Title of Invention

"A CONTROL APPARATUS FOR AN EXHAUST BRAKE AND METHOD OF CONTROLLING ACTIVATION OF ENGINE BRAKE"

Abstract A control system for an exhaust brake which operates to impede exhaust flow from a turbocharged combustion engine when the engine throttle is closed. The control system includes means for delaying application the exhaust brake only when the vehicle throttle is closed to allow the rotational speed of the turbo charger to drop thereby reducing wear to seal components.
Full Text The present invention relates to a control appanaton for an exhaust brake which
operates to impede exhaust flow from a turbocharged combustion engine when the
and mened of cofrming activation of aefine brake
engine throttle is closed. In particular, the invention' relates TO the control of an '
exhaust brake applied to a turbocharged engine.
Exhaust brake systems are widely fittled to compression ignition engines (diesel engines) used to power large vehicles such as trucks. Many types of exhaust brake system are known, all generally comprising a valve in the exhaust line from the engine which when activated at least substantially blocks the engine exhaust. This creates back pressure which retards rotation of the engine providing a braking force which is transmitted to the vehicle wheels through the vehicle drive train. With some exhaust brake systems the brake can be set to activate automatically when the engine throttle is closed (i.e. the driver lifts his foot from the throttle pedal). In other systems the exhaust brake may require manual activation by the driver, such as depression of a brake pedal.
It is now conventional for large diesel engines to be turbocharged. A turbocharger essentially comprises an exhaust driven turbine wheel which rotates a compressor wheel. The turbine wheel and compressor wheels are mounted in respective housing on opposite ends of a rotatable shaft which passes through a bore in a bearing housing located between the compressor and turbine housings. The bearing housing houses journal and thrust bearings and associated lubrication systems and seals.
The shat is typically sealed with respect to the bore of the bearing housing at the turbine wheel end by a shaft seal ring (or piston ring) which sits in an annular groove provided in the shaft behind the turbine wheel. The shaft seal prevents oil from the bearing lubrication systems from leaking into the turbine housing which can cause blue1 smoke and oil drips form the exhaust pipe, as well as preventing exhaust gas pollution of the bearing housing which can cause overheating and adversely effect bearing life.
Problems can arise with this conventional shaft seal arrangement where the turbocharged engine has an engine brake valve located downstream of the turbine. As the engine brake is activated the back pressure in the exhaust line, and thus in the
turbine wheel housing, rapidly rises and ess reach 4-5 bar. As pressure behind the turbine wheel thus increases the shaft seal ring can be pushed inboard. This movement together with the high rotational speed of the shaft, can generate excessive jhctionai heating which can cause the shaft seal ring to overheat and collapse. This in turn can cause the ring to be more susceptible to movement in the bore and induce a rapid failuie of the seal. This problem is particularly pronounced during the running in period ofthe engme/turboeharger before the seal ring "beds in".
It is an object of the present invention to obviate or mitigate the above problem.
According to a first aspect of the present invention there is provided a control system foi an exhaust brake which operates to impede exhaust flow from a turbochargixi combustion engine when the engine throttle is closed, wherein the control system includes means for determining the rotational velocity of the turbocharger and is operable to apply the exhaust brake only when the vehicle throttle is closed and the rotational speed of the turbo charger is below a threshold value.
According to a second aspect of the present invention there is provided a control system for an exhaust brake system which operates to impede exhaust flow from a turbocharged combustion engine when the engine throttle is closed, wherein the control system is operable to delay application of the exhaust brake for a period of time following closure of the engine throttle.
By the simple expedient of delaying application of the exhaust brake following activation of the exhaust brake system, the present invention allows the turbocharger shaft speed to drop significantly before the back pressure in the turbine housing rises to levels sufficient to exert forces capable of moving the turbine end seal arrangement, such as the seal ring referred to above. This greatly reduces wear to seal component!.
The invention may be applied to exhaust brake systems in which the exhaust brake is automatically activated, by for instance releasing the engine throttle, or in which manual activation is required by for instance depressing a pedal. In the latter case there will already be some delay between closure of the throttle and activation of the brake bit the system according to the invention will operate to ensure that the delay is sufficient to allow the turbine sueed to droo sufficiently to orevent wear to theseal as mentioned above. The invention operates to introduce delay between an exhaust brake activation signal or action (such as closing the throttle or depressing a brake pedal) and actual application of the exhaust brake (by closing the exhaust brake valve). In other words, introduction of a delay between activation of the brake system and closure of the exhaust brake valve.
The delay period may be pre-determined or may be a function of the rotational speed of the turbocharger either immediately prior to closure of the throttle, or as monitored following application of the exhaust brake.
For instance, one embodiment the present invention provides a control systems for an exhaust brake which operates to impede exhaust flow from a turbocharged combustion engine when the engine throttle is closed, wherein the control systems includes means for determining the rotational velocity of the turbocharger and is operable to activate the exhaust brake only when the vehicle throttle is closed and the rotational speed of the turbocharger is below a threshold value.
The present invention also provides a method of controlling activation of an engine exhaust brake which operates to impede exhaust gas flow from a turbocharged combustion engine upon closure of the engine throttle, the method comprising introducing a delay between closure of the throttle and application of the engine exhaust brake.
For instance in one embodiment of the invention the method comprises monitoring the turbocharger rotational speed, or an engine parameter indicative of the turbocharger engine speed, and activating the exhaust brake only when the throttle is closed and the turbocharger speed has dropped below a threshold value.
