The present description relates generally to systems and methods for an engine having an integrated exhaust manifold and an exhaust gas recirculation system.
Vehicle engine systems may utilize an external exhaust gas recirculation (EGR) system to reduce NOx emissions and increase engine efficiency. For example, the external EGR system may couple an engine exhaust manifold to an engine intake manifold via an EGR passage. An EGR valve disposed within the EGR passage may be controlled to achieve a desired intake air dilution for the given engine operating conditions (e.g., engine speed, engine load, and engine temperature) to maintain desirable combustion stability while providing emissions and fuel economy benefits.
However, traditional EGR systems are difficult to package within typical engine layouts. For example, an exhaust feed from the exhaust manifold may flow to a separately housed EGR valve and motor control assembly that is mounted on an external surface of the engine, requiring brackets and extensive packaging space. Additionally, complex cooling circuits and passages, such as drilled passages and plugs, may be used to cool components of the EGR system (e.g., the EGR valve), adding to the packaging space and system complexity. Overall, the extensive packaging layout adds additional weight to the vehicle, increases component and assembly costs, and reduces a performance of the EGR system.
Other attempts to reduce the packaging space and complexity of an EGR system include integrating an EGR passage into a cylinder head. One example approach is shown by Arnell et al. in U.S. Pat. No. 6,752,133 B2. Therein, an EGR passage is arranged in the cylinder head, with an EGR valve disposed therein on an intake manifold-side of the cylinder head. The inclusion of the EGR passage and the EGR valve in the cylinder head enables cooling via cooling features of the cylinder head.
However, the inventors herein have recognized potential issues with such systems. As one example, placing the EGR valve on the intake manifold side may reduce engine performance versus close coupling of the EGR valve to the exhaust manifold. As another example, the system of Arnell does not show where the EGR valve is placed relative to the cooling features of the cylinder head. The inventors herein have recognized that careful consideration of the cooling features, and not just the EGR valve positioning, is integral to the function of the EGR system, as inadequate cooling may result in EGR valve degradation.
In one example, the issues described above may be addressed by a system, comprising: a cylinder head including an integrated exhaust manifold (IEM); an exhaust gas recirculation (EGR) cartridge positioned in a cylindrical bore in the cylinder head at a central collector region of the IEM, the EGR cartridge including an EGR valve positioned therein; and a water jacket enclosed within the cylinder head, the water jacket including a first cooling passage that surrounds a circumference of the EGR cartridge. In this way, the cylinder head water jacket is specifically engineered to cool the EGR cartridge, enabling the EGR cartridge to be integrated in the cylinder head to decrease a packaging space and complexity of the external EGR system.
As one example, the EGR cartridge includes a cylindrical housing, and the housing forms an EGR flow path such that, when the EGR valve is open, exhaust gas may flow from the IEM and through the housing to an EGR passage integrated within the cylinder head. The EGR valve may be a poppet valve, and a bottom of the housing may form a valve seat for the poppet valve so that the exhaust gas may flow into the housing via the bottom when the poppet valve is lifted from the valve seat. The EGR passage may be coupled to an opening in a side of the housing that enables the exhaust gas to flow out of the housing and to the EGR passage, which may be further coupled to EGR system components that are external to the cylinder head (e.g., an EGR cooler). Further, the EGR cartridge may be arranged in a cylindrical bore in the cylinder head that extends from a top surface of the cylinder head to the IEM to fluidically couple the EGR cartridge to the IEM. As another example, a thermal conductor may be positioned between the EGR cartridge and the cylindrical bore and in direct contact with both the housing of the EGR cartridge and the cylindrical bore (e.g., metal of the cylinder head) to efficiently transfer heat between the EGR cartridge components and the cylinder head. As still another example, the water jacket may further include a second cooling passage positioned vertically above the first cooling passage that surrounds a portion of the circumference of the EGR cartridge. For example, the second cooling passage may be an additional water jacket core that is dedicated to cooling the EGR cartridge. In this way, the EGR cartridge may be cooled without complex cooling circuits and passages, reducing component and assembly costs while reducing overall vehicle weight. Further, by positioning the EGR valve within the cylinder head and directly fed by the IEM, engine performance may be increased.
