Method to perform rebreathe mode transitions

Patent metadata

Field	Value
Publication number	US-12553398-B2
Application number	US-202418758867-A
Country	US
Kind code	B2
Filing date	Jun 28, 2024
Priority date	Jun 28, 2024
Publication date	Feb 17, 2026
Grant date	Feb 17, 2026

Abstract

An engine includes pistons, a crankshaft, cylinders, an intake manifold, an exhaust manifold, intake valves, exhaust valves, a fuel rail, and an Electronic Control Unit (ECU). The ECU coordinates operations of the intake valves, the exhaust valves, and the fuel injectors based upon a position of the crankshaft to control the engine to operate in two modes. The two modes include a typical engine operating mode and a rebreathe engine operating mode. The typical engine operating mode includes the ECU controlling the exhaust valves to be actuated after the intake valves are actuated. The rebreathe engine operating mode includes the ECU controlling the exhaust valves to be actuated both during and after the intake valves are actuated. The ECU also controls a Start of Injection (SOI) of the fuel injectors to be retarded during the typical engine operating mode and to be advanced during the rebreathe engine operating mode.

First claim

What is claimed is:

1 . An engine, comprising:
a plurality of pistons configured to be actuated by combustion reactions within the engine, where the combustion reactions create exhaust gases; a crankshaft configured to be actuated by the plurality of pistons; a plurality of cylinders, each cylinder being configured to house a corresponding piston of the plurality of pistons and form a containment boundary for a corresponding combustion reaction of the combustion reactions; an intake manifold configured to supply a gas mixture to the plurality of cylinders; a plurality of intake valves that are each configured to form a controlled fluid passageway for passing the gas mixture from the intake manifold to a corresponding cylinder of the plurality of cylinders; a fuel rail connected to a plurality of fuel injectors that are each configured to inject fuel into a corresponding cylinder of the plurality of cylinders, where the injected fuel is combined with the gas mixture to form a fuel mixture that is combusted in the corresponding cylinder during the combustion reaction; an exhaust manifold configured to receive the exhaust gases from each cylinder of the plurality of cylinders and combine the exhaust gases into an exhaust stream; a plurality of exhaust valves that are each configured to form a controlled fluid passageway for passing the exhaust gases from a corresponding cylinder of the plurality of cylinders to the exhaust manifold; an Electronic Control Unit (ECU) configured to coordinate operations of the intake valves, the exhaust valves, and the fuel injectors based upon a position of the crankshaft in such a manner that the ECU controls the engine to operate in at least two modes including a typical engine operating mode and a rebreathe engine operating mode,
wherein the typical engine operating mode comprises the ECU controlling the exhaust valves to be actuated after the intake valves are actuated, and the rebreathe engine operating mode comprises the ECU controlling the exhaust valves to be actuated both during and after the intake valves are actuated, and
wherein the ECU is configured to control a Start of Injection (SOI) of the fuel injectors to be retarded during the typical engine operating mode, relative to the SOI of the fuel injectors during the rebreathe engine operating mode, and
wherein the ECU controls the SOI of the fuel injectors to be advanced during the rebreathe engine operating mode, relative to the SOI of the fuel injectors during the typical engine operating mode.

2 . The engine of claim 1 , wherein the ECU is configured to retard the SOI of the fuel during a period of time when the ECU is controlling the engine to exit the rebreathe engine operating mode.

3 . The engine of claim 1 , wherein the ECU is further configured to control a high-pressure fuel pump to maintain a constant pressure in the fuel rail before, during, and after the ECU controls the engine to exit the rebreathe engine operating mode.

4 . The engine of claim 1 , wherein the ECU is further configured to increase a duration of the operation of each fuel injector of the plurality of fuel injectors such that the fuel injectors spray additional fuel into the cylinders during a period of time when the ECU is controlling the engine to exit the rebreathe engine operating mode.

5 . The engine of claim 1 , wherein the ECU is further configured to control a high-pressure fuel pump to lower a fuel pressure of the fuel rail prior to controlling the engine to exit the rebreathe engine operating mode.

