EXHAUST GAS SYSTEM

Abstract

Exhaust gas systems and methods are disclosed. A system includes an extensible duct assembly to communicate an exhaust gas from an internal combustion engine to an exhaust gas receiver. An angularly positionable ball joint assembly may be coupled to the duct assembly to fluidly and sealably couple the duct assembly to at least one of the outlet and the exhaust receiver. A method of installing an exhaust gas system includes presenting a first portion of the exhaust gas system to one of an exhaust gas outlet and an exhaust gas receiver, and positioning a second portion of the exhaust gas system relative to the other of the exhaust gas outlet and the exhaust gas receiver. The first portion and the second portion may be adjusted to achieve an alignment, and the first portion and the second portion may be sealably coupled to fixedly retain the alignment.

Description

TECHNICAL FIELD

The various disclosed embodiments relate generally to fluid handling systems and methods. More particularly, the various embodiments are directed to coupling arrangements and methods for exhaust gas systems for internal combustion engines.

BACKGROUND

An exhaust gas system may be provided to communicate exhaust gases generated by an internal combustion engine to the ambient environment. The exhaust gases generated within the internal combustion engine include a mixture of recognized environmental pollutants, such as unburned carbon particles, hydrocarbons, oxides of nitrogen and other pollutants. Efforts to reduce the presence of pollutants released into the atmosphere has resulted in the enactment of air quality standards that set emission limits for internal combustion engines. Accordingly, exhaust gas processing systems have been developed that receive the exhaust gases from the internal combustion engine and process the exhaust gases to reduce the level of environmental pollutants before the exhaust gases are released to the atmosphere.

U.S. Pat. No. 2,470,989 (the '989 patent) discloses a sealed and flexible exhaust conduit for an internal combustion engine. The '989 patent fails to disclose an apparatus that provides suitable adjustability and axial movements. U.S. Pat. No. 3,459,444 (the '444 patent) discloses a sealed bellows flex joint for an exhaust conduit. The apparatus described in the '444 patent similarly fails to provide suitable adjustability. U.S. Pat. No. 5,069,487 (the '487 patent) discloses a flexible connector for an exhaust system. The '487 patent describes a sealed connector, but again does not provide suitable adjustability.

SUMMARY

In an aspect of the various embodiments, an exhaust gas system for an internal combustion engine includes an extensible duct assembly configured to fluidly and sealably communicate an exhaust gas from an outlet of the internal combustion engine to an exhaust gas receiver. At least one angularly deflectable ball joint assembly may be coupled to the duct assembly and configured to fluidly and sealably couple the duct assembly to at least one of the outlet and the exhaust receiver. In another aspect of the various embodiments, a method of installing an exhaust gas system for an internal combustion engine includes presenting a first portion of the exhaust gas system to a selected one of an exhaust gas outlet of the internal combustion engine and an exhaust gas receiver, and positioning a second portion of the exhaust gas system relative to the other of the exhaust gas outlet of the internal combustion engine and the exhaust gas receiver. The first portion and the second portion of the exhaust gas system may be adjusted to achieve a predetermined alignment of the first portion and the second portion. The first portion and the second portion may be sealably coupled to fixedly retain the predetermined alignment.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments are described in detail in the discussion below and with reference to the following drawings.

FIG. 1 is a diagrammatic elevational view of an exhaust gas system for an internal combustion engine, according to the various embodiments.

FIG. 2 is a diagrammatic elevational view of the exhaust gas system of FIG. 1, according to the various embodiments.

FIG. 3 is a diagrammatic elevational view of a ball joint assembly, according to the various embodiments.

FIG. 4 is a cross sectional view of a ball joint assembly, according to the various embodiments.

FIG. 5 is a cross sectional view of a ball joint assembly, according to the various embodiments.

FIG. 6 is a partial cross sectional view of the slip joint of the extensible duct section, according to the various embodiments.

FIG. 7 is a side elevational view of a bellows assembly, according to the various embodiments.

FIG. 8 is a side elevational view of a bellows assembly, according to the various embodiments.

FIG. 9 is a flowchart describing a method of installing an exhaust gas system, according to the various embodiments.