It will be appreciated that when the throttle is "closed"' the fuel supply is not necessarily stopped completely, rather the fuel supply may drop to an idle level. References to throttle closure throughout this specification are to be interpreted accordingly. For instance, the act of throttle closure in respect of a vehicle will generally comprise release of the throttle pedal by the vehicle driver.
Accordingly, the present invention relates to a control apparatus for an exhaust brake which operates to impede exhaust flow from a turbocharged combustion engine when the engine throttle is closed, wherein the control apparatus comprises means such as herein described for determining the rotational velocity of the turbocharger and is operable to apply the exhaust brake only when the vehicle throttle is closed and the rotational speed of the turbo charger is below a threshold value.
The invention also relates to a method of controlling activation of an engine brake by a control apparatus, which operates to impede exhaust gas flow from a turbocharged combustion engine upon closure of the engine throttle, the method comprising monitoring the turbocharger rotational speed, or an engine parameter indicative of the turbocharger engine speed, and characterized by activating the exhaust brake only when the throttle is closed and the turbocharger speed has dropped below a threshold value.
Other objects and advantages of the present invention will be apparent from the following description.
Specific embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawing, in which:
Figure 1 is a sectional view of part of a turbine wheel/bearing housing assembly;
Figure 2 is a graph illustrating the rate of pressure rise in the turbine vs. fall in turbine wheel speed as the engine throttle is closed.
Figure 1 is a schematic cross-section through part of a turbochargcr showing a turbine whuel 1 mounted to a turbocharger shaft 2 which extends through a bearing housing 3 Tupported on journal bearings 4. The turbine end of the shaft 2 is sealed with respect to the bearing housing 3 by a shaft seal ring 5 which sits in an annular groove 6 denned in the shaft 2. In this example the bore 7 in the bearing housing is stepped reducing in diameter to define an annular shoulder 8. This assembly is entirely conventional. It will be appreciated that much of the detail of the turbocharger construction is irrelevant to the present invention and thus is not shown.
In a conventional exhaust brake control system the exhaust brake is applied automatically immediately the engine throttle is closed. This results in a rapid rise in pressure in the turbine housing behind the turbine wheel which tends to push the seal ring 5 inbonrd. Axial movement of the seal ring 5 within the annular slot 6, coupled with the high rotational speed of the turbine wheel and shaft, can create excessive factional heating and rapidly wear the seal leading to early failure. The present invention greatly reduces mis effect by the simple expedient of introducing a time delay between closure of the throttle and actuation of the exhaust brake.
Referring to Figure 2, this shows how the turbine wheel/shaft speed drops when the ttrottle is closed at time = 0. In a conventional automatic exhaust brake
control system the exhaust brake will be immediately applied so that the pressure will rapidly rise in the turbine housing as illustrated by line PI . The effect of delaying the actuation oi the exhaust brake in accordance with the present invention (either by introducing a predetermined time delay or waiting for the turbocharger to drop below a certain spc ed) is illustrated by the pressure line P^. A relatively short time delay TD (typically of the order of 0.1 to 2 seconds) is sufficient to allow the turbine speed to drop significantly before pressure levels required to exert substantial axial force on the seal ring are reached. There is thus a corresponding reduction in factional heating
The invention is not limited to exhaust brake systems in which the exhaust brake is automatically activated when the throttle is closed. For instance, in a system requiring manual activation of the exhaust brake, by for instance depressing a brake pedal, the delay will be introduced following that manual activation to ensure that there is sufficient delay for the turbocharger speed to drop as required.
The skilled person will be able to implement the present invention in a number of ways. For instance, in modem microprocessor controlled engine management systems the required time delay between closure of the throttle and application of the engine brake could readily be programmed into the engine management system. The delay may ss programmed as a fixed period of time following closure of the throttle or may be related to the engine and/or turbocharger speed immediately prior to closure of tie throttle. For instance, the engine management system could incorporate a "look-up table" relating engine speed or turbocharger speed to required exhaust brake time delay.
Alternatively, the rotational speed of the turbocharger could be directly monitored from an appropriate sensor providing a signal to the exhaust brake control system, and the exhaust brake applied only when the throttle is closed and the monitored turbocharger speed has dropped to a predetermined value. Similarly, the exhaust bratce control system could monitor another parameter of the engine, such as exhaust manifold pressure, which is indicative of the turbocharger speed. In embodiments of the invention in which the application of the exhaust brake is directly controlled from determination of the turbocharger rotational speed it is possible that on some occasions there my be no time delay between closure if the vehicle throttle and application of the exhaust brake of the turbocharger speed is already below the threshold value when the throttle is closed.
Whilst it may be convenient to incorporate the exhaust brake control system into an otherwise conventional engine management system, it will be appreciated that a separate control system could be provided which responds to closure of the throttle in any of the alternative ways suggested above.
The exact duration of the delay may vary to suit any particular turbocharger installation "jut will generally be a compromise between the desire to limit wear to the
The effect of exhaust brake back pressure on shaft seal ring wear is particularly pronounced during the running-in period of an engine/turbocharger. Accordingly, certain embodiments of the present invention may be designed to introduce & delay into the engine brake activation for a limited period only of the exhaust/turaocharger life cycle. For instance, the exhaust brake delay could be programmed to operate for only a predetermined number of miles travelled (with the possibility of re-setting this in the event that a turbocharger seal ring or entire turbochargor is replaced during the life of the engine/vehicle).
In summary, the essence of the present invention is the concept of introducing a delay in the operation of the exhaust brake following closure of the throttle and activation of the exhaust brake system (which may be automatic or require manual activation) and the skilled person will be able to implement the invention in a variety of different ways suited to different applications