It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
The following description relates to systems and methods for providing recirculated exhaust gas in a vehicle engine, such as the engine shown in
In some examples, vehicle 5 may be a hybrid vehicle with multiple sources of torque available to one or more vehicle wheels 55. In other examples, vehicle 5 is a conventional vehicle with only an engine. In the example shown, vehicle 5 includes engine 10 and an electric machine 52. Electric machine 52 may be a motor or a motor/generator. Crankshaft 140 of engine 10 and electric machine 52 are connected via transmission 54 to vehicle wheels 55 when one or more clutches 56 are engaged. In the depicted example, a first clutch 56 is provided between crankshaft 140 and electric machine 52, and a second clutch 56 is provided between electric machine 52 and transmission 54. Controller 12 may send a signal to an actuator of each clutch 56 to engage or disengage the clutch, so as to connect or disconnect crankshaft 140 from electric machine 52 and the components connected thereto, and/or connect or disconnect electric machine 52 from transmission 54 and the components connected thereto. Transmission 54 may be a gearbox, a planetary gear system, or another type of transmission.
The powertrain may be configured in various manners including as a parallel, a series, or a series-parallel hybrid vehicle. In electric vehicle embodiments, a system battery 58 may be a traction battery that delivers electrical power to electric machine 52 to provide torque to vehicle wheels 55. In some embodiments, electric machine 52 may also be operated as a generator to provide electrical power to charge system battery 58, for example, during a braking operation. It will be appreciated that in other embodiments, including non-electric vehicle embodiments, system battery 58 may be a typical starting, lighting, ignition (SLI) battery coupled to an alternator.
Cylinder 14 of engine 10 can receive intake air via a series of intake air passages 142, 144, and 146. Intake air passage 146 can communicate with other cylinders of engine 10 in addition to cylinder 14. In some examples, one or more of the intake passages may include a boosting device, such as a turbocharger or a supercharger. For example,
A throttle 162 including a throttle plate 164 may be provided in the engine intake passages for varying the flow rate and/or pressure of intake air provided to the engine cylinders. For example, throttle 162 may be positioned downstream of compressor 174, as shown in
Exhaust passage 148 can receive exhaust gases from other cylinders of engine 10 in addition to cylinder 14. An exhaust gas sensor 128 is shown coupled to exhaust passage 148 upstream of an emission control device 178. Exhaust gas sensor 128 may be selected from among various suitable sensors for providing an indication of an exhaust gas air/fuel ratio (AFR), such as a linear oxygen sensor or UEGO (universal or wide-range exhaust gas oxygen), a two-state oxygen sensor or EGO (as depicted), a HEGO (heated EGO), a NOx sensor, a HC sensor, or a CO sensor, for example. Emission control device 178 may be a three-way catalyst, a NOx trap, various other emission control devices, or combinations thereof.
External exhaust gas recirculation (EGR) may be provided to the engine via a high pressure EGR system 83, delivering exhaust gas from a zone of higher pressure in exhaust passage 148, upstream of turbine 176, to a zone of lower pressure in intake air passage 146, downstream of compressor 174 and throttle 162, via an EGR passage 81. An amount EGR provided to intake air passage 146 may be varied by controller 12 via an EGR valve 80. For example, controller 12 may be configured to actuate and adjust a position of EGR valve 80 to adjust the amount of exhaust gas flowing through EGR passage 81. EGR valve 80 may be adjusted between a fully closed position, in which exhaust gas flow through EGR passage 81 is blocked, and a fully open position, in which exhaust gas flow through the EGR passage is enabled. As an example, EGR valve 80 may be continuously variable between the fully closed position and the fully open position. As such, the controller may increase a degree of opening of EGR valve 80 to increase an amount of EGR provided to intake air passage 146 and decrease the degree of opening of EGR valve 80 to decrease the amount of EGR provided to intake air passage 146. As an example, EGR valve 80 may be an electronically activated solenoid valve. In other examples, EGR valve 80 may be positioned by an incorporated stepper motor, which may be actuated by controller 12 to adjust the position of EGR valve 80 through a range of discreet steps (e.g., 52 steps), or EGR valve 80 may be another type of flow control valve.