FIG. 10 is a side elevational view of a bellows undulation alignment tool, according to the various embodiments.

FIG. 11 is another side elevational view of the bellows undulation alignment tool, according to the various embodiments.

DETAILED DESCRIPTION

Various embodiments include exhaust gas systems and methods. Specific details of several embodiments are set forth in the following description and in FIGS. 1 through 11 to provide an understanding of such embodiments. One of ordinary skill in the art will understand that additional embodiments are possible, and that many embodiments may be practiced without several of the details disclosed in the following description. Although the various disclosed embodiments are directed to exhaust gas systems and methods, it is understood that that the disclosed embodiments may also be applied, without significant alteration, to other gas handling systems for internal combustion engines. For example, the various embodiments may be applied to an air induction system for an internal combustion engine, or to an exhaust gas recirculation (EGR) system, or still other fluid handling systems for internal combustion engines.

FIG. 1 is a diagrammatic elevational view of an exhaust gas system 10 for an internal combustion engine, according to the various embodiments. The exhaust gas system 10 may be configured to receive exhaust gases from an internal combustion engine 12, and to communicate the exhaust gases to an exhaust gas receiver 14. The internal combustion engine 12 may include various reciprocating internal combustion engines, such as a diesel engine or a gasoline engine, or it may include non-reciprocating engines, such as a gas turbine engine. The exhaust gas receiver 14 may include, for example, an exhaust discharge stack, or an exhaust processing system, such as a catalytic conversion device, or other similar processing systems. In general terms, the exhaust gas system 10 may be configured to sealably communicate the exhaust gases from the internal combustion engine 12 to the exhaust gas receiver 14. The exhaust gas system 10 may also be configured to permit positional flexibility of the exhaust gas system 10 during an installation procedure, so that a suitable clearance may be provided between the exhaust gas system 10 and other components of the internal combustion engine 12 or the exhaust gas receiver 14 that are proximate to the exhaust gas system 10, or both.

With reference still to FIG. 1, and now also to FIG. 2, the exhaust gas system 10 of FIG. 1 will be discussed in greater detail. The exhaust gas system 10 may include a first adapter 16 positioned on one end of the exhaust gas system 10, and a second adapter 18 positioned on an opposing end of the exhaust gas system 10. In general terms, the first adapter 16 may be configured to adaptably and fluidly couple to an exhaust gas outlet of the internal combustion engine 12, while the second adapter 18 may be configured to adaptably and fluidly couple to an inlet of the exhaust gas receiver 14. The first adapter 16 and the second adapter 18, or both, may be configured to receive a user-adjustable cylindrical-mechanical clamping device to sealably couple the first adapter 16 and the second adapter 18 to the exhaust gas outlet of the internal combustion engine 12, and the inlet of the exhaust gas receiver 14, respectively. One suitable cylindrical-mechanical coupling device may include a V-band MARMAN clamp, available from Eaton Aeroquip Corporation of Maumee, Ohio, although other suitable alternatives may be used.

The exhaust gas system 10 may also include a first ball joint assembly 20 that is fluidly coupled to the first adapter 16, and a second ball joint assembly 22 that is fluidly coupled to the second adapter 18. In general, the first ball joint assembly 20 and the second ball joint assembly 22 are configured to provide angular variability so that positional compensation of the exhaust gas system 10 may be achieved, as will be discussed in detail below. Accordingly, in the various embodiments, the first ball joint assembly 20 and the second ball joint assembly 22 may include a user-adjustable cylindrical-mechanical clamp, such as the NORMACONNECT SEC duct clamp, available from Norma Group GmbH of Frankfurt, Germany, although other suitable alternatives may be used.

