John Bucknell, PE

A power-based control system and method for an engine comprising a turbocharger involve obtaining a set of parameters that each affect exhaust gas energy and using the set of parameters to (i) determine a target mass flow into the engine and a target boost for the turbocharger to achieve a torque request, (ii) determine a target power for a compressor of the turbocharger to achieve the target engine mass flow and the target turbocharger boost, (iii) determine a target pressure ratio and a… Show more

A power-based control system and method for an engine comprising a turbocharger involve obtaining a set of parameters that each affect exhaust gas energy and using the set of parameters to (i) determine a target mass flow into the engine and a target boost for the turbocharger to achieve a torque request, (ii) determine a target power for a compressor of the turbocharger to achieve the target engine mass flow and the target turbocharger boost, (iii) determine a target pressure ratio and a target mass exhaust flow for the turbine of the turbocharger to achieve a target turbine power equal to the target compressor power, and (iv) determine a target position of the wastegate valve to achieve the target turbine pressure ratio and mass exhaust flow, and commanding a wastegate valve to the target position. Show less

Techniques for integrating a machine-readable matrix with a component of a mechanical structure using three-dimensional (3-D) printing are disclosed. Such techniques include generating at least one data model representing the component, and projecting a matrix pattern identifying one or more features of the component onto a selected surface portion of the component to produce a modified data model for use as an input to a 3-D printer.

A system and method for controlling condensation formation in an engine having EGR and forced induction includes a controller for determining a water vapor mass fraction of an exhaust stream based on a water vapor mass fraction of an intake stream and water vapor from combustion. An estimated condensation temperature (CT) is determined for a current EGR level based on the water vapor mass fractions and is compared to an intake stream temperature upstream of the compressor inlet. The controller… Show more

A system and method for controlling condensation formation in an engine having EGR and forced induction includes a controller for determining a water vapor mass fraction of an exhaust stream based on a water vapor mass fraction of an intake stream and water vapor from combustion. An estimated condensation temperature (CT) is determined for a current EGR level based on the water vapor mass fractions and is compared to an intake stream temperature upstream of the compressor inlet. The controller commands the current EGR level as a maximum EGR level upon determining the intake stream temperature is less than the CT, and an increase in the current EGR level upon determining the intake stream temperature is greater than the CT. An air charge temperature (ACT) of the forced induction system may be controlled based on utilizing a target ACT as the CT to be controlled by a coolant pump. Show less

A technique is provided for compensating an untrimmed oxygen (O2) sensor utilized in operation of an exhaust gas recalculation (EGR) system associated with an engine. The technique includes, in one implementation, receiving a measurement from the O2 sensor at a known pressure, where the O2 sensor is positioned on an intake side of an engine system. Humidity compensation and pressure compensation are then determined for the O2 sensor measurement, where the pressure compensation is based in part… Show more

A technique is provided for compensating an untrimmed oxygen (O2) sensor utilized in operation of an exhaust gas recalculation (EGR) system associated with an engine. The technique includes, in one implementation, receiving a measurement from the O2 sensor at a known pressure, where the O2 sensor is positioned on an intake side of an engine system. Humidity compensation and pressure compensation are then determined for the O2 sensor measurement, where the pressure compensation is based in part on the humidity compensation. The EGR system is controlled using the untrimmed O2 sensor measurement that has been compensated for pressure and humidity. Show less

A boost purge ejector tee arrangement is integrated into a turbocompressor associated with an engine and includes first and second passages, an inlet port and a nozzle. The first passage is formed into a housing of the turbocompressor and includes an outlet in communication with a turbocompressor inlet. The second passage is formed into the housing and includes a boost air inlet in communication with an internal outlet area of the turbocompressor and intersecting the first passage. The inlet… Show more

A boost purge ejector tee arrangement is integrated into a turbocompressor associated with an engine and includes first and second passages, an inlet port and a nozzle. The first passage is formed into a housing of the turbocompressor and includes an outlet in communication with a turbocompressor inlet. The second passage is formed into the housing and includes a boost air inlet in communication with an internal outlet area of the turbocompressor and intersecting the first passage. The inlet port is associated with the housing and intersects the first passage. The nozzle is positioned in the first passage such that an outlet of the nozzle is proximate the intersection of the inlet port and first passage. During a boost mode of operation, the second passage is adapted to receive boost air flow, which flows through the nozzle thereby creating a vacuum and drawing purge through the inlet port. Show less

An exhaust gas treatment device is disposed in an exhaust gas treatment system and comprises a rolled metal cylinder of corrugated metal sheet having longitudinally extending passages extending axially from an inlet end to an outlet end and a conduit disposed between layers of the rolled metal cylinder and configured for circulation of a heat transfer medium there through, the conduit extending axially and radially the rolled metal cylinder.