Under some conditions, the EGR system may be used to regulate the temperature of the air and fuel mixture within the combustion chamber. Further, EGR may be desired to attain a desired engine dilution, thereby improving fuel efficiency and emissions quality, such as emissions of nitrogen oxides. As an example, EGR may be requested at low-to-mid engine loads. Thus, it may be desirable to measure or estimate the EGR mass flow. EGR sensors may be arranged within EGR passage 81 and may provide an indication of one or more of mass flow, pressure, and temperature of the exhaust gas, for example. Additionally, EGR may be desired after emission control device 178 has attained its light-off temperature. An amount of EGR requested may be based on engine operating conditions, including engine load (as estimated via pedal position sensor 134), engine speed (as estimated via a crankshaft acceleration sensor), engine temperature (as estimated via an engine coolant temperature sensor 116), etc. For example, controller 12 may refer to a look-up table having the engine speed and load as the input and output a desired amount of EGR corresponding to the input engine speed-load. In another example, controller 12 may determine the desired amount of EGR (e.g., desired EGR flow rate) through logic rules that directly take into account parameters such as engine load, engine speed, engine temperature, etc. In still other examples, controller 12 may rely on a model that correlates a change in engine load with a change in a dilution requirement, and further correlates the change in the dilution requirement with a change in the amount of EGR requested. For example, as the engine load increases from a low load to a mid load, the amount of EGR requested may increase, and then as the engine load increases from a mid load to a high load, the amount of EGR requested may decrease. Controller 12 may further determine the amount of EGR requested by taking into account a best fuel economy mapping for a desired dilution rate. After determining the amount of EGR requested, controller 12 may refer to a look-up table having the requested amount of EGR as the input and a signal corresponding to a degree of opening to apply to the EGR valve (e.g., as sent to the stepper motor or other valve actuation device) as the output.
EGR may be cooled via passing through EGR cooler 85 within EGR passage 81. EGR cooler 85 may reject heat from the EGR gases to engine coolant, for example. Because EGR valve 80 is positioned upstream of EGR cooler 85, EGR valve 80 may be referred to as a “hot side” EGR valve. An example EGR system configuration will be described below with respect to
Each cylinder of engine 10 may include one or more intake valves and one or more exhaust valves. For example, cylinder 14 is shown including at least one intake poppet valve 150 and at least one exhaust poppet valve 156 located at an upper region of cylinder 14. In some examples, each cylinder of engine 10, including cylinder 14, may include at least two intake poppet valves and at least two exhaust poppet valves located at an upper region of the cylinder. Intake valve 150 may be controlled by controller 12 via an actuator 152. Similarly, exhaust valve 156 may be controlled by controller 12 via an actuator 154. The positions of intake valve 150 and exhaust valve 156 may be determined by respective valve position sensors (not shown).
During some conditions, controller 12 may vary the signals provided to actuators 152 and 154 to control the opening and closing of the respective intake and exhaust valves. The valve actuators may be of an electric valve actuation type, a cam actuation type, or a combination thereof. The intake and exhaust valve timing may be controlled concurrently, or any of variable intake cam timing, variable exhaust cam timing, dual independent variable cam timing, or fixed cam timing may be used. When can actuation is used, each cam actuation system may include one or more cams and may utilize one or more of cam profile switching (CPS), variable cam timing (VCT), variable valve timing (VVT), and/or variable valve lift (VVL) systems that may be operated by controller 12 to vary valve operation. For example, cylinder 14 may alternatively include an intake valve controlled via electric valve actuation and an exhaust valve controlled via cam actuation, including CPS and/or VCT. In other examples, the intake and exhaust valves may be controlled by a common valve actuator (or actuation system) or a variable valve timing actuator (or actuation system).
Cylinder 14 can have a compression ratio, which is a ratio of volumes when piston 138 is at bottom dead center (BDC) to top dead center (TDC). In one example, the compression ratio is in the range of 9:1 to 10:1. However, in some examples, such as where different fuels are used, the compression ratio may be increased. This may happen, for example, when higher octane fuels or fuels with higher latent enthalpy of vaporization are used. The compression ratio may also be increased if direct injection is used due to its effect on engine knock.
In some examples, each cylinder of engine 10 may include a spark plug 192 for initiating combustion. An ignition system 190 can provide an ignition spark to combustion chamber 14 via spark plug 192 in response to a spark advance signal SA from controller 12, under select operating modes. A timing of signal SA may be adjusted based on engine operating conditions and driver torque demand. For example, spark may be provided at or near maximum brake torque (MBT) timing to maximize engine power and efficiency. Controller 12 may input engine operating conditions, including engine speed and engine load, into a look-up table and output the corresponding MBT timing for the input engine operating conditions, for example.