6 . The engine of claim 1 , further comprising:
an intake line configured to receive air from an external environment of the engine; an exhaust pipe configured to receive the exhaust stream from the exhaust manifold and supply at least part of the exhaust stream to the external environment of the engine; an Exhaust Gas Recirculation (EGR) line, connected to the exhaust pipe and the intake line, that is configured to receive a portion of the exhaust gas stream from the exhaust manifold, and an EGR valve configured to control a flow of the portion of the exhaust gas stream in the EGR line.

7 . The engine of claim 6 , wherein the ECU is further configured to control the EGR valve to a reduced aperture before controlling the engine to operate in the rebreathe engine operating mode.

8 . The engine of claim 7 , wherein the ECU is further configured to control the EGR valve to maintain the reduced aperture until the ECU controls the engine to operate in the rebreathe engine operating mode.

9 . The engine of claim 6 , wherein the ECU is further configured to control the EGR valve to gradually open after the ECU has controlled the engine to exit the rebreathe engine operating mode.

10 . The engine of claim 1 , wherein the ECU is further configured to advance a pilot SOI after the ECU has controlled the engine to exit the rebreathe engine operating mode.

11 . The engine of claim 1 , further comprising:
a plurality of camshafts, each camshaft comprising a plurality of cams and each cam being configured to actuate a corresponding intake valve or a corresponding exhaust valve; wherein each cam of the plurality of cams comprises an inner lobe and an outer lobe, the inner lobe being associated with the rebreathe engine operating mode and the outer lobe being associated with the typical engine operating mode; wherein the ECU is configured to facilitate a transition between the typical engine operating mode and the rebreathe engine operating mode by controlling whether only the outer lobes of the cams or both the outer lobes and the inner lobes of the cams actuate the corresponding exhaust valves.

12 . A method for operating an engine, comprising:
housing a plurality of pistons in a plurality of cylinders, where each cylinder houses a corresponding piston of the plurality of pistons and forms a containment boundary for a corresponding combustion reaction; supplying a gas mixture to the plurality of cylinders with an intake manifold, where an amount of the gas mixture to be supplied to each cylinder of the plurality of cylinders is controlled with a corresponding intake valve of a plurality of intake valves; injecting fuel with a plurality of fuel injectors, connected to a fuel rail, where each of the injectors inject fuel into a corresponding cylinder of the plurality of cylinders; combining the injected fuel with the gas mixture to form a fuel mixture; combusting the fuel mixture during combustion reactions that are contained inside of the engine by the plurality of cylinders, thereby creating exhaust gases; actuating the plurality of pistons with the combustion reactions, thereby actuating a crankshaft connected to the plurality of pistons; controlling, with exhaust valves, an amount of the exhaust gases passed from a corresponding cylinder of the plurality of cylinders to an exhaust manifold that combines the exhaust gases into an exhaust stream; coordinating operations of the intake valves, the exhaust valves, and the fuel injectors with an Electronic Control Unit (ECU) based upon a position of the crankshaft in such a manner that the ECU controls the engine to operate in at least two modes including a typical engine operating mode and a rebreathe engine operating mode,
wherein the typical engine operating mode comprises controlling the exhaust valves with the ECU to be actuated after the intake valves are actuated, and the rebreathe engine operating mode comprises controlling the exhaust valves with the ECU to be actuated both during and after the intake valves are actuated, and
wherein a Start of Injection (SOI) of the fuel injectors is controlled by the ECU to be

Assignees

• Saudi Arabian Oil Co

Inventors

• Whitney Christopher E
• Shah Ashish
• Sellnau Mark
• Sharp Dustin
• Kumar Praveen

Classifications

• F02D2200/0406

  Intake manifold pressure · CPC title

• F02D41/403

  with pilot injections · CPC title

• F02D41/3845

  by controlling the flow into the common rail, e.g. the amount of fuel pumped · CPC title

• F02D41/0077

  Control of the EGR valve or actuator, e.g. duty cycle, closed loop control of position (EGR valve position sensor F02M26/48) · CPC title

• F02D41/006

  using internal EGR (control of valve overlap for internal EGR F02D13/0261; arrangements for internal EGR F02M26/01) · CPC title