Ford Global Technolgoies, LLC

Karen Elizabeth Maceroni

Daniel Joseph Styles

Christopher Donald Wicks

Mark Michael Madin

Joseph Norman Ulrey

Keith Michael Plagens

Jeffrey Allen Doering

Thomas George Leone

Gregory McConville

James Alfred Hilditch

Furqan Zafar Shaikh

Rick L Williams

John Erik Mikael Hellstrom

Keith D Miazgowicz

Ahsanul Karim

Lawrence Marshall

August Thomas Vaught

Lynn Aimee Chesney

Wayne Paul Woodside

Chris Donald Wicks

An engine system includes a layered cylinder head with a plurality of intake ports and a stratified tubular member integrated into the cylinder head, configured as a condensate port, surrounding each of the plurality of intake ports and forming a plurality of nozzles located on at least one side of the tubular member. Each of the nozzles arranged to have a plurality of openings extending into a cavity of each intake port such that there is no seal between the tubular member and the cylinder head.

Integral cylinder head with port condensate

A power train system includes a heat exchanger reservoir to collect condensate, a layered intake manifold, and integral tubing leading from the reservoir to an interior of the intake manifold via an intake manifold wall such that there is no seal between the condensate port and the manifold. The tubing splits into at least two branches transitioning into a set of wings containing a plurality of nozzles protruding into the interior.

Condensate port of an integral intake manifold

A system and methods for routing condensate collected in a heat exchanger reservoir to either an air intake system or a position in the engine exhaust based on the type of contaminate in the condensate and operating parameters of the engine or the catalyst are described. In one particular example, condensate is routed to a first position along the engine air intake system in a first mode of operation, and a second position upstream of the catalyst along the engine exhaust in a second mode of operation, and a third position downstream of the catalyst along the engine exhaust in a third mode of operation. When substantially no contaminates are detected, the condensate may be routed into the engine exhaust upstream of the catalyst in order to cool the catalyst.

System and methods for engine air path condensation management

Methods and systems are provided for airflow control in an engine system which includes a throttle turbine generator including a turbine and a turbine generator. In one example, a method may include adjusting an angle of a throttle positioned in an engine inlet passage based on a desired airflow by taking into account the effects on the throttle angle due to rotation motion of the turbine, thereby accurately controlling airflow to the engine system. The method may further include predicting an airflow to the engine system based on the position of the throttle, thereby accurately monitoring torque of the engine system.

Methods and systems for airflow control

Methods and systems are provided for reducing exhaust energy delivered to a turbine of a turbine-generator coupled to a split exhaust engine system in order to reduce turbine over-speed conditions and/or to reduce a generator output. In one example, a method may include retarding a first timing of a first exhaust valve utilized to deliver a blowdown portion of exhaust energy to the turbine, and/or advancing a second timing of a second exhaust valve utilized to deliver a scavenging portion of exhaust energy to an exhaust catalyst in response to a turbine speed greater than a threshold speed.

Systems and methods for control of turbine-generator via exhaust valve timing and duration modulation in a split exhaust engine system

Various systems and methods are provided for controlling the temperature of outlet gasses from a throttle bypass turbine. In one embodiment, a method of operating a throttle bypass turbine comprises controlling a temperature of outlet gas flowing out of the turbine by routing the outlet gas through an exhaust gas recirculation heat exchanger positioned in an exhaust gas recirculation passage, the turbine coupled to an intake passage.

Throttle bypass turbine with exhaust gas recirculation

A system and methods for routing condensate collected in a heat exchanger reservoir to either a combustion chamber of an engine or a position in the engine exhaust based on the type of contaminate in the condensate and operating parameters of the engine or the catalyst are described. In one particular example, the method includes accumulating a portion of compressed air in an accumulator, and when an engine output is below a predetermined amount, coupling a part of the accumulated air with the condensate through a passage into the combustion chamber. Thereby, the methods described may be used to distribute condensate formed in the heat exchanger even at low engine loads.

Embodiments for a turbine-generator position in a compressor bypass flow path are presented. In one example, a method for an engine having a compressor comprises generating energy via a turbine-generator positioned in a bypass flow path of the compressor. In this way, the energy of the recirculated intake air may be recovered by the turbine-generator.

Compressor bypass turbine-generator

An intake assembly in an engine is provided. The intake assembly includes a compressor and a plenum in fluidic communication with the compressor, the plenum having an integrated charge air cooler including a coolant inlet and a coolant outlet in fluidic communication with a coolant passage and cooling plates extending into a plenum enclosure and coupled to the coolant passage. The intake assembly further includes a throttle body coupled to the plenum.

Intake system with an integrated charge air cooler

Methods and systems are provided for providing auxiliary heat to a pre-compressor duct wall to reduce condensate formation. A coolant valve may control the delivery of heated engine coolant to the pre-compressor duct wall. The coolant valve may be adjusted based on condensate formation at the pre-compressor duct wall.

Systems and methods for heating a pre-compressor duct to reduce condensate formation

An exhaust gas recirculation (EGR) system for a vehicle is provided. The EGR system includes a turbine fluidly coupled downstream of an exhaust manifold and an EGR conduit including a first port coupled to an exhaust passage directly downstream of the turbine, an axis of the first port arrange at a non-perpendicular angle with respect to the rotation axis of the turbine and a second port coupled to an intake system.

Exhaust gas recirculation system

An EGR mixer comprises an upstream conduit section having a contracting flow area in a direction of air flow through the mixer, a downstream conduit section having an expanding flow area in the direction of air flow through the mixer, a slot formed in the downstream conduit section for admitting exhaust to the air flow, and an abrupt flow-expanding ridge disposed between the upstream and downstream conduit sections. With the EGR mixer configured in this manner, recirculated exhaust may be effectively homogenized into an intake air flow with reduced drag.

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Casco, MI, United States of America

Karen Elizabeth Maceroni