Claims:We claim:

1. An improved structure of mounting brackets for diesel engine Emission After Treatment System (EATS), said structure comprises a plurality of mounting brackets for connecting said EATS with diesel engine assembly for effective positioning of said brackets to reduce thermal stresses developed therein under high temperatures due to thermal deformation in different directions thereof and thus increasing the fatigue life of said mounting brackets.

2. Mounting brackets structure as claimed in claim 1, wherein said plurality of mounting brackets comprises five brackets connecting said EATS with the following components of said diesel engine assembly:

(i) a first bracket (12) for connecting said EATS with the engine head of said diesel engine;

(ii) a second bracket (14) for connecting said EATS with the crank case on the right-side of said diesel engine;

(iii) a third bracket (16) for connecting said EATS with the crank case on the left-side of said diesel engine;

(iv) a fourth bracket (18) for connecting said EATS with the turbocharger with the front cover of said diesel engine; and

(v) a fifth bracket (20) for connecting Diesel Oxidation Catalyst (DOC) to Diesel Particulate Filter (DPF) of said EATS of said diesel engine;

wherein said mounting brackets (12, 14, 16, 18, 20) are aligned with the neutral axis A-A of the thermal expansion thereof and have predefined flexibility to deform in said direction to prevent high thermal stresses developing therein and/or to effectively transmit the subjected vibration loads to the crank case.

3. Mounting brackets structure as claimed in claim 2, wherein said first mounting bracket (12) is configured to have a predefined flexibility therein to allow deformation thereof in Y and Z directions to prevent high thermal stresses developing therein, and said first mounting bracket (12) is aligned with the neutral line in X direction thereof to prevent high thermal stresses developing therein to avoid deformation thereof in X direction.

4. Mounting brackets structure as claimed in claim 2, wherein said second mounting bracket (14) is welded close to the neutral line of thermal deformation thereof in Y and Z directions and configured as a main load-carrying bracket to bear almost the entire weight of said EATS together with said third mounting bracket (16) and to impart an improved vibration resistance and increasing the fatigue life thereof .

5. Mounting brackets structure as claimed in claim 2, wherein said third mounting bracket (16) is welded away from the neutral line A-A for imparting a predefined flexibility thereto to undergo a predefined deformation thereof in X and Z directions to avoid high thermal stresses developing therein, said bracket (16) configured as main load-carrying bracket bearing almost the entire weight of said EATS together with said second mounting bracket (14).

6. Mounting brackets structure as claimed in claim 2, wherein said second mounting bracket (14) and said third mounting bracket (16) are welded to the Diesel Particulate Filter (DPF) of said EATS assembly.

7. Mounting brackets structure as claimed in claim 2, wherein said fourth mounting bracket (18) is connected between the turbocharger and front cover of diesel engine and configured to have a predefined flexibility therein to undergo thermal deformation thereof in X and Z directions to prevent the development of high thermal stresses therein.

8. Mounting brackets structure as claimed in claim 2, wherein said fifth mounting bracket (20) is connected between said Diesel Oxidation Catalyst (DOC) and said Diesel Particulate Filter (DPF) and transmits high vibration load of said Diesel Oxidation Catalyst (DOC) via said Diesel Particulate Filter (DPF) to the engine block of said diesel engine assembly, said bracket (20) configured with a predefined flexibility therein to undergo predefined thermal deformation thereof to prevent the development of high thermal stresses therein.

