CN107075998A - 用于在通过催化转换器处理之前引起改进的废气混合的排气系统和设备 - Google Patents

用于在通过催化转换器处理之前引起改进的废气混合的排气系统和设备 Download PDF

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CN107075998A
CN107075998A CN201580056082.4A CN201580056082A CN107075998A CN 107075998 A CN107075998 A CN 107075998A CN 201580056082 A CN201580056082 A CN 201580056082A CN 107075998 A CN107075998 A CN 107075998A
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埃里克·富尔彻
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Abstract

公开了一种废气混合器以及包括这种废气混合器的排气系统，该废气混合器用于在内燃机的排气流中给予涡流和湍流。

Description

用于在通过催化转换器处理之前引起改进的废气混合的排气 系统和设备
相关申请的交叉引用
本申请要求2014年10月15日提交的美国临时专利申请号62/064,258的优先权，其全部内容通过引用并入本文。
背景技术
在压缩点火内燃机的运行中，废气(尾气)的排放控制是持续的关注点。在燃料的节约与废气排放(即，NOx、碳氢化合物、微粒和煤烟)之间存在不断的权衡。最近的空气质量管控甚至已经更加严格要求减少这些排放。由于该原因在某种程度上，车辆和发动机制造商已经创造或要求包括选择性催化还原剂(SCR)以及柴油微粒过滤器(DPF)的排气系统。
在运行中，发动机废气流流过配备有至少一个传感器的发动机排气管道，该至少一个传感器用以检测排放水平，诸如，例如废气流中的NOx水平。废气(诸如，例如NOx)排放的水平经由公用区域网络(CAN)传输至ECU。然后排气流进入减少碳氢化合物、煤烟和微粒的DPF。当NOx传感器信号指示来自DPF出口的废气流中的NOx水平超过可接受的水平时，将信号从ECU发送至与DEF供应器通信的喷射器，以将预定量的DEF喷射到废气流中。DEF中的氨与废气混合。废气流穿过SCR，在SCR中，用DEF中的氨将废气流催化成N2气体和2H2O，然后从排气管中排出。
DEF是昂贵的，并且DEF的使用要求重型柴油车辆的操作者将车辆上的副油箱填充有待在发动机的运行期间使用的DEF。需要更有效地使用DEF供应器，以将发动机的停机时间、由于DEF供应而发生的成本降到最低，并且减少来自发动机的排气管的NOx排放量。
发明内容
在一个方面，公开了一种用于压缩点火内燃机的排气系统，该排气系统提供了DEF在废气流中的改进的混合，以促进更有效地使用DEF，并且减少如此配备的发动机的NOx排放。
在另外的方面，公开了一种用于包括在压缩点火内燃机的排气系统中的设备，该设备引起废气流中的废气和喷射的DEF的改进的湍流涡流以及混合。作为使废气流穿过该新型设备的结果引入的涡流和混合减少了DEF的消耗，同时满足如此配备的发动机的废气流出物中NOx排放所要求的标准。
附图说明
图1是具有排气系统的内燃机的示意图；
图2A是用在废气混合器的入口部分中的人字形(herringbone)基板的前视图；
图2B是用在废气混合器的出口部分中的人字形基板的前视图；
图3是废气混合器的侧视图的示意图；
图4是废气混合器的一个实施方案的立体图。
具体实施方式
现在转至附图，其中相同的附图标记指代相同的结构，图1是内燃机10的示意图，该内燃机可以是压缩点火发动机，具有电子控制单元(ECU)12，该电子控制单元具有存储器13，在该存储器中包括有用于以本领域普通技术人员理解的方式运行发动机的运行指令15。ECU存储器可以是RAM、ROM、PROM、EPROM、EEPROM、FLASH或任何其他的存储器。伴随这些运行指令包括在ECU存储器中的是排气系统指令，所述排气系统指令响应于所感测的废气情况使排气系统14的各个方面运行。排气系统指令可以包括表格，该表格存储有NOx排放的水平以及与NOx的水平相称的待喷射到废气流中的DEF的量/时机，或者排气系统指令可以包含图解，该图解示出了NOx水平和关联的DEF喷射量/时机。就此而言，该排气系统被示出用于柴油发动机，但是预期的是任何内燃机均可以利用本申请的废气混合器的实施方案。