In some examples, each cylinder of engine 10 may be configured with one or more fuel injectors for providing fuel thereto. As a non-limiting example, cylinder 14 is shown including a fuel injector 166. Fuel injector 166 may be configured to deliver fuel received from a fuel system 8. Fuel system 8 may include one or more fuel tanks, fuel pumps, and fuel rails. Fuel injector 166 is shown coupled directly to cylinder 14 for injecting fuel directly therein in proportion to the pulse width of a signal FPW received from controller 12 via an electronic driver 168. In this manner, fuel injector 166 provides what is known as direct injection (hereafter also referred to as “DI”) of fuel into cylinder 14. While
In an alternate example, fuel injector 166 may be arranged in intake air passage 146 rather than coupled directly to cylinder 14 in a configuration that provides what is known as port injection of fuel (hereafter also referred to as “PFI”) into an intake port upstream of cylinder 14. In yet other examples, cylinder 14 may include multiple injectors, which may be configured as direct fuel injectors, port fuel injectors, or a combination thereof. As such, it should be appreciated that the fuel systems described herein should not be limited by the particular fuel injector configurations described herein by way of example.
Fuel injector 166 may be configured to receive different fuels from fuel system 8 in varying relative amounts as a fuel mixture and further configured to inject this fuel mixture directly into cylinder 14. Further, fuel may be delivered to cylinder 14 during different strokes of a single cycle of the cylinder. For example, directly injected fuel may be delivered at least partially during a previous exhaust stroke, during an intake stroke, and/or during a compression stroke. As such, for a single combustion event, one or multiple injections of fuel may be performed per cycle. The multiple injections may be performed during the compression stroke, intake stroke, or any appropriate combination thereof in what is referred to as split fuel injection.
Fuel tanks in fuel system 8 may hold fuels of different fuel types, such as fuels with different fuel qualities and different fuel compositions. The differences may include different alcohol contents, different water contents, different octane numbers, different heats of vaporization, different fuel blends, and/or combinations thereof, etc. One example of fuels with different heats of vaporization includes gasoline as a first fuel type with a lower heat of vaporization and ethanol as a second fuel type with a greater heat of vaporization. In another example, the engine may use gasoline as a first fuel type and an alcohol-containing fuel blend, such as E85 (which is approximately 85% ethanol and 15% gasoline) or M85 (which is approximately 85% methanol and 15% gasoline), as a second fuel type. Other feasible substances include water, methanol, a mixture of ethanol and water, a mixture of water and methanol, a mixture of alcohols, etc. In still another example, both fuels may be alcohol blends with varying alcohol compositions, wherein the first fuel type may be a gasoline alcohol blend with a lower concentration of alcohol, such as E10 (which is approximately 10% ethanol), while the second fuel type may be a gasoline alcohol blend with a greater concentration of alcohol, such as E85 (which is approximately 85% ethanol). Additionally, the first and second fuels may also differ in other fuel qualities, such as a difference in temperature, viscosity, octane number, etc. In still another example, fuel tanks in fuel system 8 may hold diesel fuel. Moreover, fuel characteristics of one or both fuel tanks may vary frequently, for example, due to day to day variations in tank refilling.
Controller 12 is shown in
Controller 12 receives signals from the various sensors of
As described above,
Continuing to
Water pump 46 may be driven by an electric motor 36, which may be driven using power drawn from system battery 58 (shown in
One or more blowers (not shown) and cooling fans may be included in cooling system 100 to provide airflow assistance and augment a cooling airflow through the under-hood compartment. For example, cooling fans 91 and 95, coupled to radiator 40, may be operated when the vehicle is moving and the engine is running to provide cooling airflow assistance through radiator 40. The cooling fans may be coupled behind radiator 40 (when looking from a grille of vehicle 5 toward engine 10). Cooling fans 91 and 95 may draw a cooling airflow into the under-hood compartment through an opening in the front-end of vehicle 5, for example, through the grille (not shown). Such a cooling airflow may then be utilized by radiator 40 and other under-hood components (e.g., fuel system components, batteries, etc.) to keep the engine and/or transmission cool. Further, the airflow may be used to reject heat from a vehicle air conditioning system. While this example depicts two cooling fans, other examples may use only a single cooling fan.