The exhaust gas system 10 may also include an extensible duct section 24 that is fluidly coupled to the first ball joint assembly 20 and the second ball joint assembly 22. The extensible duct section 24 may include a bellows assembly 26 that is configured to accommodate relative motion between the internal combustion engine 12 and the exhaust gas receiver 14 that may arise due to vibration generated by at least one of the internal combustion engine 12 and the exhaust gas receiver 14, or thermal differences between the various components of the exhaust gas system 10. The bellows assembly 26 may accordingly include a plurality of circumferential undulations that permit longitudinal variations so that a natural length (e.g., an uninstalled length) of the bellows assembly 26 may be contracted or expanded, while also permitting angular and lateral adjustability. The bellows assembly 26 will also be described in greater detail below. The extensible duct section 24 may also include a slip joint 28 that is configured to telescopically receive a portion of a transition duct 30. The slip joint 28 may include a circumferential clamp that is configured to fixably and sealably couple the bellows assembly 26 to the transition duct 30. One suitable example of a circumferential clamp may include the ACCUSEAL circumferential clamp available from Norma Group GmbH of Frankfurt, Germany, although other suitable alternatives may be used. Alternatively, other methods that fixably and sealably couple the bellows assembly 26 and the transition duct 30 may also be used. For example, the bellows assembly 26 and the transition duct 30 may be fused together using a welding process. The transition duct 30 may be suitably configured to direct an exhaust gas flow from the extensible duct section 24 to the exhaust gas receiver 14. Accordingly, the transition duct 30 may include one or more bends so that the exhaust gas flow may be properly routed, and may also include duct sections of different diameters.

Referring now to FIG. 3, the first ball joint assembly 20 and the second ball joint assembly 22 will be described in greater detail. In general, the first ball joint assembly 20 and the second ball joint assembly 22 are configured to fluidly couple a first duct portion 32 to a second duct portion 34 along a longitudinal axis 36. The first duct portion 32 and the second duct portion 34 may be formed as any portion of the exhaust gas system 10, such as a portion of the transition duct 30 or a portion of the bellows assembly 26. The first ball joint assembly 20 and the second ball joint assembly 22 may be further configured to permit the second duct portion 34 to be angularly deflected, or otherwise angularly positionable relative to the first duct portion 32 through an angle φ. Although the angle φ is shown in FIG. 3 as extending in a first (e.g., a positive) direction, it is understood that the first ball joint assembly 20 and the second ball joint assembly 22 also permit the angle φ to extend in a second and opposite (e.g., a negative) direction. Still further, it is understood that the first ball joint assembly 20 and the second ball joint assembly 22 permit the angle φ to extend outwardly or inwardly into a plane of FIG. 3. According to the various embodiments, the angle φ may include angular variations of approximately five degrees. The first ball joint assembly 20 and the second ball joint assembly 22 may also include a circumferential clamp 38 to fixedly retain a selected angular orientation when a tensioning mechanism 40 coupled to the circumferential clamp 38 applies an inwardly-directed radial force F₁ to the first ball joint assembly 20 and the second ball joint assembly 22. The clamp 38 may also be operable to fluidly seal the first ball joint assembly 20 and the second ball joint assembly 22.

With reference still to FIG. 3, and also to FIG. 4, the first ball joint assembly 20 and the second ball joint assembly 22 may include a first semi-spherical portion 42 coupled to the first duct portion 32 that is suitably configured to slidably and rotatably receive a second semi-spherical portion 44 coupled to the second duct portion 34. When a suitable angular orientation (e.g., a suitable angle φ) is obtained, the circumferential clamp 38 may apply the inwardly-directed radial force F₁ (through actuation of the tensioning mechanism 40) to the first semi-spherical portion 42 and the second semi-spherical portion 44 to sealably and fixably couple the first duct portion 32 and the second duct portion 34, as shown in FIG. 5. In one embodiment, the flow of exhaust gases passes through the first duct portion 32 and the second duct portion 34 from left to right in FIG. 5. In one embodiment, the flow of exhaust gases passes through the first duct portion 32 and the second duct portion 34 from left to right in FIG. 5.