9. An improved structure of mounting brackets for diesel engine Emission After Treatment System (EATS), said structure comprises five brackets connecting said EATS with the following components of said diesel engine assembly:

(I) a first bracket (12) welded at one end thereof to said EATS and welded on the other end thereof to the engine head of said diesel engine;

(II) a second bracket (14) welded at one end thereof to said Diesel Particulate Filter (DPF) of said EATS and welded on the other end thereof to the crank case on the right-side of said diesel engine;

(III) a third bracket (16) welded at one end thereof to said Diesel Particulate Filter (DPF) of said EATS and welded on the other end thereof to the crank case on the left-side of said diesel engine;

(IV) a fourth bracket (18) securely fastened at one end thereof to the turbocharger of said diesel engine assembly and securely fastened on the other end thereof to the front cover of said diesel engine; and

(V) a fifth bracket (20) welded at one end thereof to said Diesel Oxidation Catalyst (DOC) subjected to high vibration load and welded at the other end thereof to said Diesel Particulate Filter (DPF) to transmit said vibration load to the engine block of said diesel engine assembly;

wherein said mounting brackets (12, 14, 16, 18, 20) are aligned with the neutral axis A-A of the thermal expansion thereof and have predefined flexibility to deform in said direction to prevent high thermal stresses developing therein and/or to effectively transmit the subjected vibration loads to the crank case.

10. Mounting brackets structure as claimed in claim 9, wherein said mounting brackets are configured as follows:

(a) said first mounting bracket (12) has a predefined flexibility therein to allow deformation thereof in Y and Z directions to prevent high thermal stresses developing therein, and said first mounting bracket (12) is aligned with the neutral line thereof to prevent thermal stresses developing therein to avoid deformation thereof in X direction;

(b) said second mounting bracket (14) is welded close to the neutral line of thermal deformation thereof in Y and Z directions and configured as a configured as a main load-carrying bracket to bear almost the entire weight of said EATS together with said third mounting bracket (16) and to impart an improved vibration resistance and increasing the fatigue life thereof;

(c) said third mounting bracket (16) is welded away from the neutral line A-A thereof to impart a predefined flexibility thereto to undergo a predefined deformation in X and Z directions thereof to avoid high thermal stresses developing therein, said bracket (16) configured as main load-carrying bracket bearing almost the entire weight of said EATS together with said second mounting bracket (14);

(d) said second mounting bracket (14) and said third mounting bracket (16) welded to the Diesel Particulate Filter (DPF) of said EATS assembly;

(e) said fourth mounting bracket (18) is connected between the turbocharger and front cover of diesel engine and configured to have a predefined flexibility therein to undergo thermal deformation thereof in X and Z directions to prevent the development of high thermal stresses therein; and

(f) said fifth mounting bracket (20) is connected between said Diesel Oxidation Catalyst (DOC) and said Diesel Particulate Filter (DPF) and transmits vibration load of said Diesel Oxidation Catalyst (DOC) via said Diesel Particulate Filter (DPF) to the engine block of said diesel engine assembly, said bracket (20) configured with a predefined flexibility therein to undergo predefined thermal deformation thereof to prevent the development of high thermal stresses therein.

Dated this 30th day of April 2019.

Digitally Signed.
(SANJAY KESHARWANI)
REGN. NO. IN/PA-2043
APPLICANT’S PATENT AGENT. , Description:FIELD OF INVENTION

The present invention relates to the mounting brackets for after treatment system in an internal combustion engine. In particular, the present invention relates to the effective structure and positioning of the mounting brackets for after treatment system in a diesel engine. More particularly, the present invention relates to an effective structure and positioning of the mounting brackets for a diesel engine emission after treatment system (EATS) having improved vibrational load distribution and transmission as well as reduced thermal stresses.

BACKGROUND OF THE INVENTION

The exhaust gases usually contain substantial amounts of air pollutants such as nitrogen oxides (NOx), carbon oxides (Cox), hydrocarbons (HC) and particulate matter (PM), the treatment of which is very critical for emission control. This is called as aftertreatment process, which uses Diesel Oxidation Catalyst (DOC), Selective Catalytic Reduction (SCR) catalyst and Diesel Particulate Filter (DPF). DOC helps in converting carbon monoxide (CO) and hydrocarbons present therein into carbon dioxide (CO2) and water. SCR helps in conversion of NOx to N2 and O2. DPF helps to remove diesel particulate matter or soot from the exhaust gas.

