Low pressure exhaust gas recirculation apparatus

• US 8,905,009 B2
• Filed: 04/24/2012
• Issued: 12/09/2014
• Est. Priority Date: 04/27/2011
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Moritani, Yuichiro, Miyazaki, Shinsuke, Sasaki, Kazushi, Hashimoto, Koji
• Primary Examiner(s): Cronin, Stephen K
• Assistant Examiner(s): Laguarda, Gonzalo
• Application Number:
  US13/454,176
• Publication Number:
  US 20120272646A1
• Time in Patent Office: 959 Days
• Field of Search: 123/568.16, 123/568.17, 123/568.18, 123/568.19, 123/559.1, 123/336, 123/337, 123/568.2, 123/563, 123/568.12, 123/568.21, 701/103, 701/107, 701/108, 251/305, 606/051, 606/052
• US Class Current: 123/568.16
• CPC Class Codes: F02B 29/0406 Layout of the intake air cooling or coolant circuit
• CPC Class Codes: F02D 2041/0017 by simultaneous control of throttle and exhaust gas recirculation
• CPC Class Codes: F02D 2200/0404 Throttle position
• CPC Class Codes: F02D 41/0077 Control of the EGR valve or actuator, e.g. duty cycle, closed loop control of position EGR valve position sensor F02M26/48
• CPC Class Codes: F02D 41/221 relating to the failure of actuators or electrically driven elements
• CPC Class Codes: F02M 26/05 High pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust system upstream of the turbine and reintroduced into the intake system downstream of the compressor
• CPC Class Codes: F02M 26/06 Low pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust downstream of the turbocharger turbine and reintroduced into the intake system upstream of the compressor
• CPC Class Codes: F02M 26/10 having means to increase the pressure difference between the exhaust and intake system, e.g. venturis, variable geometry turbines, check valves using pressure pulsations or throttles in the air intake or exhaust system
• CPC Class Codes: F02M 26/15 in relation to engine exhaust purifying apparatus
• CPC Class Codes: F02M 26/21 with EGR valves located at or near the connection to the intake system
• CPC Class Codes: F02M 26/24 with two or more coolers
• CPC Class Codes: F02M 26/25 with coolers having bypasses
• CPC Class Codes: F02M 26/54 Rotary actuators, e.g. step motors
• CPC Class Codes: F02M 26/64 the EGR valve being operated together with an intake air throttle
• CPC Class Codes: F02M 26/70 Flap valves; Rotary valves; Sliding valves; Resilient valves
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

When a failure occurs in synchronizing mechanism, an intake air throttle valve is rotated in a direction that is opposite from a normal operational time valve closing direction, so that an arm of a driven plate contacts a throttle valve side stopper to stop rotation of the intake air throttle valve. Thereafter, when a low pressure EGR valve is rotated from a full close position to a full open position, an EGR valve side stopper contacts the arm of the driven plate to stop the low pressure EGR valve. A rotational angle of the EGR valve is sensed with a sensor and is outputted to an ECU. The ECU determines that a failure mode is set when a valve angle sensed with the sensor coincides with a rotation stop position of the EGR valve.

Claims

1. A low pressure EGR apparatus applied to an internal combustion engine having a supercharger installed in an intake and exhaust system, wherein the low pressure EGR apparatus recirculates a portion of exhaust gas, which has passed through an exhaust gas purifying device provided in an exhaust passage of the internal combustion engine, to an intake passage at a location that is on an upstream side of a compressor of the supercharger, as low pressure EGR gas, the low pressure-EGR apparatus comprising:

a low pressure EGR passage that connects between a portion of the exhaust passage, which is located on a downstream side of the exhaust gas purifying device, and a portion of the intake passage, which is located on an upstream side of the compressor;

a low pressure EGR valve that adjusts a flow quantity of the low pressure EGR gas to be recirculated into the intake passage through the low pressure EGR passage;

a valve drive device that drives the low pressure EGR valve;

a throttle valve that is installed in one of the exhaust passage and the intake passage, wherein the throttle valve reduces an opening degree of the one of the exhaust passage and the intake passage to increase the flow quantity of the low pressure EGR gas to be recirculated into the intake passage;

