Abstract: A heat exchanger having a modified header design for absorbing high thermal loads, is described. The heat exchanger includes a housing having an interior space, a core within the interior space of the housing, the core comprising a plurality of flow passages, and a header positioned at an end of the housing and in communication with the core, wherein the header includes a thermal absorbing formation. The thermal absorbing formation may take the form of a continuous raised rib around an inner circumference of the header. The raised rib absorbs excess heat and reduces thermal strain on the heat exchanger.

Abstract: A method for driving exhaust gas recirculation comprising the steps of restricting exhaust gas flow into the turbine inlet to create backpressure in the exhaust system under low engine operating conditions, and providing an unrestricted exhaust gas flow to the turbine under normal engine operating conditions. Restriction of exhaust gas flow is accomplished through the use of an exhaust gas throttle valve disposed upstream of the turbine inlet. The valves can be adjustable knife edge flap valves or D-shaped valves situated in each passageway of a divided exhaust manifold, which are closed to varying degrees to generate desired levels of backpressure while allowing exhaust gas to pass though open regions of the partially obstructed flow pathway to reach the engine turbocharger. This allows the turbine to continue to spin, while at the same time exhaust gas back pressure upstream of the turbocharger is used to drive exhaust gas recirculation.

Abstract: An engine braking system includes a turbocharger having a turbine and a compressor. An exhaust manifold includes a first pipe for channeling a first portion of the engine exhaust and a second pipe for channeling a second portion of the engine exhaust. The first and second pipes are connected to an inlet of the turbine. A cross pipe, as part of an exhaust gas recirculation (EGR) conduit, is open between the first and second pipes and at one end to the remaining portion of the EGR conduit. A valve can be arranged within the cross pipe and ca be operable in a first mode of operation to block flow between the first and second pipes and allow flow between the first pipe and the remaining portion of the EGR conduit and to allow flow between the first and second pipes and the inlet of the turbine. The valve is operable in a second mode of operation to allow flow between the first and second pipes, and to reduce or block flow between the second pipe and the turbine inlet.

Abstract: An expansion tank (10) for a vehicle cooling system (18) of an engine using a liquid coolant (16) includes a tank body (12) defining a first volume (V1) containing coolant (16), wherein the coolant defines a variable coolant elevation level (CEL) within the tank body. The tank body (12) also defines an upper volume (20) containing air. A bladder (14) is disposed in the tank body (12) and defines a second volume (V2) containing air. The bladder (14) includes a flexible membrane (36) actuated by an actuator (46). When the engine is stopped or is below a predetermined temperature, the flexible membrane (36) is moveable to a first position (FP) which lowers the coolant elevation level (CEL), and when the engine is started or reaches a predetermined temperature, the flexible membrane (36) is moveable to a second position (SP) which raises the coolant elevation level. A communicating line (38) is in fluid communication between the upper volume (20) and the second volume (V2) to fluidly communicate air therebetween.

Abstract: A system for driving an EGR stream for an engine includes an exhaust gas turbine, a main compressor and a supplemental EGR compressor. The turbine drives the main compressor to pressurize intake air and drives the supplemental EGR compressor to pressurize an EGR exhaust gas stream to be introduced into the intake air system. A supplemental EGR compressor takes suction of exhaust gas downstream from the turbine. A three-way valve proportions exhaust gas between the engine exhaust gas discharge conduit and the suction of the supplemental EGR compressor. The turbine drives a shaft and the main compressor and the supplemental EGR compressor are driven by having corresponding compressor wheels fixed onto the common shaft.

Abstract: A control system for engine braking for a vehicle powered by a turbocharged engine uses a supercharger to assist a turbocharger compressor to boost turbocharger air flow into the engine cylinders. An engine driven air pumping device draws ambient air, or alternately exhaust gas through the pump inlet, compresses the air, and delivers the compressed air through the pump outlet to the turbocharger compressor inlet or alternately the turbocharger compressor outlet. The increased air flow into the cylinders and out of the cylinder exhaust valves increases retarding power of the vehicle.

Abstract: A first loop contains engine coolant passageways (28, 30) and a first radiator (34). A second loop contains a first EGR cooler (48). A third loop contains a second EGR cooler (50), a second radiator (36), a charge air cooler (26LP), a first valve (66), and a second valve (64). Valve (64) apportions coolant flow entering an inlet (64A) to parallel flow paths, one including second radiator (36) and the other being a bypass around radiator (36). The apportioned flows merge into confluent flow to both an inlet of charge air cooler (26LP) and a first inlet (66B) of valve (66). Valve (66) has an outlet (66C) communicated to an inlet of second EGR cooler (50). The first condition of valve (66) closes a second inlet (66A) to coolant flowing toward both the second inlet (66A) and inlet (64A) while opening inlet (66B) to outlet (66C).