Cooling fans 91 and 95 may be coupled to battery-driven motors 93 and 97, respectively. Motors 93 and 97 may be driven using power drawn from system battery 58 (shown in
Controller 12 (shown in
Next,
Turning first to
As mentioned above, cylinder head 200 includes an IEM, where an exhaust manifold is integrated into cylinder head 200 instead of coupled to the cylinder head as a separate component. For example, the IEM may be cast and/or drilled into cylinder head 200 such that the cylinder head metal defines the IEM passages. As shown, cylinder head 200 may include a bore 230 for housing an exhaust gas pressure sensor configured to measure a pressure of an exhaust gas feed from an IEM exhaust port core 240 (illustrated in
EGR passage 207 may be fluidically coupled to an EGR cooler (e.g., EGR cooler 85 of
Cylinder head 200 and the components packaged therein, including IEM exhaust port core 240 and EGR cartridge 210, are cooled by a water jacket 250, the water jacket 250 having an upper jacket 252 and a lower jacket 254. For example, liquid coolant (e.g., water) may be circulated through water jacket 250 (e.g., via water pump 46 of
Further,
As shown in
In the example shown in
Water jacket 250 may cool cylinder head 200 and the components coupled therein (e.g., EGR cartridge 210) via convection due to the circulating coolant within water jacket 250. An amount of heat transferred via convection is a function of a velocity of the current flow, a surface area of contact between the coolant and cylinder head 200, a temperature difference between cylinder head 200 and the circulating coolant, and fluid properties of the coolant. Convection is a relatively fast process compared with conduction (e.g., if the coolant were not moving). Thus, a faster velocity of the coolant results in more efficient cooling of cylinder head 200 (e.g., a greater heat transfer and at a faster rate). More surface area between cylinder head 200 and the also coolant results in more efficient cooling of cylinder head 200. As an example, coolant may flow around EGR cartridge 210 at a minimum flow rate of 1 meter per second (m/s) for adequate cooling of EGR cartridge 210 to prevent degradation of the EGR cartridge components and prevent boiling of the circulating coolant. In particular, water jacket 250 may be shaped to control a velocity of the coolant flowing throughout water jacket 250 as well as the surface area of contact between the coolant and cylinder head 200, particularly the surface area adjacent to EGR cartridge 210.
In particular,
The section view of
Further, EGR cartridge bore 220 may have a variable diameter or a constant diameter. In the example shown in
Referring to
As shown in
EGR valve 216 is shown as a poppet valve in
EGR valve 216 is shown in an open position in
Actuator 226 may actuate EGR valve 216 between the open position shown in
When EGR valve 216 is closed (e.g., fully closed), the poppet valve is pressed against and in direct contact with valve seat 218, preventing the first portion of exhaust gas to flow through EGR valve housing 214 to EGR passage 207. Instead, all of the exhaust gas (both the first portion and the second portion) may flow to the exhaust system (e.g., the flow path shown by arrow 204). However, even when exhaust gas does not flow through EGR cartridge 210 due to the closed EGR valve 216, heat from combustion may still be transferred to EGR cartridge 210 due to its position within cylinder head 200.
In order to effectively cool EGR cartridge 210 under all engine operating conditions, a crushable metal liner 224 is positioned directly between an in direct contact with an outer circumference of EGR valve housing 214 and an inner circumference of EGR cartridge bore 220, as indicated by dashed boxes, providing a heat conduction path between EGR valve housing 214 and cylinder head 200. Metal liner 224 may be comprised of brass or another metal having a high thermal conductivity, such as at least 100 W/(m K), and provides efficient heat transfer between EGR valve housing 214 (and the components disposed therein, such as valve guide 228) to cylinder head 200 through full, direct metal-to-metal (e.g., surface) contact. For example, metal liner 224 may be in direct contact with cylinder head 200, without any voids or gaps (e.g., air pockets) between metal liner 224 and cylinder head 200, and metal liner 224 may also be in direct contact with EGR valve housing 214, without any voids or gaps between metal liner 224 and EGR valve housing 214. Further, metal liner 224 may be comprised of radial thermal conductor rings. For example, metal liner 224 may efficiently transfer heat from EGR valve housing 214 to the metal of cylinder head 200 surrounding EGR valve housing 214 and in direct contact with metal liner 224. The heat transferred to cylinder head 200 may be further transferred to the circulating coolant in upper jacket 252, particularly to the coolant within top portion 258 and EGR cartridge jacket core 256. For example, top portion 258 of upper jacket 252 overlaps with a vertical positioning of valve seat 218 to fully surround valve seat 218, and EGR cartridge jacket core 256 overlaps with a vertical positioning of valve guide 228 to partially surround valve guide 228. Thus, top portion 258 and EGR cartridge jacket core 256 are positioned to vertically overlap with hot points in EGR cartridge 210 (e.g., valve seat 218 and valve guide 228, respectively) in order to increase a rate of cooling at these hot points.
