (not shown).
During a third stroke C, the piston 106 moves toward bottom dead center and a mixture of compressed air, i.e., compressed gas, and fuel is drawn into the combustion chamber 104. The pressure of the compressed gas may be sufficient to initiate combustion of the fuel. However, due to the high velocity of the gas and fuel mixture and an ignition delay characteristic of the fuel, combustion may not occur until the gas and fuel mixture has substantially arrived at the combustion chamber 104. This combustion further aids the movement of the piston 106 toward bottom dead center.
During a fourth stroke D, the piston 106 moves toward top dead center and exhaust gas from combustion is removed by way of an exhaust valve (not shown). Furthermore, a portion of the exhaust gas may be compressed by the upward movement of the piston 106 and delivered to the accumulator (not shown) to combine with compressed fresh air previously delivered. For example, the exhaust valve (not shown) may be actuated to close earlier than normal, thus trapping a portion of exhaust gas within the combustion chamber 104. The increasing pressure of the remaining exhaust gas may overcome the force of a check valve (not shown), thus providing a passage to the accumulator. In an alternative embodiment, the exhaust valve may be actuated to close later than normal. This action may serve to draw back a portion of the exhaust gas into the combustion chamber 104 during a subsequent expansion stroke, e.g., a fifth stroke E or a first stroke A. The exhaust gas returning to the combustion chamber 104 creates an internal exhaust gas recirculation (EGR) effect.
A fifth stroke E and a sixth stroke F are repeats of the respective third and fourth strokes C and D. Operation then repeats at the first stroke A. However, variations of the above described strokes may be employed. For example, during periods of heavy load operation, the third and fourth strokes C and D, and consequently the fifth and sixth strokes E and F, may be repeated an additional time before returning to the first stroke A, thus creating eight strokes of operation. Alternatively, during light load operation, the fifth and sixth strokes E and F may be deleted, thus leaving strokes A, B, C, and D as the operating strokes.
Typically, an engine 102 will have multiple cylinders 108. Depending upon the embodiment of the present invention used, all cylinders may function alike, or some cylinders may function differently. For example, in the embodiments represented by
A preferred method of operation of the present invention may be illustrated with reference to the flow diagram of FIG. 10.
In a first control block 1002, a gas such as fresh air, recirculated exhaust gas, or a combination thereof, is compressed to a pressure sufficient to initiate combustion of a fuel. The compressed gas may be delivered and stored in an accumulator 112 for use as needed.
In a second control block 1004, a quantity of the compressed gas is delivered as a stream toward a combustion chamber 104 by way of a passageway 110.
In a third control block 1006, a quantity of fuel is injected into the stream of gas in the passageway 110 such that the fuel and compressed gas combine to create a near homogeneous mixture.
In a fourth control block 1008, the fuel and gas mixture is delivered to the combustion chamber 104 such that combustion occurs substantially within the combustion chamber 104. Preferably, the velocity at which the gas and fuel mixture travel through the passageway 110, the length of the passageway 110, and an ignition delay characteristic of the fuel are factored together to delay combustion until the gas and fuel mixture is at the desired location.
Other aspects can be obtained from a study of the drawings, the disclosure, and the appended claims.
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|---|---|---|---|
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| 2122785 | Tinker et al. | Jul 1938 | A |
| 2914047 | Colton | Nov 1959 | A |
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| 4860699 | Rocklein | Aug 1989 | A |
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| 5054457 | Sakamoto | Oct 1991 | A |
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| 5207204 | Kawachi et al. | May 1993 | A |
| 5211682 | Kadowaki et al. | May 1993 | A |
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| 5699758 | Clarke | Dec 1997 | A |
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| 6371093 | Kaku et al. | Apr 2002 | B1 |
| Number | Date | Country | |
|---|---|---|---|
| 20040187804 A1 | Sep 2004 | US |