Abstract: An internal combustion engine (100) includes an intake manifold (106) and at least one exhaust manifold (108). A first compressor (120) that is operably associated with a first turbine (128) has a first air inlet (126) and a first air outlet (118). The first air inlet (126) is adapted to admit air into the first compressor (120), and the first air outlet (118) is fluidly connected to the intake manifold (106). The first turbine (128) fluidly communicates with a tailpipe (138). A second compressor (124) is operably associated with a second turbine (160) and has a first tributary fluid inlet (152), a second tributary fluid inlet (154), and a second fluid outlet (122). The first tributary fluid inlet (152) is fluidly connected to the tailpipe (138) at a junction (147), the second tributary fluid inlet (154) is adapted to admit air into the second compressor (124), and the second fluid outlet (122) is fluidly connected to the intake manifold (106).

Abstract: An internal combustion engine (100) includes an intake manifold (106) and at least one exhaust manifold (108). A first compressor (120) that is operably associated with a first turbine (128) has a first air inlet (126) and a first air outlet (118). The first air inlet (126) is adapted to admit air into the first compressor (120), and the first air outlet (118) is fluidly connected to the intake manifold (106). The first turbine (128) fluidly communicates with a tailpipe (138). A second compressor (124) is operably associated with a second turbine (160) and has a first tributary fluid inlet (152), a second tributary fluid inlet (154), and a second fluid outlet (122). The first tributary fluid inlet (152) is fluidly connected to the tailpipe (138) at a junction (147), the second tributary fluid inlet (154) is adapted to admit air into the second compressor (124), and the second fluid outlet (122) is fluidly connected to the intake manifold (106).

Abstract: An apparatus and method for varying a counter force to valve spring preload of a brake exhaust valve to undertake engine braking, includes a solenoid controlled hydraulic actuator. A control cylinder is arranged to move with a rocker arm and a control piston is arranged to slide within the control cylinder. During engine braking the control piston slides to press the valve stem to open the brake exhaust valve. An oil chamber is arranged above the control piston and is open into the control cylinder. A source of pressurized oil is selectably introduced into the oil chamber by the solenoid controlled hydraulic actuator to slide the control piston within the control cylinder to open and hold open the brake exhaust valve.

Abstract: A circuit for cooling exhaust gas being recirculated through an EGR system (36) of an engine (10) from an exhaust system (20) successively through first and second heat exchangers (38, 40) to an intake system (16) for entrainment with intake air. Each heat exchanger has a respective coolant inlet through which liquid coolant enters and a respective coolant outlet through which liquid coolant exits after having absorbed heat from recirculated exhaust gas. The circuit has a third heat exchanger (32) to which coolant coming from the outlet of one of the first and second heat exchangers rejects heat, and parallel branches (84, 86) through which coolant enters the inlet of the other of the first and second heat exchangers. One of the parallel branches has a fourth heat exchanger (34) to which coolant flowing through that branch rejects heat, and one or more devices (50, 50A) for controlling the quantity of coolant flowing through each branch.

Abstract: A method for manufacturing an engine includes the steps of: casting a side skirt having first and second opposing sidewalls and casting a transverse wall of the cast material connecting the sidewalls. The transverse wall will form a bulkhead and a main bearing cap. A first void and a second void are cast into the transverse wall on opposite lateral sides of a main bearing journal location, each void adjacent to one of the sidewalls. A main bearing journal hole is then machined into the transverse wall. Cast material is removed along a first removal path from the edge of the transverse wall and ending into the first void, and along a second removal path from the edge of the transverse wall and ending into the second void. A tool exerts an opening force within the circular bore to fracture the cast material along the first and second fracture planes to separate the main bearing cap from the bulkhead.

Abstract: An expansion tank (10) for a vehicle cooling system (18) of an engine using a liquid coolant (16) includes a tank body (12) defining a first volume (V1) containing coolant (16), wherein the coolant defines a variable coolant elevation level (CEL) within the tank body. The tank body (12) also defines an upper volume (20) containing air. A bladder (14) is disposed in the tank body (12) and defines a second volume (V2) containing air. The bladder (14) includes a flexible membrane (36) actuated by an actuator (46). When the engine is stopped or is below a predetermined temperature, the flexible membrane (36) is moveable to a first position (FP) which lowers the coolant elevation level (CEL), and when the engine is started or reaches a predetermined temperature, the flexible membrane (36) is moveable to a second position (SP) which raises the coolant elevation level. A communicating line (38) is in fluid communication between the upper volume (20) and the second volume (V2) to fluidly communicate air therebetween.