a synchronizing mechanism that drives the throttle valve in a closing direction for closing the one of the exhaust passage and the intake passage synchronously with a valve opening movement of the low pressure EGR valve, which is a rotational movement of the low pressure EGR valve in an opening direction for opening the low pressure EGR passage, wherein the synchronizing mechanism drives the throttle valve in an opening direction for opening the one of the exhaust passage and the intake passage synchronously with a valve closing movement of the low pressure EGR valve, which is a rotational movement of the low pressure EGR valve in a closing direction for closing the low pressure EGR passage, wherein the synchronizing mechanism includes a drive plate that is rotated integrally with the low pressure EGR valve, a driven plate that is rotated integrally with the throttle valve, and a cam mechanism that transmits rotation of the drive plate to the driven plate;

a failure mode setting mechanism that sets a failure mode by limiting rotation of the throttle valve and rotation of the low pressure EGR valve and sets the failure mode in a state where coupling between the drive plate and the driven plate is released due to malfunction of the cam mechanism; and

a failure mode determining device that determines whether the failure mode is set based on a rotational position of the low pressure EGR valve, wherein;

the failure mode setting mechanism includes;

a spring that urges the throttle valve in an opposite direction, which is opposite from the closing direction of the throttle valve for closing the one of the exhaust passage and the intake passage synchronously with the valve opening movement of the low pressure EGR valve;

a throttle valve side stopper that mechanically stops the throttle valve at a predetermined rotational position when the throttle valve is urged by the spring and is thereby rotated; and

a valve side stopper that mechanically stops rotation of the low pressure EGR valve in response to a stop position of the throttle valve;

the failure mode determining device includes a valve angle sensor that senses a rotational position of the low pressure EGR valve as a valve angle; and

the failure mode determining device determines that the failure mode is set in a case where the valve angle, which is sensed with the valve angle sensor, is the rotational position of the low pressure EGR valve, which is stopped by the valve side stopper, at a time of rotating the low pressure EGR valve from a full close position of the low pressure EGR valve, at which an opening degree of the low pressure EGR valve is minimum, to a full open position of the low pressure EGR valve, at which the opening degree of the low pressure EGR valve is maximum, wherein;

the throttle valve side stopper is placed to oppose the driven plate in a rotational direction of the driven plate for rotating the driven plate integrally with the throttle valve through urging of the throttle valve with the spring; and

the throttle valve stops at the predetermined rotational position when the driven plate contacts the throttle valve side stopper.

3. The low pressure EGR apparatus according to claim 1, wherein:

the valve side stopper is placed to oppose the driven plate; and

the valve side stopper contacts the driven plate to stop rotation of the low pressure EGR valve at the time of rotating the low pressure EGR valve from the full close position of the low pressure EGR valve in the opening direction for opening the low pressure EGR passage in a state where the driven plate contacts the throttle valve side stopper to stop the throttle valve at the predetermined rotational position.

6. The low pressure EGR apparatus according to claim 1, wherein the predetermined rotational position, at which the rotation of the throttle valve is stopped by the throttle valve side stopper at a time of setting the failure mode, is between a full close position of the throttle valve, at which the opening degree of the throttle valve is minimum, and a full open position of the throttle valve, at which the opening degree of the throttle valve is maximum.

7. The low pressure EGR apparatus according to claim 1, wherein the valve side stopper mechanically stops the rotation of the low pressure EGR valve when the low pressure EGR valve is rotated from the full close position of the low pressure EGR valve toward the full open position of the low pressure EGR valve in a state where the throttle valve is kept stopped by the throttle valve side stopper.

2. A low pressure EGR apparatus applied to an internal combustion engine having a supercharger installed in an intake and exhaust system, wherein the low pressure EGR apparatus recirculates a portion of exhaust gas, which has passed through an exhaust as purifying device provided in an exhaust passage of the internal combustion engine, to an intake passage at a location that is on an upstream side of a compressor of the supercharger, as low pressure EGR gas, the low pressure-EGR apparatus comprising:

a low pressure EGR passage that connects between a portion of the exhaust passage, which is located on a downstream side of the exhaust gas purifying device, and a portion of the intake passage, which is located on an upstream side of the compressor;

a low pressure EGR valve that adjusts a flow quantity of the low pressure EGR gas to be recirculated into the intake passage through the low pressure EGR passage;

a valve drive device that drives the low pressure EGR valve;

a throttle valve that is installed in one of the exhaust passage and the intake passage, wherein the throttle valve reduces an opening degree of the one of the exhaust passage and the intake passage to increase the flow quantity of the low pressure EGR gas to be recirculated into the intake passage;