Further, coolant continues to circulate through top portion 258 and EGR cartridge jacket core 256 to maintain EGR cartridge cooling even when EGR is not provided, and heat is efficiently transferred away from EGR cartridge 210 to the circulating coolant via metal liner 224. For example, heat may be removed from the cylinder head metal adjacent to EGR cartridge 210 via convention from the coolant velocity on the inner surface of the water jacket passages that form top portion 258 and EGR cartridge jacket core 256. In this way, high heat degradation of EGR cartridge components, such as degradation of valve guide 228 and EGR valve seal 222, may be reduced or prevented.
Next,
At 802, method 800 includes estimating and/or measuring operating conditions. The operating conditions may include, for example, engine speed, engine load, engine temperature (e.g., based on signal ECT received from temperature sensor 116 of
At 804, method 800 includes flowing coolant around the EGR cartridge via a cylinder head water jacket. Because the EGR cartridge is internally packaged in the cylinder head, coolant passages of the cylinder head water jacket are positioned adjacent to the EGR cartridge, as described above with particular reference to
At 806, method 800 includes determining if EGR is requested. As an example, EGR may be desired to attain a desired engine dilution, thereby increasing fuel efficiency and emissions quality. For example, EGR may be requested at low-to-mid engine loads. Additionally, EGR may be desired after an exhaust catalyst (e.g., emission control device 178 of
If EGR is not requested, method 800 proceeds to 808 and includes maintaining current engine operating conditions without supplying EGR. As such, the EGR valve will be actuated fully closed by the EGR valve actuator or maintained fully closed, thereby blocking a flow of exhaust gas from the IEM to EGR passage. However, coolant will continue to be circulated around the cylinder head water jacket, including around the EGR cartridge, to prevent heat-related degradation of the EGR cartridge. Method 800 may then end.
Returning to 806, if instead EGR is requested, method 800 proceeds to 810 and includes determining an amount (e.g., flow rate) of EGR requested. For example, the controller may refer to a look-up table having the engine speed and load as the inputs, which may output an EGR amount (or dilution amount) corresponding to the input engine speed-load. In another example, the controller may determine the EGR amount through logic rules that directly take into account parameters such as engine load, engine speed, engine temperature, etc. In still other examples, the controller may rely on a model that correlates a change in engine load with a change in a desired dilution, and further correlates the change in the desired dilution with a change in the amount of EGR requested. For example, as the engine load increases from a low load to a mid load, the amount of EGR requested may increase, and then as the engine load increases from a mid load to a high load, the amount of EGR requested may decrease. The controller may further determine the amount of EGR requested by taking into account a best fuel economy mapping for the desired dilution.
At 812, method 800 includes opening the EGR valve to supply the requested amount of EGR. For example, the controller may determine an open position of the EGR valve by inputting the requested amount of EGR into a look-up table or map, which may output a corresponding open position of the EGR valve (or degree of opening to apply to the EGR valve). As an example, as the requested amount of EGR increases, the degree of opening of the EGR valve may be increased. The controller may transmit a control signal to the EGR valve actuator to adjust the EGR valve to the determined open position. Further, the EGR valve position may be adjusted as operating conditions, and thus the desired engine dilution, change. Additionally, coolant will continue to be circulated around the cylinder head water jacket, including around the EGR cartridge, to prevent heat-related degradation of the EGR cartridge. Following 812, method 800 ends.