An engine assembly may include a first heat exchanger, a fluid supply system providing a fluid flow to the first heat exchanger, a fuel system, an engine block defining first and second cylinder bores, a first piston disposed within the first cylinder bore, and a second piston disposed within the second cylinder bore. The first cylinder bore may receive fuel from the fuel system for combustion therein to drive the first piston. The fluid flow may be pressurized within the first heat exchanger… Show more

An engine assembly may include a first heat exchanger, a fluid supply system providing a fluid flow to the first heat exchanger, a fuel system, an engine block defining first and second cylinder bores, a first piston disposed within the first cylinder bore, and a second piston disposed within the second cylinder bore. The first cylinder bore may receive fuel from the fuel system for combustion therein to drive the first piston. The fluid flow may be pressurized within the first heat exchanger and the pressurized fluid may be provided to the second cylinder bore to drive the second piston. Show less

In one exemplary embodiment of an exhaust system, the system includes an exhaust manifold in fluid communication with an internal combustion engine and a forced induction device in fluid communication with the exhaust manifold, the forced induction device including a housing. The system further includes a flow control device to control fluid communication between the forced induction device and a catalyst substrate and to control fluid communication between the exhaust manifold and the catalyst… Show more

In one exemplary embodiment of an exhaust system, the system includes an exhaust manifold in fluid communication with an internal combustion engine and a forced induction device in fluid communication with the exhaust manifold, the forced induction device including a housing. The system further includes a flow control device to control fluid communication between the forced induction device and a catalyst substrate and to control fluid communication between the exhaust manifold and the catalyst substrate. Show less

A fluid flow valve in a cylinder head comprises a first valve end and an axially disposed second shaft end connected by a valve shaft. A first valve member is located at the first valve end and a second valve member is located axially from, and in fixed relationship to, the first valve member along the valve shaft. A valve support extends axially between and connects the first valve member and the second valve member; the valve support including an axially extending wall portion having… Show more

A fluid flow valve in a cylinder head comprises a first valve end and an axially disposed second shaft end connected by a valve shaft. A first valve member is located at the first valve end and a second valve member is located axially from, and in fixed relationship to, the first valve member along the valve shaft. A valve support extends axially between and connects the first valve member and the second valve member; the valve support including an axially extending wall portion having circumferentially spaced support struts extending radially between the valve shaft and the wall portion. Fluid flow passages extend axially through the wall portion, between the circumferentially spaced support struts, wherein fluid flows simultaneously about the exterior of the wall portion and through the fluid flow passages in the wall portion when the valve member is biased to an open position. Show less

A method and system for controlling an engine with a supercharger includes a bypass valve control module controlling a bypass valve for the supercharger having a bypass flow area in response to a desired manifold absolute pressure, an inlet valve control module controlling an inlet throttle for a supercharger in response to a bypass flow area and a port throttle control module controlling a port throttle in response to the desired mass airflow.

A supercharged engine has a charge air intake and an engine exhaust outlet, a positive displacement supercharger connected to the air intake, a charge air and bypass control valve comprising a rotary body throttle valve including a rotary valve body, a primary air passage and a separate bypass air passage each extending through the rotary body. The primary air passage is fully open in a first rotary position of the rotary body wherein the bypass air passage is closed, and the bypass air passage… Show more

A supercharged engine has a charge air intake and an engine exhaust outlet, a positive displacement supercharger connected to the air intake, a charge air and bypass control valve comprising a rotary body throttle valve including a rotary valve body, a primary air passage and a separate bypass air passage each extending through the rotary body. The primary air passage is fully open in a first rotary position of the rotary body wherein the bypass air passage is closed, and the bypass air passage is fully open in a second rotary position wherein the primary air passage is closed. Airflow through the passages varies in an inverse manner as the rotary body is rotated between the first and second positions, whereby airflow through the control valve is controlled with a single actuator movable through the full range of positions and airflow through the primary and bypass passages is inversely varied. Show less

An engine assembly includes a vapor canister in selective fluid communication with a crankcase to store alcohol vapor when the temperature inside the crankcase causes alcohol accumulated in the crankcase to boil. The vapor canister is in selective fluid communication with an air induction system to recirculate the alcohol vapor through the engine in a metered fashion.