Therefore, it is imperative to control the amount of pollutants being emitted out to the atmosphere, which is done by means of an after-treatment system the treatment and removal or reduction of the pollutants present in the exhaust gases. The after-treatment unit is typically mounted on the vehicle’s diesel engine.

It is mandatory to adhere to stringent emissions standards while running diesel engine powered vehicles on/off road.
The mounting of this exhaust gas after-treatment system on the engine is very crucial as the engine’s vibration and heat from the exhaust system directly affects the operational life of the after-treatment system.

Therefore, there is an existing need for developing and implementing an improved exhaust gas after-treatment system with effectively configured and positioned mounting brackets therefor, for properly connecting the after-treatment system to diesel engine assembly.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide an improved exhaust gas after-treatment system for a diesel engine.

Another object of the present invention is to provide a mounting bracket configuration for the exhaust gas or emission after-treatment system (EATS) for a diesel engine, which experiences reduced thermal stresses.

Still another object of the present invention is to provide mounting brackets for EATS for diesel engine to enhance the fatigue life of these mounting brackets.

Yet another object of the present invention is to provide multiple mounting brackets for EATS for diesel engine, which transmit vibration loads of different components by connecting thereto.

A further object of the present invention is to provide multiple mounting brackets for EATS for diesel engine, which facilitate thermal expansion of the engine components in different directions to reduce deformations thereof.
These and other objects and advantages of the present invention will become more apparent from the following description, when read with the accompanying figures of drawing, which are however not intended to limit the scope of the present invention in any way.

DESCRIPTION OF THE INVENTION

The present invention is configured to effectively distribute and transmit the vibrational load experienced by the exhaust gas or emission after-treatment system (EATS) by means of multiple mounting brackets configured in accordance with the present invention, which significantly reduce stresses due to thermal expansion by reconfiguring and welding these brackets near the neutral line of deformation thereof. With this approach, some level of flexibility is achieved for the deformation of improved mounting brackets and these are attached in ideal positions for reducing stresses developed therein due to thermal expansions thereof.

SUMMARY OF THE INVENTION

In accordance with the present invention, in an embodiment of the invention, there is provided an improved structure of mounting brackets for the diesel engine Emission After Treatment System (EATS), the structure comprises a plurality of mounting brackets for connecting EATS with diesel engine assembly for effective positioning of the brackets to reduce thermal stresses developed therein under high temperatures due to thermal deformation in different directions thereof and thus increasing the fatigue life of the mounting brackets.

Typically, the plurality of mounting brackets comprises five brackets connecting EATS with the following components of the diesel engine assembly:

(i) a first bracket for connecting EATS with the engine head of the diesel engine;

(ii) a second bracket for connecting the EATS with the crank case on the right-side of the diesel engine;

(iii) a third bracket for connecting EATS with the crank case on the left-side of the diesel engine;

(iv) a fourth bracket for connecting EATS with the turbocharger with the front cover of the diesel engine; and

(v) a fifth bracket for connecting DOC to DPF of EATS of the diesel engine;

wherein the mounting brackets are aligned with the neutral axis A-A of the thermal expansion thereof and have predefined flexibility to deform in the direction to prevent high thermal stresses developing therein and/or to effectively transmit the subjected vibration loads to the crank case.

Typically, the first mounting bracket is configured to have a predefined flexibility therein to allow deformation thereof in Y and Z directions to prevent high thermal stresses developing therein, and the first mounting bracket is aligned with the neutral line in X direction thereof to prevent high thermal stresses developing therein to avoid deformation thereof in X direction.

Typically, the second mounting bracket is welded close to the neutral line of thermal deformation thereof in Y and Z directions and configured as a main load-carrying bracket to bear almost the entire weight of EATS together with the third mounting bracket and to impart an improved vibration resistance and increasing the fatigue life thereof.