在一个实施方案中，排气系统14包括从发动机排气出口18延伸穿过排气系统的排气出口20的废气管道16。该废气管道具有足够大小的内径21，以允许废气从发动机无限制地流出并穿过排气系统。在本实施例中，排气系统配备有通过公用区域网络(CAN)30或任何其他电子系统电子地连接至ECU的NOx排气传感器25。传感器25感测排气流19中的NOx水平，并且将指示排气流中的NOx水平的数据信号发送至ECU。排气系统还包括DPF24，该DPF具有与排气管道的内径21基本上相同内径的入口17和出口35，使得存在废气流穿过DPF入口到DPF出口的无限制流动。正如本实施例中那样，如果排气系统是柴油排气系统，则设置有在管道33处通过DEF喷射器29流体地连接至排气管道16的DEF供应源27，该DEF供应源可以是箱或其他合适的容器。DEF供应器和喷射器被定位在废气混合器单元22的上游，该废气混合器单元被定位在选择性催化反应剂(SCR)23的上游。废气混合器具有与管道16的内径21基本上相同内径的入口26和出口28。当NOx排气传感器检测到废气流中的NOx水平超过存储器中排气系统运行指令中指出的预定水平时，ECU指挥从DEF供应器27通过喷射器29将预定量的DEF喷射到排气流中。废气混合器具有一种构造，如下文将进行讨论的，该构造将给予废气流和喷射的DEF改进的涡流以及混合，以改进DEF与排气流的混合。DEF与废气的改进的混合允许SCR更有效地将更多的NOx转换成H2O和N2，这将导致更少的NOx排放。废气混合器还允许使用较少量的DEF来实现期望的NOx排放的降低。
现在转至图2A至图4，现在将描述废气混合器。具体地，主体32可以设置为任何形状，并且示出的是管状的。该主体具有彼此间隔的相对的端部34和36以及内表面31和外表面37，该内表面和外表面在相对的端部之间基本上连续地(完整地)延伸以限定内部38，该内部具有至少与排气系统相同的内径40，以便不会阻碍废气流动流。
废气混合器基板(基底)42、45设置在主体的各个相对端部处，并且被装配到主体的内部空间中。在一个实施例中，废气基板具有比主体的长度41的1/2稍微短些的长度43。套筒56定位在主体中排气基板之间，并且固定在适当的位置使得在套筒的任一侧在套筒和基板之间形成空间57。套筒和空间在主体的内部创造了低压区域49。套筒可以凸焊或以任何其他方式固定，以将其保持在基板之间的适当位置处。因此，可以理解的是，基板从废气混合器入口或废气出口朝向彼此延伸，使得在基板之间存在低压区域49，以增强从废气混合器的入口将废气流吸引到废气混合器的出口。主体在其端部倾斜并且与保持器端部环58、60配合，以将基板保持在主体中。本领域技术人员会理解的是，排气混合器的设计可以根据排气系统的整体要求来改变基板或套管的尺寸比例或各种部件的比例。
废气混合器基板42、45具有人字形结构46，并且可以在其第一端部或第二端部与保持器环48、50周向地配合，以便以紧凑的形式容纳基板，以方便处理和制造。然而要理解的是，保持器环并不是必须的，并且预期基板可以直接配合到混合器的主体内部中，而不需要使用保持器环。废气基板由具有一定长度和宽度的连续的波纹状箔金属催化剂构成的金属基板(基底)或其他刚性基板制成，该连续的波纹状箔金属催化剂是波纹状的并且折叠成扇形折叠构造，以形成如2015年10月14日提交的共同未决申请PCT/US2015/055440中公开的基板的人字形构造，该共同未决申请通过引用全部并入本文中，或者废气基板可以由在其角部结合并且布置成人字形构造的各个波纹状金属基板片制成。基板还可以通过使用切割堆叠方法或缠绕结构来制成。基板的重要方面是每个基板相对于彼此以及相对于废气流动的人字形构造，这将在下面描述。
如图2A和图2B中看到的，废气基板在主体中定向，使得图2A所示的入口基板的人字形构造被定向成偏离图2B所示的出口废气基板的人字形构造的取向的90度。以这种方式，废气流进入废气混合器入口，并且随着废气流穿过人字形基板，致使废气流在X-Y平面中产生涡流并进行混合。然后废气流被吸引通过低压区域，并且遇到定向成偏离入口废气基板的取向90度的出口排气基板。穿过出口废气基板混合器导致在X-Z平面中进行湍流混合并产生涡流，从而给予(提供)废气流最大的混合。如果NOx传感器已经感测到废气流中的NOx水平要求在废气混合器的上游喷射一定量的DEF，则DEF也与废气流混合。与不使用所描述的废气混合器的情况下需要将较多量的DEF喷射到排气流中相比，这种混合允许较少量的DEF被喷射到废气流中，以随着废气流穿过SCR，实现相同的化学反应。
用于说明示出的实施方案的词语可以被理解成描述性的词语而不是限制性的词语。虽然已经对实施方案进行了描述，但对于本领域技术人员来说显而易见的是，在不偏离所附权利要求所阐述的本发明的范围和精神的情况下，许多变形和修改是可能的。

