Method and system for exhaust gas heat recovery

• US 9,689,295 B1
• Filed: 01/29/2016
• Issued: 06/27/2017
• Est. Priority Date: 01/29/2016
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Styles, Daniel Joseph, Uhrich, Michael James
• Primary Examiner(s): Maines, Patrick
• Application Number:
  US15/010,382
• Time in Patent Office: 515 Days
• CPC Class Codes: B60H 1/04 from cooling liquid of the plant B60H1/025, B60H1/03 take precedence
• CPC Class Codes: F01N 1/00 Silencing apparatus characterised by method of silencing by cooling F01N3/02; using liquids F01N3/04
• CPC Class Codes: F01N 11/005 the temperature or pressure being estimated, e.g. by means of a theoretical model
• CPC Class Codes: F01N 2240/02 a heat exchanger
• CPC Class Codes: F01N 2900/08 said parameters being related to the engine
• CPC Class Codes: F01N 3/0205 using heat exchangers
• CPC Class Codes: F01N 3/10 by thermal or catalytic conversion of noxious components of exhaust by using other chemical processes, chemical aspects of catalytic conversion, e.g. using specified catalysts, B01D53/34
• CPC Class Codes: F01N 5/02 the devices using heat
• CPC Class Codes: F01N 9/00 Electrical control of exhaust gas treating apparatus monitoring or diagnostic devices for exhaust-gas treatment apparatus F01N11/00; conjoint electrical control of two or more combustion engine functions F02D43/00
• CPC Class Codes: F02D 2041/1472 the characteristics being a humidity or water content of the exhaust gases
• CPC Class Codes: F02D 2200/021 Engine temperature
• CPC Class Codes: F02D 41/0007 for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02D 41/005 according to engine operating conditions
• CPC Class Codes: F02D 41/0052 Feedback control of engine parameters, e.g. for control of air/fuel ratio or intake air amount
• CPC Class Codes: F02D 41/064 at cold start F02D41/067 takes precedence
• CPC Class Codes: F02D 41/144 Sensor in intake manifold
• CPC Class Codes: F02D 41/1446 the characteristics being exhaust temperatures
• CPC Class Codes: F02D 41/1448 the characteristics being an exhaust gas pressure
• CPC Class Codes: F02D 41/1454 the characteristics being an oxygen content or concentration or the air-fuel ratio
• CPC Class Codes: F02M 2026/001 Arrangements; Control features; Details
• CPC Class Codes: F02M 26/22 : with coolers in the recirculation passage
• CPC Class Codes: F02M 26/33 : controlling the temperature of the recirculated gases
• CPC Class Codes: F02M 26/52 : Systems for actuating EGR valves
• CPC Class Codes: F02M 26/65 : Constructional details of EGR valves
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 : Engine management systems

Abstract

Methods and systems are provided for exhaust gas heat recovery at an exhaust gas heat exchanger. Exhaust gas may flow in both directions through an exhaust bypass passage and the heat exchanger coupled to the bypass passage. Hot or cold EGR may be delivered from the exhaust passage to the engine intake manifold and heat from the exhaust gas may be recovered at the heat exchanger.

Claims

1. A method comprising:

operating in a first mode with exhaust gas flowing through an exhaust bypass, and in a first direction through a heat exchanger coupled in the exhaust bypass, and then to an exhaust tailpipe; and

operating in a second mode with exhaust flowing through an exhaust passage, then in a second, opposite direction through the heat exchanger, and then to an engine intake;

selecting between the first and second mode based on engine temperature, wherein the selecting includes selecting the first mode when the engine temperature is below a threshold, and selecting the second mode when the engine temperature is above the threshold; and

maintaining operation in the first mode after the engine temperature is above the threshold responsive to a request for hot EGR.

2. The method of claim 1, wherein the flowing exhaust gas in the first direction includes flowing exhaust from downstream of an exhaust catalyst into the exhaust bypass, and then through a first end of the heat exchanger proximate the exhaust catalyst, to a second end of the heat exchanger, proximate the tailpipe, and wherein the flowing exhaust gas in the second direction includes flowing exhaust from downstream of the exhaust catalyst towards the tailpipe, then flowing exhaust from upstream of the tailpipe into the second end of the heat exchanger, then through the first end of the heat exchanger to the engine intake via an exhaust gas recirculation (EGR) passage.

3. The method of claim 2, wherein during the first mode, an EGR valve is closed.

4. The method of claim 1, further comprising, adjusting an opening of an EGR valve based on the request for hot EGR, the opening increased as the request for hot EGR increases.

5. The method of claim 1, further comprising, during the first mode, transferring heat from the flowing exhaust gas to the heat exchanger, then from the heat exchanger to coolant flowing through a heater core, and then heating a vehicle cabin by drawing heat from the heater core based on a cabin heating demand.

6. The method of claim 1, wherein during the first operating mode, a first valve coupled downstream of the exhaust catalyst in the exhaust passage is closed and a second valve coupled in the exhaust bypass is open, and wherein during the second mode, the first valve is open and the second valve is closed.

7. The method of claim 6, wherein one or more of the first and second valves are butterfly valves coupled to a common shaft, and wherein the valves are actuated together.

8. An engine system, comprising:

an engine intake manifold;

an engine exhaust manifold including an exhaust catalyst and a muffler coupled to each other via each of an exhaust passage and an exhaust bypass, the bypass coupled parallel to the exhaust passage;

an heat exchanger coupled in the exhaust bypass;

a coolant system fluidly coupled to the heat exchanger and to a heater core;

a valve system including a first valve coupled in the exhaust passage and a second valve coupled in the exhaust bypass upstream of a first end of the heat exchanger;

an EGR passage coupling the first end of the heat exchanger to the intake manifold, the EGR passage including an EGR valve; and

a controller with computer readable instructions stored on non-transitory memory for;

closing the EGR valve and operating the valve system in a first mode with the first valve closed, and the second valve open, to flow exhaust gas from the catalyst to the muffler through the exhaust bypass in a first direction through the heat exchanger;

in response to an increase in engine temperature, and a demand for heated EGR, opening the EGR valve while maintaining the valve system in the first mode; and

in response to the increase in engine temperature and no demand for heated EGR, maintaining the EGR valve closed while transitioning the valve system to a second mode with the first valve open, and the second valve closed, to flow exhaust gas from the catalyst into the exhaust bypass with exhaust flowing in a second, opposite direction through the heat exchanger, and then flowing exhaust from the heat exchanger to the intake manifold.

9. The system of claim 8, wherein the closing the EGR valve and operating the valve system in the first mode is responsive to an engine cold-start condition.

10. The system of claim 8, wherein flowing exhaust gas in the first direction through the heat exchanger includes exhaust gas entering the heat exchanger at the first end and exiting at a second, opposite end, and wherein flowing exhaust gas in the second direction through the heat exchanger includes exhaust gas entering the heat exchanger at the second end and exiting at the first end.

11. The system of claim 8, wherein the first and second valves are butterfly valves, each of the first and second valves coupled on a common shaft and actuated by a common actuator.

12. The system of claim 8, wherein when the valve system is operated in the first mode, heat from the exhaust gas released at the heat exchanger is transferred to engine coolant circulating through a heater core, the heat then transferred to a vehicle cabin, and wherein when the valve system is operated in the second mode, heat from the exhaust gas released at the heat exchanger is transferred to engine coolant circulating through a radiator, the heat then dissipated to atmosphere.