Typically, the third mounting bracket is welded away from the neutral line A-A for imparting a predefined flexibility thereto to undergo a predefined deformation thereof in X and Z directions to avoid high thermal stresses developing therein, the bracket configured as main load-carrying bracket bearing almost the entire weight of EATS together with the second mounting bracket.

Typically, the second mounting bracket and the third mounting bracket are welded to DPF of EATS assembly.

Typically, the fourth mounting bracket is connected between the turbocharger and front cover of diesel engine and configured to have a predefined flexibility therein to undergo thermal deformation thereof in X and Z directions to prevent the development of high thermal stresses therein.

Typically, the fifth mounting bracket is connected between DOC and DPF and transmits high vibration load of DOC via DPF to the engine block of the diesel engine assembly, the bracket configured to have a predefined flexibility therein to undergo predefined thermal deformation thereof to prevent the development of high thermal stresses therein.

In accordance with the present invention, in another embodiment of the invention, there is provided an improved structure of mounting brackets for the diesel engine Emission After Treatment System (EATS), the structure comprises five brackets connecting EATS with the following components of the diesel engine assembly:

(I) a first bracket welded at one end thereof to EATS and welded on the other end thereof to the engine head of the diesel engine;

(II) a second bracket welded at one end thereof to DPF of EATS and welded on the other end thereof to the crank case on the right-side of the diesel engine;

(III) a third bracket welded at one end thereof to DPF of EATS and welded on the other end thereof to the crank case on the left-side of the diesel engine;

(IV) a fourth bracket securely fastened at one end thereof to the turbocharger of the diesel engine assembly and securely fastened on the other end thereof to the front cover of the diesel engine; and

(V) a fifth bracket welded at one end thereof to DOC subjected to high vibration load and welded at the other end thereof to DPF to transmit the vibration load to the engine block of the diesel engine assembly;

wherein the mounting brackets are aligned with the neutral axis A-A of the thermal expansion thereof and have predefined flexibility to deform in the direction to prevent high thermal stresses developing therein and/or to effectively transmit the subjected vibration loads to the crank case.

Typically, the mounting brackets are configured as follows:

(a) the first mounting bracket has a predefined flexibility therein to allow deformation thereof in Y and Z directions to prevent high thermal stresses developing therein, and the first mounting bracket is aligned with the neutral line thereof to prevent high thermal stresses developing therein to avoid deformation thereof in X direction;

(b) the second mounting bracket is welded close to the neutral line of thermal deformation thereof in Y and Z directions and configured as a configured as a main load-carrying bracket to bear almost the entire weight of EATS together with the third mounting bracket and to impart an improved vibration resistance and increasing the fatigue life thereof;

(c) the third mounting bracket is welded away from the neutral line A-A thereof to impart a predefined flexibility thereto to undergo a predefined deformation in X and Z directions thereof to avoid high thermal stresses developing therein, the bracket configured as main load-carrying bracket bearing almost the entire weight of EATS together with the second mounting bracket;

(d) the second mounting bracket and the third mounting bracket welded to the DPF of the EATS assembly;

(e) the fourth mounting bracket is connected between the turbocharger and front cover of diesel engine and configured to have a predefined flexibility therein to undergo thermal deformation thereof in X and Z directions to prevent the development of high thermal stresses therein; and

(f) the fifth mounting bracket is connected between DOC and DPF and transmits vibration load of DOC via DPF to the engine block of the diesel engine assembly, the bracket configured with a predefined flexibility therein to undergo predefined thermal deformation thereof to prevent the development of high thermal stresses therein.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described in the following with reference to the accompanying drawings.

Figure 1 shows the front view of the layout of the Emission After Treatment System (EATS) with improved multiple mounting brackets thereof configured in accordance with the present invention.

Figure 2 shows right-side view of the layout of EATS of Fig. 1.