Claims (5)

1.一种在内燃机的排气流中给予涡流、混合和湍流的废气混合器，包括：
主体，所述主体具有相对于彼此间隔开并且由低压区域隔开的相对的第一端部和第二端部，所述第一端部具有入口并且所述第二端部具有出口，所述主体具有内表面和外表面，所述内表面和所述外表面在相对的所述第一端部和第二端部之间基本上连续地延伸以限定内部；所述入口和所述出口均具有基本上等于排气管道直径的直径；
所述主体在第一端部处还配备有具有人字形构造的第一排气基板，并且在第二端部处还配备有具有人字形构造的第二排气基板；
所述第一排气基板和所述第二排气基板由所述低压区域隔开，并且被定位成相对于彼此取向偏离，使得一个基板在X-Y平面中对废气流施加湍流和涡流，而另一个基板在X-Z平面中对所述废气流施加湍流和涡流。
2.根据权利要求1所述的废气混合器，其中，每个所述排气基板均由具有一定长度和宽度的连续的波纹状箔金属催化剂基板形成，所述连续的波纹状箔金属催化剂基板在预定的接合处被扇形折叠成扇形折叠式波纹状连续箔形状，所述形状具有面向彼此的至少两层相对的波纹状箔；每个层中的所述波纹相对于彼此定位，以在所述层之间形成基本上一致的图案，所述形状具有一定的长度和面；所述基板具有一定的长度和面，每个所述基板的长度从所述入口或所述出口延伸至所述低压区域。
3.一种用于内燃机的排气系统，包括：
具有一定长度的具有入口和出口的排气流管道、废气流传感器、在入口处与所述管道连接且具有出口的微粒过滤器；以及
废气混合器，所述废气混合器具有主体，所述主体具有相对于彼此间隔开并且由低压区域隔开的相对的第一端部和第二端部，所述第一端部具有入口并且所述第二端部具有出口，所述主体具有内表面和外表面，所述内表面和所述外表面在相对的所述第一端部和第二端部之间基本上完整地延伸以限定内部；所述入口和所述出口均具有基本上等于排气管道直径的直径；
所述主体在第一端部处还配备有具有人字形构造的第一排气基板，并且在第二端部处还配备有具有人字形构造的第二排气基板；
所述第一排气基板和所述第二排气基板由所述低压区域隔开，并且被定位成相对于彼此定向偏离，使得一个基板在X-Y平面中对废气流施加湍流、混合和涡流，而另一个基板在X-Z平面中对所述废气流施加湍流、混合和涡流。
4.根据权利要求3所述的排气系统，其中，所述微粒过滤器是柴油微粒过滤器。
5.根据权利要求4所述的排气系统，还包括在所述柴油微粒过滤器的出口之后流体地连接至所述排气管道的柴油排气流体供应器；以及选择性催化还原单元。
CN201580056082.4A 2014-10-15 2015-10-15 废气混合器及包括该废气混合器的排气系统 Expired - Fee Related CN107075998B (zh)

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