An exhaust gas turbocharger comprising: a twin scroll turbine housing; a turbine wheel positioned in the twin scroll housing; an exhaust gas inlet, operatively connected to port exhaust gas through each side of the twin scroll turbine housing and onto the turbine wheel; a bypass, operatively connected to the exhaust gas inlet to port exhaust gas around the twin scroll turbine housing to bypass the turbine wheel; and a valve, operatively positioned to control exhaust gas flow to each side of the… Show more

An exhaust gas turbocharger comprising: a twin scroll turbine housing; a turbine wheel positioned in the twin scroll housing; an exhaust gas inlet, operatively connected to port exhaust gas through each side of the twin scroll turbine housing and onto the turbine wheel; a bypass, operatively connected to the exhaust gas inlet to port exhaust gas around the twin scroll turbine housing to bypass the turbine wheel; and a valve, operatively positioned to control exhaust gas flow to each side of the twin scroll turbine housing and the bypass. Show less

An integrated inlet manifold tuning valve for a variable configuration air inlet manifold and a charge motion control system. A tuning valve, which is preferably approximately a quarter-barrel valve, is arranged at an end of the low- and high-speed runners at or near an intake port for an internal combustion engine. The tuning valve operates to tune the variable manifold and provide a mixture motion for charge motion control.

An intercooler for a vehicle engine incorporating an exhaust gas turbocharger and an air conditioning system, the intercooler comprising: a charge air cooler loop operatively connected to cool heated, pressurized air from the turbocharger before it flows into the vehicle engine; and an air conditioning system bypass loop operatively connecting the air conditioning system to the charge air cooler loop.

A waste heat recovery system that efficiently converts waste heat from an engine coolant and an engine exhaust in a vehicle. The system includes a coolant heat exchanger that receives heat from the engine coolant, an exhaust heat exchanger that receives heat from the engine exhaust and an economizer heat exchanger. A plurality of valves control the flow of the fluid in different modes as determined by a power ratio between the heat provided by the exhaust heat exchanger and the heat provided by… Show more

A waste heat recovery system that efficiently converts waste heat from an engine coolant and an engine exhaust in a vehicle. The system includes a coolant heat exchanger that receives heat from the engine coolant, an exhaust heat exchanger that receives heat from the engine exhaust and an economizer heat exchanger. A plurality of valves control the flow of the fluid in different modes as determined by a power ratio between the heat provided by the exhaust heat exchanger and the heat provided by the coolant heat exchanger, including an economizer heat exchanger after coolant heat exchanger mode at low power ratios, where the fluid from the pump flows to the economizer heat exchanger after the coolant heat exchanger and an economizer heat exchanger before coolant heat exchanger mode at high power ratios, where the fluid from the pump flows to the economizer heat exchanger before the coolant heat exchanger. Show less

A control system for an engine includes first and second modules. The first module estimates a total amount of exhaust gas recirculation (EGR) in the engine, wherein the total amount of EGR includes (i) EGR within cylinders of the engine and (ii) EGR flowing through an EGR system of the engine. The second module selectively controls an overlap of intake and exhaust valve timing in the engine based on (i) a position of an EGR valve in the EGR system and (ii) a comparison of the estimated total… Show more

A control system for an engine includes first and second modules. The first module estimates a total amount of exhaust gas recirculation (EGR) in the engine, wherein the total amount of EGR includes (i) EGR within cylinders of the engine and (ii) EGR flowing through an EGR system of the engine. The second module selectively controls an overlap of intake and exhaust valve timing in the engine based on (i) a position of an EGR valve in the EGR system and (ii) a comparison of the estimated total amount of EGR in the engine and an EGR threshold. Show less

A HVAC-APU system is provided for a battery electric vehicle. The system includes, but is not limited to a refrigerant fluid. A power cycle loop section, a cabin heating cycle loop section, and a cabin refrigeration cycle loop section are in selective fluid communication with each other to advance the refrigerant fluid through the system. A compressor-expander train includes, but is not limited to a reversing compressor-expander and a high-pressure pump that are operably connected by a shaft… Show more

A HVAC-APU system is provided for a battery electric vehicle. The system includes, but is not limited to a refrigerant fluid. A power cycle loop section, a cabin heating cycle loop section, and a cabin refrigeration cycle loop section are in selective fluid communication with each other to advance the refrigerant fluid through the system. A compressor-expander train includes, but is not limited to a reversing compressor-expander and a high-pressure pump that are operably connected by a shaft. The high-pressure pump pressurizes the refrigerant fluid to form a high-pressure refrigerant fluid. An auxiliary fuel cell and combustion unit heats a heat transfer fluid. A heat exchanger transfers heat from the heated transfer fluid to the high-pressure refrigerant fluid to form a heated high-pressure refrigerant fluid. The reversing compressor-expander expands the heated high-pressure refrigerant fluid to rotate the shaft in a first direction to drive the high-pressure pump. Show less