Figure 3 shows left-side view of the layout of EATS of Fig. 1 with multiple mounting brackets thereof.

Figure 4 shows the thermal expansion of EATS of Fig. 1 and exhaust gas system in X-direction.

Figure 5a shows the right-side view of the thermal expansion of EATS of Fig. 1 and exhaust gas system in Y-direction.
Figure 5b shows the left-side view of the thermal expansion of EATS of Fig. 1 and exhaust gas system in Y-direction.

Figure 6a shows the EATS of Fig. 1 (front view) and exhaust gas system with the thermal expansion thereof in Z-direction.

Figure 6b shows the right side view of EATS and exhaust gas system of Fig. 6a with the thermal expansion thereof in Z-direction.

Figure 6c shows the left side view of EATS and exhaust gas system of Fig. 6a with the thermal expansion thereof in Z-direction.

Figure 7 shows the first bracket of the mounting brackets for EATS configured in accordance with the present invention.

Figure 8 shows the second bracket of the mounting brackets for EATS configured in accordance with the present invention.

Figure 9 shows the third bracket of the mounting brackets for EATS configured in accordance with the present invention.

Figure 10 shows the fourth bracket of the mounting brackets for EATS configured in accordance with the present invention.

Figure 11 shows the fifth and last bracket of the mounting brackets for EATS configured in accordance with the present invention.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

In the following multiple mounting brackets for the exhaust gas or emission after-treatment system (EATS configured in accordance with the present invention) for a diesel engine will be described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention.

Figure 1 shows the front view of the layout of the Emission After Treatment System (EATS) with improved multiple mounting brackets thereof configured in accordance with the present invention. In this preferred embodiment of EATS, there are five different brackets, i.e. first bracket 12 connecting EATS with engine head (Fig. 3), second and third brackets 14, 16 connecting EATS to crank case, fourth bracket 18 (Fig. 2) connecting turbocharger to engine front cover, and fifth bracket 20 for connecting Diesel Oxidation Catalyst (DOC) to Diesel Particulate Filter (DPF).

Figure 2 shows right-side view of the layout of EATS of Fig. 1 with the fourth bracket 18 connecting turbocharger to engine front cover and depicting DOC and DPF connected to each other.

Figure 3 shows left-side view of the layout of EATS of Fig. 1 with first bracket 12 connecting EATS with the engine head.

Figure 4 shows the thermal expansion of EATS of Fig. 1 and exhaust gas system in X-direction with respect to a neutral line A-A. Accordingly, the maximum positive thermal expansion Pmax is at the left-most side and the maximum negative thermal expansion Nmax at the right hand side here.

Figure 5a shows the right-side view of the thermal expansion of EATS of Fig. 1 and exhaust gas system in Y-direction. Here also, the maximum positive thermal expansion Pmax is on the left-side of DOC and the maximum negative thermal expansion Nmax at a mid-point shown here.

Figure 5b shows the left-side view of the thermal expansion of EATS of Fig. 1 and exhaust gas system in Y-direction. The neutral line A-A is marked across DPF.
Figure 6a shows the EATS of Fig. 1 (front view) and exhaust gas system with the thermal expansion thereof in Z-direction. Accordingly, the maximum positive thermal expansion Pmax is on the top of DOC and the maximum negative thermal expansion Nmax at the lowest point shown here. Neutral line A-A is marked across DPF.

Figure 6b shows the right side view of EATS and exhaust gas system of Fig. 6a with the thermal expansion thereof in Z-direction. Accordingly, the maximum positive thermal expansion Pmax is on the top of DOC and the maximum negative thermal expansion Nmax at the lowest point shown here. Neutral line A-A is marked across DPF.

Figure 6c shows the left side view of EATS and exhaust gas system of Fig. 6a with the thermal expansion thereof in Z-direction. Accordingly, the maximum positive thermal expansion Pmax is on the top of DOC and the maximum negative thermal expansion Nmax at the lowest point shown here. Neutral line A-A is marked across DPF.