Abstract: A control system for engine braking for a vehicle powered by a turbocharged engine uses a supercharger to assist a turbocharger compressor to boost turbocharger air flow into the engine cylinders. An engine driven air pumping device draws ambient air, or alternately exhaust gas through the pump inlet, compresses the air, and delivers the compressed air through the pump outlet to the turbocharger compressor inlet or alternately the turbocharger compressor outlet. The increased air flow into the cylinders and out of the cylinder exhaust valves increases retarding power of the vehicle.

Abstract: A system for driving an EGR stream for an engine includes an exhaust gas turbine, a main compressor and a supplemental EGR compressor. The turbine drives the main compressor to pressurize intake air and drives the supplemental EGR compressor to pressurize an EGR exhaust gas stream to be introduced into the intake air system. A supplemental EGR compressor takes suction of exhaust gas downstream from the turbine. A three-way valve proportions exhaust gas between the engine exhaust gas discharge conduit and the suction of the supplemental EGR compressor. The turbine drives a shaft and the main compressor and the supplemental EGR compressor are driven by having corresponding compressor wheels fixed onto the common shaft.

Abstract: A method of cooling exhaust gas (F) from an engine in an EGR cooler (10) for recirculation to the engine includes the steps of transporting the exhaust gas from the engine to a core assembly (22) disposed inside a single housing assembly (20), and dividing the housing assembly into at least a first cooling volume (42) of the EGR cooler (10) and a second cooling volume (44) of the EGR cooler (10). The core assembly (22) extends at least partially into the first cooling volume (42) and the second cooling volume (44). The method also includes the steps of introducing a first cooling fluid (CF1) into the first cooling volume (42), and introducing a second cooling fluid (CF2) into the second cooling volume (44). The exhaust gas (F) is transported from the core assembly (22) to the engine.

Abstract: A first loop contains engine coolant passageways (28, 30) and a first radiator (34). A second loop contains a first EGR cooler (48). A third loop contains a second EGR cooler (50), a second radiator (36), a charge air cooler (26LP), a first valve (66), and a second valve (64). Valve (64) apportions coolant flow entering an inlet (64A) to parallel flow paths, one including second radiator (36) and the other being a bypass around radiator (36). The apportioned flows merge into confluent flow to both an inlet of charge air cooler (26LP) and a first inlet (66B) of valve (66). Valve (66) has an outlet (66C) communicated to an inlet of second EGR cooler (50). The first condition of valve (66) closes a second inlet (66A) to coolant flowing toward both the second inlet (66A) and inlet (64A) while opening inlet (66B) to outlet (66C).

Abstract: A heating system for an engine breather system includes a housing configured to contain a heating fluid to be in heat transfer communication with a portion of the engine breather system, such as with the outlet conduit. A heating fluid supply channel is connected to a supply of heating fluid that is at a first pressure and to the housing and arranged to direct heating fluid into the housing. A heating fluid return channel is connected to the housing and to a supply of heating fluid that is at a second pressure that is lower than the first pressure, and is arranged to direct heating fluid away from the housing. The heating fluid can be engine oil, engine coolant, compressed air or exhaust gas.

Abstract: An engine braking system includes a turbocharger having a turbine and a compressor. An exhaust manifold includes a first pipe for channeling a first portion of the engine exhaust and a second pipe for channeling a second portion of the engine exhaust. The first and second pipes are connected to an inlet of the turbine. A cross pipe, as part of an exhaust gas recirculation (EGR) conduit, is open between the first and second pipes and at one end to the remaining portion of the EGR conduit. A valve can be arranged within the cross pipe and ca be operable in a first mode of operation to block flow between the first and second pipes and allow flow between the first pipe and the remaining portion of the EGR conduit and to allow flow between the first and second pipes and the inlet of the turbine. The valve is operable in a second mode of operation to allow flow between the first and second pipes, and to reduce or block flow between the second pipe and the turbine inlet.

Abstract: A lift bracket (300) includes a topmost portion (304) having an opening (302) arranged for engagement with an engagement portion of a lifting apparatus. The topmost portion (304) is substantially flat and defines a first plane (A-A). A base portion (320) of the lift bracket (300) has at least one fastener opening (322) for fastening the base portion to the engine. The base portion (320) also lies in the first plane (A-A). A yield structure (305) is disposed between the topmost portion (304) and the base portion (320), and includes a mid-portion (312) that defines at least one second plane (B-B) that is spaced and parallel to the first plane (A-A). When a tensile force is applied to the topmost portion (304), the yielding structure (305) yields, the topmost portion displaces away from the base portion (320), and the second plane (B-B) displaces towards the first plane (A-A).