In this way, EGR may be provided with a smaller flow path length and volume between an exhaust valve of a cylinder and an EGR valve, reducing time-to-torque and increasing maximum low end torque. For example, by packaging the EGR valve in a cylinder head having an integrated exhaust manifold, the EGR valve may have a direct exhaust gas feed from exhaust ports contained within the cylinder head, enabling a rapid EGR response when the EGR valve is opened. Further, by packaging the EGR valve in the IEM cylinder head, EGR system complexity may be reduced, thereby reducing a number of components and assembly costs. For example, a water jacket of the cylinder head may be engineered to cool not only the cylinder head, but the EGR valve packaged therein, eliminating an EGR valve cooling system that is external to the cylinder head. As another example, due to the reduction of EGR system components external to the cylinder head, noise, vibration, and harshness may be reduced.
The technical effect of packaging an EGR valve of an EGR system within a cylinder head having an integrated exhaust manifold is that engine performance is increased while a cost and complexity of the EGR system is decreased.
In one example, a system comprises: a cylinder head including an integrated exhaust manifold (IEM); an exhaust gas recirculation (EGR) cartridge positioned in a cylindrical bore in the cylinder head at a central collector region of the IEM, the EGR cartridge including an EGR valve positioned therein; and a water jacket enclosed within the cylinder head, the water jacket including a first cooling passage that surrounds a circumference of the EGR cartridge. In the preceding example, additionally or optionally, the EGR cartridge includes a cylindrical housing having a first opening at a bottom of the housing a second opening in a side of the housing, and wherein the housing forms a passage between the first opening and the second opening. In one or both of the preceding examples, the system additionally or optionally further comprises an EGR passage within in the cylinder head positioned vertically above and parallel to an exhaust port exit of the IEM, and wherein the second opening of the housing of the EGR cartridge is flush with the EGR passage. In any or all of the preceding examples, additionally or optionally, the EGR valve comprises a poppet valve, the first opening forms a valve seat for the poppet valve, and the first cooling passage surrounds the circumference of the EGR cartridge at a vertical position that overlaps with the valve seat. In any or all of the preceding examples, the system additionally or optionally further comprises a thermal conductor positioned between the housing of the EGR cartridge and the cylindrical bore and in direct contact with each of the housing and the cylindrical bore. In any or all of the preceding examples, additionally or optionally, the thermal conductor is a crushable metal liner. In any or all of the preceding examples, additionally or optionally, the water jacket further includes a second cooling passage positioned vertically above the first cooling passage. In any or all of the preceding examples, additionally or optionally, the second cooling passage surrounds a portion of the circumference of the EGR cartridge at a vertical position that overlaps with the second opening. In any or all of the preceding examples, additionally or optionally, the second cooling passage includes tapered channels that fluidically couple the second cooling passage to the first cooling passage. In any or all of the preceding examples, additionally or optionally, the EGR cartridge further includes a valve guide that couples the EGR valve within the cylindrical housing, and the second cooling passage surrounds a portion of the circumference of the EGR cartridge at a vertical position that overlaps with the valve guide.
As another example, a system comprises: an engine including a cylinder head, the cylinder head including an integrated exhaust manifold (IEM) and a water jacket contained therein, the water jacket including an upper jacket and a lower jacket fluidically coupled via drill passages; and an exhaust gas recirculation (EGR) system including an EGR cartridge coupled within a cylindrical bore in the cylinder head, the EGR cartridge positioned to receive engine exhaust gas directly from the IEM, and an EGR passage integrated in the cylinder head, the EGR passage fluidically coupling the EGR cartridge to a cooler positioned external to the engine. In the preceding example, additionally or optionally, a top portion of the upper jacket vertically overlaps with the EGR cartridge and fully surrounds a circumference of the EGR cartridge. In one or both of the preceding examples, additionally or optionally, the water jacket further includes an EGR cartridge core fluidically coupled to and positioned vertically above the top portion of the upper jacket. In any or all of the preceding examples, additionally or optionally, the EGR cartridge includes a valve guide positioned therein, and the EGR cartridge core surrounds a portion of the valve guide. In any or all of the preceding examples, additionally or optionally, a vertical position of the EGR cartridge core overlaps with a vertical position of the valve guide. In any or all of the preceding examples, additionally or optionally, the EGR cartridge includes a cylindrical housing with an EGR valve coupled therein, and wherein the IEM is fluidically coupled to the EGR passage when the EGR valve is in an open position. In any or all of the preceding examples, additionally or optionally, the cylindrical housing forms a valve seat for the EGR valve, and the top portion of the upper jacket fully surrounds a circumference of the valve seat.