FIG. 6 is a partial cross sectional view of the slip joint 28 of the extensible duct section 24, according to the various embodiments. The slip joint 28 may be configured to permit the transition duct 30 to be telescopically received within the bellows assembly 26, so that the transition duct 30 and the bellows assembly 26 may be longitudinally adjusted relative to one another, along an adjustment axis 46. The slip joint 28 may also include a circumferential clamp 48 that is configured to apply an inwardly-directed radial force F₂ to the transition duct 30 and the bellows assembly 26 through the actuation of a tensioning mechanism 50. Accordingly, when the transition duct 30 is telescopically positioned relative to the bellows assembly 26 at a selected position along the adjustment axis 46, the circumferential clamp 48 may be selectively adjusted to transmit the inwardly-directed radial force F₂ to the transition duct 30 and the bellows assembly 26 to fixedly and sealably couple the transition duct 30 to the bellows assembly 26. Although FIG. 6 shows the transition duct 30 received within the bellows assembly 26, it is understood that other configurations are possible. For example, the transition duct 30 may be configured to internally receive the bellows assembly 26.

FIG. 7 is a side elevational view of a bellows assembly 52, according to one embodiment. The bellows assembly 52 may include a first undulating section 54 and a second undulating section 56 that are separated by a straight section 58 having a length L₁. The first undulating section 54 may have a first natural length L₂ when in a relaxed state, and the second undulating section 56 may have a second natural length L₃ when in a relaxed state. In the various embodiments, the lengths L₁, L₂ and L₃ may be selectively adjusted to achieve one or more structural properties. For example, the lengths L₁, L₂ and L₃ may be selected to achieve a suitable flexural property for the bellows assembly 52. The lengths L₁, L₂ and L₃ may be selected to provide one or more dynamic properties. For example, the lengths L₁, L₂ and L₃ may be selected to provide a suitable resonant frequency for the bellows assembly 52. In accordance with the various embodiments, it is understood that one of the first undulating section 54 and the second undulating section 56 may be omitted from the bellows assembly 52. It is also understood that the length L₁ may be eliminated, so that the first undulating section 54 and the second undulating section 56 form a continuous undulating length extending along bellows assembly 52. The bellows assembly 52 may also be configured to include the first semi-spherical portion 42 of the ball joint assembly 20, 22 (FIGS. 4 and 5), while an opposing end of the bellows assembly 52 may be configured to receive the transition duct 30. Accordingly, the opposing end may include a relief groove 60 to circumferentially compress and sealably engage the transition duct 30 (FIG. 2).

FIG. 8 is a side elevational view of a bellows assembly 62, according to one embodiment. The bellows assembly 62 may include a transition section 63 that permits a first diameter D₁ of the bellows assembly 62 to engage a transition duct 30 (FIG. 2) having a second diameter D₂. The bellows assembly 62 may also be configured to include the second semi-spherical portion 44 of the ball joint assembly 20, 22 (FIGS. 4 and 5).

FIG. 9 is a flowchart that will be used to describe a method 64 of installing an exhaust gas system for an internal combustion engine, according to the various embodiments. At 66, a first portion of an exhaust gas system may be presented to one of an internal combustion engine and an exhaust gas receiver. At 68, a second portion of the exhaust gas system may be positioned relative to the other of the internal combustion engine and the exhaust gas receiver. At 70, the first portion and the second portion of the exhaust gas system may be adjusted to achieve a predetermined alignment of the exhaust gas system. For example, the first ball joint assembly 20 and the second ball joint assembly 22 (FIG. 2) may be rotatably and angularly adjusted to achieve the predetermined alignment. More generally, the slip joint 28 (FIG. 2), the first ball joint assembly 20 and the second ball joint assembly 22 may be adjusted to achieve the predetermined alignment. With reference to FIGS. 10 and 11, a bellows undulation alignment tool 74 may assist in achieving the predetermined alignment. Because the predetermined alignment may include reducing at least one of the curvature of the bellows assembly 52 and the compression or extension of the first undulating section 54 or the second undulating section 56 of the bellows assembly 52, the bellows undulation alignment tool 74 may include grooves 76 corresponding to a predetermined suitable spacing between the undulations in the first undulating section 54 or the second undulating section 56 of the bellows assembly 52. As shown in FIG. 11, by removably engaging the bellows undulation alignment tool 74 with the first undulating section 54 or the second undulating section 56 of the bellows assembly 52, the bellows assembly 52 may be suitably positionally adjusted. It is understood, however, that the bellows undulation alignment tool 74 is intended to be used to check an alignment of the bellows assembly 52, and is not retained in position (as shown in FIG. 11) after the installation has been completed.