a synchronizing mechanism that drives the throttle valve in a closing direction for closing the one of the exhaust passage and the intake passage synchronously with a valve opening movement of the low pressure EGR valve, which is a rotational movement of the low pressure EGR valve in an opening direction for opening the low pressure EGR passage, wherein the synchronizing mechanism drives the throttle valve in an opening direction for opening the one of the exhaust passage and the intake passage synchronously with a valve closing movement of the low pressure EGR valve, which is a rotational movement of the low pressure EGR valve in a closing direction for closing the low pressure EGR passage, wherein the synchronizing mechanism includes a drive plate that is rotated integrally with the low pressure EGR valve, a driven plate that is rotated integrally with the throttle valve, and a cam mechanism that transmits rotation of the drive plate to the driven plate;

a failure mode setting mechanism that sets a failure mode by limiting rotation of the throttle valve and rotation of the low pressure EGR valve and sets the failure mode in a state where coupling between the drive plate and the driven plate is released due to malfunction of the cam mechanism; and

a failure mode determining device that determines whether the failure mode is set based on a rotational position of the low pressure EGR valve, wherein;

the failure mode setting mechanism includes;

a spring that urges the throttle valve in an opposite direction, which is opposite from the closing direction of the throttle valve for closing the one of the exhaust passage and the intake passage synchronously with the valve opening movement of the low pressure EGR valve;

a throttle valve side stopper that mechanically stops the throttle valve at a predetermined rotational position when the throttle valve is urged by the spring and is thereby rotated; and

a valve side stopper that mechanically stops rotation o the low pressure EGR valve in response to a stop position of the throttle valve;

the failure mode determining device includes a valve angle sensor that senses a rotational position of the low pressure EGR valve as a valve angle; and

the failure mode determining device determines that the failure mode is set in a case where the valve angle, which is sensed with the valve angle sensor, is the rotational position of the low pressure EGR valve, which is stopped by the valve side stopper, at a time of rotating the low pressure EGR valve from a full close position of the low pressure EGR valve, at which an opening degree of the low pressure EGR valve is minimum, to a full open position of the low pressure EGR valve, at which the opening degree of the low pressure EGR valve is maximum,

wherein the cam mechanism has an insensitive zone, which limits a variation in an opening degree of the throttle valve in the full close position of the throttle valve with respect to a variation in an opening degree of the low pressure EGR valve in the full open position of the low pressure EGR valve.

4. The low pressure EGR apparatus according to claim 2, wherein:

the throttle valve side stopper is placed to oppose the driven plate in a rotational direction of the driven plate for rotating the driven plate integrally with the throttle valve through urging of the throttle valve with the spring; and

the throttle valve stops at the predetermined rotational position when the driven plate contacts the throttle valve side stopper.

5. The low pressure EGR apparatus according to claim 2, wherein:

the cam mechanism includes;

a cam groove that is formed in the drive plate; and

a roller that is provided in the driven plate and moves along the cam groove in response to rotation of the drive plate; and

the insensitive zone is set by a portion of a cam profile of the cam groove, which is formed by an arc that has a constant length from a rotational center of the drive plate.

8. The low pressure EGR apparatus according to claim 2, wherein:

the valve side stopper is placed to oppose the driven plate; and

the valve side stopper contacts the driven plate to stop rotation of the low pressure EGR valve at the time of rotating the low pressure EGR valve from the full close position of the low pressure EGR valve in the opening direction for opening the low pressure EGR passage in a state where the driven plate contacts the throttle valve side stopper to stop the throttle valve at the predetermined rotational position.

9. The low pressure EGR apparatus according to claim 2, wherein the predetermined rotational position, at which the rotation of the throttle valve is stopped by the throttle valve side stopper at a time of setting the failure mode, is between a full close position of the throttle valve, at which the opening degree of the throttle valve is minimum, and a full open position of the throttle valve, at which the opening degree of the throttle valve is maximum.

10. The low pressure EGR apparatus according to claim 2, wherein the valve side stopper mechanically stops the rotation of the low pressure EGR valve when the low pressure EGR valve is rotated from the full close position of the low pressure EGR valve toward the full open position of the low pressure EGR valve in a state where the throttle valve is kept stopped by the throttle valve side stopper.