As another example, a method comprises: flowing coolant around an exhaust gas recirculation (EGR) valve coupled in an cylinder head of an engine via a water jacket of the cylinder head, the EGR valve positioned to receive exhaust gas directly from an exhaust manifold integrated in the cylinder head; and adjusting a position of the EGR valve based on a desired EGR rate. In the preceding example, additionally or optionally, flowing coolant around the EGR valve includes flowing coolant through the water jacket at a flow rate of at least one meter per second. In one or both of the preceding examples, additionally or optionally, adjusting the position of the EGR valve based on the desired EGR rate includes adjusting the EGR valve to a further open position as the desired EGR rate increases and adjusting the EGR valve to a further closed position as the desired EGR rate decreases.
In another representation, an engine system comprises: a cylinder head including an integrated exhaust manifold (IEM); an exhaust gas recirculation (EGR) cartridge positioned in a cylindrical bore in the cylinder head, the cylindrical bore directly coupled to the IEM; and a water jacket enclosed within the cylinder head, the water jacket including one or more cooling passages that surround the EGR cartridge. In the preceding example, the engine system additionally or optionally further comprises a water pump fluidically coupled to the water jacket, the water pump configured to flow coolant through the water jacket during engine system operation. In one or both of the preceding examples, additionally or optionally, the EGR cartridge includes a cylindrical housing, the cylindrical housing thermally coupled to the cylindrical bore via a brass liner in direct contact with each of the cylindrical housing and the cylindrical bore. In any or all of the preceding examples, additionally or optionally, the EGR cartridge further includes a valve guide that couples a poppet valve to the cylindrical housing. In any or all of the preceding examples, additionally or optionally, the cylindrical housing forms a valve seat for the poppet valve. In any or all of the preceding examples, additionally or optionally, the valve seat is at a bottom-most position of the cylindrical housing and forms a first opening in the cylindrical housing. In any or all of the preceding examples, additionally or optionally, the cylindrical housing includes a second opening in a side of the cylindrical housing. In any or all of the preceding examples, additionally or optionally, the second opening is rotated 90 degrees from the first opening and overlaps with a vertical position of the valve guide. In any or all of the preceding examples, additionally or optionally, the one or more cooling passages that surround the EGR cartridge include a first cooling passage that fully surrounds a circumference of the EGR cartridge at a vertical position that overlaps with the valve seat. In any or all of the preceding examples, additionally or optionally, the one or more cooling passages that surround the EGR cartridge include a second cooling passage that partially surrounds the circumference of the EGR cartridge at a vertical position that overlaps with each of the valve guide and the second opening. In any or all of the preceding examples, additionally or optionally, the second cooling passage is positioned vertically above the first cooling passage and is fluidically coupled to the first cooling passage. In any or all of the preceding examples, additionally or optionally, during engine system operation, coolant flows from the first cooling passage to the second cooling passage and back to the first cooling passage.
Note that the example control and estimation routines included herein can be used with various engine and/or vehicle system configurations. The control methods and routines disclosed herein may be stored as executable instructions in non-transitory memory and may be carried out by the control system including the controller in combination with the various sensors, actuators, and other engine hardware. The specific routines described herein may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various actions, operations, and/or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the features and advantages of the example embodiments described herein, but is provided for ease of illustration and description. One or more of the illustrated actions, operations, and/or functions may be repeatedly performed depending on the particular strategy being used. Further, the described actions, operations, and/or functions may graphically represent code to be programmed into non-transitory memory of the computer readable storage medium in the engine control system, where the described actions are carried out by executing the instructions in a system including the various engine hardware components in combination with the electronic controller.
It will be appreciated that the configurations and routines disclosed herein are exemplary in nature, and that these specific embodiments are not to be considered in a limiting sense, because numerous variations are possible. For example, the above technology can be applied to V-6, I-4, I-6, V-12, opposed 4, and other engine types. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, and other features, functions, and/or properties disclosed herein.
As used herein, the term “approximately” is construed to mean plus or minus five percent of the range unless otherwise specified.
The following claims particularly point out certain combinations and sub-combinations regarded as novel and non-obvious. These claims may refer to “an” element or “a first” element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.
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