WE CLAIM:
1. A control apparatus for an exhaust brake which operates to
impede exhaust flow from a turbocharged combustion engine when
the engine throttle is closed, wherein the control apparatus
comprises means such as herein described for determining the
rotational velocity of the turbocharger and is operable to apply the
exhaust brake only when the vehicle throttle is closed and the
rotational speed of the turbo charger is below a threshold value.
2. A control apparatus as claimed in claim 1, wherein said means for
determining the rotation velocity of the turbocharger has means
such as herein described for monitoring the rotational speed of the
turbocharger directly or from an engine parameter indicative of the
turbocharger speed.
3. A control apparatus as claimed in claim 1, wherein it has means to
delay application of the exhaust brake for a period of time following
closure of the engine throttle.
4. A control apparatus as claimed in claim 3, wherein said period of
time is a function of the rotational speed of the turbocharger
immediately prior to closure of the throttle, and said control
apparatus has means for monitoring the rotational speed of the
turbocharger either directly or from an engine parameter indicative
of the turbocharger speed.
5. A control apparatus as claimed in any of claims 3 and 4, wherein
means are provided for continually monitoring the rotational speed
of the turbocharger either directly or by monitoring an engine
parameter indicative of the turbocharger speed and said exhaust
brake is applied only when the throttle is closed and the monitored
turbocharger speed has dropped below a predetermined value.
6. A control apparatus as claimed in any of the preceding claims,
wherein it has a microprocessor programmed to delay application of the exhaust brake for a period of time following closure of the engine throttle.
7. A method of controlling activation of an engine brake by a control
apparatus, which operates to impede exhaust gas flow from a
turbocharged combustion engine upon closure of the engine
throttle, the method comprising monitoring the turbocharger
rotational speed, or an engine parameter indicative of the
turbocharger engine speed, and characterized by activating the
exhaust brake only when the throttle is closed and the
turbocharger speed has dropped below a threshold value.
8. A method of controlling activation of an engine exhaust brake by a
control apparatus as claimed in claim 7, which operates to impede
exhaust gas flow from a turbocharged combustion engine upon
closure of the engine throttle, the method comprising , introducing
a delay between closure of the throttle and application of the
engine exhaust brake.
9. An engine whenever incorporated with a control apparatus as
claimed in any of the preceding claims.
10. A control apparatus for an exhaust brake substantially as
hereinbefore described with reference to the accompanying
drawings.
11. A method of controlling activation of an engine brake substantially
as hereinbefore described with reference to the accompanying
drawings.



Documents:

107-del-2003-abstract.pdf

107-del-2003-claims.pdf

107-del-2003-complete specificaation (granted).pdf

107-del-2003-correspondence-others.pdf

107-del-2003-correspondence-po.pdf

107-del-2003-description (complete).pdf

107-del-2003-drawings.pdf

107-del-2003-form-1.pdf

107-del-2003-form-19.pdf

107-del-2003-form-2.pdf

107-del-2003-form-3.pdf

107-del-2003-form-5.pdf

107-del-2003-gpa.pdf

107-del-2003-petition-137.pdf

107-del-2003-petition-138.pdf


Patent Number 243755
Indian Patent Application Number 107/DEL/2003
PG Journal Number 45/2010
Publication Date 05-Nov-2010
Grant Date 03-Nov-2010
Date of Filing 13-Feb-2003
Name of Patentee HOLSET ENGINEERING CO. LIMITED
Applicant Address ST ANDREWS ROAD, HUDDERSFIELD, HD1 6RA, GREAT BRITAIN
Inventors:
# Inventor's Name Inventor's Address
1 KEN BALL C/O HOLSET ENGINEERING CO LIMITED, OF ST ANDREWS ROAD, HUDDERSFIELD, HD1 6RA, GREAT BRITAIN
2 PIERRE FRENCH C/O HOLSET ENGINEERING CO LIMITED, OF ST ANDREWS ROAD, HUDDERSFIELD, HD1 6RA, GREAT BRITAIN
PCT International Classification Number F02D 9/06
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 0203490.8 2002-02-14 U.K.