With continued reference to FIG. 9, at 72, the method 64 may include sealably coupling the first portion and the second portion to fixedly retain the predetermined alignment. For example, the tensioning mechanism 40 of the first ball joint assembly 20 and the second ball joint assembly 22 may be suitably adjusted by imparting, for example, a predetermined torque to a screw mechanism that, in turn, radially compresses the first ball joint assembly 20 and the second ball joint assembly 22. The tensioning mechanism 48 of the slip joint 28 may also be suitably adjusted by imparting a predetermined torque to a screw mechanism that radially compresses the slip joint 28. The method 64 may also include adjusting a third portion. In one embodiment, the first portion corresponds to the first ball joint assembly 20, the second portion corresponds to the slip joint 28, and the third portion corresponds to the second ball joint assembly 22.

INDUSTRIAL APPLICABILITY

With reference again to FIG. 1, during operation of the internal combustion engine 12, a fuel is combined with air in a combustion process to generate motive energy. The combustion process also generates high temperature exhaust gases that are discharged from the internal combustion engine 12. In order to reduce the discharge of various exhaust gas components that are released into the environment, the exhaust gases may be directed to an exhaust gas receiver 14 that is operable to process the exhaust gases. For example, the exhaust gas receiver 14 may be configured to remove particulates, unburned hydrocarbons, oxides of nitrogen, sulfur, or still other exhaust gas components from the exhaust gases discharged from the internal combustion engine 12. Exhaust gas system 10 is configured to communicate the exhaust gases from the internal combustion engine 12 to the exhaust gas receiver 14 without leakage and in compliance with exhaust emission standards.

In order to reduce the discharge of various exhaust gas components that are released into the environment, the exhaust gases may be directed by the exhaust gas system 10 to an exhaust gas receiver 14 that is operable to process the exhaust gases. For example, the exhaust gas receiver 14 may be configured to remove particulates, unburned hydrocarbons, oxides of nitrogen, sulfur, or still other exhaust gas components from the exhaust gases discharged from the internal combustion engine 12. Exhaust gas system 10 is configured to communicate the exhaust gases from the internal combustion engine 12 to the exhaust gas receiver 14 without leakage to maintain compliance with exhaust emission standards.

Because the exhaust gases generally exhibit significant thermal energy, the exhaust gas system 10 provides alignment flexibility during an installation procedure, so that adequate clearance between the exhaust gas system 10 and various neighboring components and structures is conveniently obtained. Suitable alignment flexibility may also enhance the longevity of components in the exhaust gas system 10. For example, the exhaust gas system 10 may include components that offer vibration isolation between the internal combustion engine 12 and the exhaust gas receiver 14, such as a bellows assembly, for example. Alignment flexibility may extend the life of components within the exhaust gas system 10 and reduce maintenance and repair costs.

The exhaust gas system may generally be configured to fulfill various structural objectives. For example, the exhaust gas system may be suitably configured to provide adequate positional adjustability so that adequate clearance between the exhaust gas system and other components and structures typically associated with an internal combustion engine is obtained. The exhaust gas system may also provide structural flexibility to allow for thermal expansion and contraction of the system, and to provide vibration isolation between the internal combustion engine and other structures.

Although various embodiments have been illustrated and described herein, it should be appreciated that any arrangement calculated to achieve the same purpose may be substituted for the various embodiments shown. This disclosure is intended to cover various adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not described herein, will be apparent to those skilled in the art upon reviewing the above description.

Claims

1. An exhaust gas system for an internal combustion engine, comprising:

an extensible duct assembly configured to fluidly and sealably communicate an exhaust gas from an outlet of the internal combustion engine to an exhaust gas receiver; and

at least one angularly positionable ball joint assembly coupled to the duct assembly and configured to fluidly and sealably couple the duct assembly to at least one of the outlet and the exhaust gas receiver.

2. The exhaust gas system of claim 1, wherein the extensible duct assembly includes a bellows assembly positioned between the outlet and the exhaust gas receiver and configured to sealably permit a longitudinal adjustment of the duct assembly.