Figure 7 shows the first bracket 12 of the multiple mounting brackets devised for EATS of Fig. 1. This bracket 12 is shaped to impart some flexibility to allow deformation in Y and Z directions. It is clear from the Figures 5a-5b and Figures 6a-6c that the region where first bracket 12 is welded to EATS, has deformed in Y and Z directions. This configuration of bracket 12 allows EATS to thermally expand/ contract in respective direction without exerting high stress in bracket 12. Figure 4 makes it clear that first bracket 12 is aligned with neutral line A-A of thermal expansion in X-direction, due to this perfect bracket placement, first bracket 12 does not deform in X- direction and there is not stress-induced impact thereon.

Figure 8 shows the second bracket 14 of the multiple mounting brackets devised for EATS of Fig. 1. Second and third brackets 14, 16 are the main load carrying member amongst these multiple brackets. The entire weight of EATS of Fig. 1 is almost carried by these two brackets 14, 16. Thus, these are configured a little rigid as compared to the rest of the brackets 12, 18 and 20. This imparts EATS a better vibration resistance, thereby increasing the fatigue life of the components. It is clear from Figures 4, 5a and 6a that second bracket 14 is welded close to neutral line (A-A) of X, Y and Z direction of the thermal deformation.

Figure 9 shows the third bracket 16 of the multiple mounting brackets devised for EATS of Fig. 1. It is clear from Figures 4 and 6a-6c that third bracket 16 is disposed slightly away from neutral line A-A. Thus, third bracket 16 may experience some deformation in X and Z directions. However, to avoid the stress due to this deformation otherwise possible in X and Z directions, third bracket 16 is configured slightly flexible in these directions. Therefore, this bracket 16 permits slight deformation in these directions without experiencing too much of thermal stress.

Figure 10 shows the fourth bracket 18 of the multiple mounting brackets devised for EATS of Fig. 1. It is also clear from Figures 4 and 6a-6c that the turbocharger is undergoing thermal deformation in X and Z directions. Fourth bracket 18 connecting the turbocharger to the front cover of the diesel engine is made flexible in X and Z directions. As shown in Figure 5a-5b, the bracket is configured to deform in X and Z directions without inducing very high stress.

Figure 11 shows the fifth and last bracket of the mounting brackets for EATS configured in accordance with the present invention. As described above, almost the entire weight of EATs is borne by second 14 and third bracket 16 and transmitted to the crank case. These brackets 14, 16 are welded to DPF, which is therefore subjected to high vibration load, if not properly transmitted. The fifth bracket 20 achieves this function of transmitting the vibrational load from DOC to DPF and further transmitted to the engine block. This fifth bracket 20 is also flexible enough to allow some deformation without exerting too much stress.
TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

The multiple mounting brackets for the exhaust gas after-treatment system for a diesel engine configured in accordance with the present invention offers the following advantages:

• Reduced stresses due to thermal expansion.

• Reduced thermal stresses in different directions, e.g. X, Y, Z-directions.

• Enhanced fatigue life of improved multiple mounting brackets.

• Effectively transmits vibration loads of different components by connecting thereto.

• Reduced thermal deformations of diesel engine components in different directions.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

It is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention.

Although, the embodiments presented in this disclosure have been described in terms of its preferred embodiments, the skilled person in the art would readily recognize that these embodiments can be applied with modifications possible within the spirit and scope of the present invention as described in this specification by making innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies and assemblies, in terms of their size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention.

The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

Throughout this specification, the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to imply including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention.

The description of the exemplary embodiments is intended to be read in conjunction with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top”, and “bottom” as well as derivatives thereof (e.g. “horizontally”, “downwardly”, “upwardly” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion.

These relative terms are for convenience of description and do not require that the corresponding apparatus or device be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected”, refer to a relationship, wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.