3. The exhaust gas system of claim 2, wherein the extensible duct assembly includes a transition conduit configured to be telescopically received by the bellows assembly.

4. The exhaust gas system of claim 3, wherein the bellows assembly and the transition conduit are configured to be circumferentially compressed to sealably couple the bellows assembly and the transition conduit.

5. The exhaust gas system of claim 1, wherein the at least one angularly positionable ball joint assembly is configured to be circumferentially compressed to fluidly and sealably couple the ball joint assembly.

6. The exhaust gas system of claim 1, wherein the at least one angularly positionable ball joint assembly includes a first angularly deflectable ball joint assembly configured to sealably and fluidly couple to the outlet and a second angularly deflectable ball joint assembly configured to sealably and fluidly couple to the exhaust gas receiver, and wherein the extensible duct assembly is configured to sealably and fluidly couple to the first angularly deflectable ball joint assembly and to the second angularly deflectable ball joint assembly to fluidly and sealably communicate the exhaust gas from the outlet to the exhaust gas receiver.

7. An exhaust gas system for an internal combustion engine, comprising:

a first end configured to couple with an exhaust outlet of the internal combustion engine;

an opposing second end configured to couple to an exhaust receiver, wherein at least one of the first end and the second end is rotatably adjustable; and

an extensible section having an adjustable length and configured to fluidly couple the first end to the second end.

8. The exhaust gas system of claim 7, wherein the extensible section includes a bellows assembly configured to permit a sealable longitudinal adjustment of the length.

9. The exhaust gas system of claim 8, further including a transition conduit configured to be telescopically received by the bellows assembly.

10. The exhaust gas system of claim 9, wherein the bellows assembly and the transition conduit are configured to be circumferentially compressed by a clamp to sealably couple the bellows assembly and the transition conduit.

11. The exhaust gas system of claim 7, wherein at least one of the first end and the second end includes a ball joint assembly configured to permit a rotatable deflection of the at least one of the first end and the second end, wherein the ball joint assembly is circumferentially compressible by a clamp to fluidly seal the ball joint assembly.

12. A method of installing an exhaust gas system for an internal combustion engine, comprising:

presenting a first portion of the exhaust gas system to a selected one of an exhaust gas outlet of the internal combustion engine and an exhaust gas receiver;

positioning a second portion of the exhaust gas system relative to the other of the exhaust gas outlet of the internal combustion engine and the exhaust gas receiver;

adjusting the first portion and the second portion of the exhaust gas system by angularly deflecting at least one ball joint assembly to achieve a predetermined alignment of the first portion and the second portion; and

sealably coupling the first portion and the second portion to fixedly retain the predetermined alignment.

13. The method of claim 12, wherein presenting the first portion includes loosely coupling a ball joint assembly to the selected one of the exhaust gas outlet and the exhaust gas receiver.

14. The method of claim 12, wherein positioning the second portion includes loosely coupling a ball joint assembly to the other of the exhaust gas outlet and the exhaust gas receiver.

15. The method of claim 12, wherein adjusting the first portion and the second portion includes adjusting an extensible section that is positioned between the exhaust gas outlet and the exhaust gas receiver.

16. The method of claim 15, wherein the extensible section includes a bellows assembly, and wherein adjusting the extensible section includes applying a tool to undulations of the bellows assembly to provide a desired spacing between the undulations.

17. The method of claim 16, wherein the extensible section includes a transition conduit configured to slidably receive the bellows assembly, and wherein adjusting the extensible section includes adjusting a length of the transition conduit and the bellows assembly.

18. The method of claim 12, wherein sealably coupling the first portion and the second portion includes applying a circumferential compression to a first ball joint assembly coupled to the selected one of the exhaust gas outlet and the exhaust gas receiver, and applying a circumferential compression to a second ball joint assembly coupled to the other of the exhaust gas outlet and the exhaust gas receiver.

19. The method of claim 12, wherein sealably coupling the first portion and the second portion includes applying a circumferential compression to an extensible section that is positioned between the exhaust gas outlet and the exhaust gas receiver.

20. The method of claim 19, wherein applying the circumferential compression to the extensible section includes applying the circumferential compression to a bellows assembly and a transition conduit.