Technical field:

The disclosure relates to the field of decarbonizing system for an internal combustion engine, and more particularly to a pneumatic decarbonizing system that cleans the diesel engine by removing the carbon particles deposited inside engine.

Background:

The internal combustion engines upon running over a period, pose to have carbon deposits in the combustion chamber and in the internal body parts of the engine. The deposits consists mainly of incombustible fuel portions, such as non-combustible carbon compounds which partly enter into chemical combination with each other and which partly form layers upon each other on the engine parts and gradually form permanent coatings, for example, in the form of sediments. The carbon deposits in the combustion chamber will result in incomplete combustion and may also pose high level of CO emissions, and thus the carbon deposits in the combustion chamber needs to be cleaned periodically.

The conventional method of decarbonizing the combustion chamber and the other parts of the engine is by periodic engine overhauls in which the engine is dismantled and manual cleaning is adopted. Such an engine overhauling demands more labour and also makes it necessary to stop the engine over a significant period of time. Further, the manual overhauling and cleaning of engine is costly and time-consuming for dismantling and assembly of the engine.

Further to the physical cleaning system, the fluidized decarbonizing apparatus for cleaning the internal body parts of the internal combustion engines are also performed. The known decarbonizing system employed is by providing chemical additives to the engine to dissolve soft carbon deposits on the combustion surfaces. These reacting chemicals are applied in several ways, one way being by simply adding the selective chemicals to the fuel tank that supplies diesel fuel to the engine whereby the chemical is mixed and carried through the entire closed fuel system.

The document US2003158061 (Ahmadi Majid et al) states an apparatus and application tool for removing engine deposits in a reciprocating internal combustion engine by directing a substantial portion of a cleaning composition to an interior cavity of the engine.

The document US5289837 (Betancourt Eduardo) reports purging system which cleans out deposits of carbon and other substances that accumulate over time in the fuel system by delivering a mixture of fuel and cleaning solution into the fuel intake ports while the engine is running, so that the engine pulls the mixture through the carburetor jets or injectors. The document US2008001 1327 (Shriner Kenneth et al) recites a cleaning solution for cleaning the air-intake system of an EGR-valve-equipped diesel engine. The cleaning solution is applied to the air intake system while the diesel engine is running, thereby drawing the cleaning solution into intake system to clean the same.

The addition of the additives to the air line or fuel line as disclosed in the prior art documents requires the operation of diesel engines to remove the smooth carbon deposits. The residue and other foreign material to be removed from the carbon-covered surfaces are not necessarily removed from this conventional system, as the engine requires being in running condition. If the carbon deposits are not completely removed from the diesel-fuel system, such residual particles contaminate the system and eventually return to the fuel tank for deposit therein. Hence, these foreign particles are always present to clog and/or obstruct fuel flow at some later time.

Another system of decarbonizing the internal body parts of the internal combustion engine is provided in view of the difficulties in the additive fuel method of cleaning. This system has apparatus for feeding the decarbonising fluid from a receptacle and pressuring it with an electric pump which is either submerged or placed outside of the receptacle. The fluid tank which is at atmospheric pressure had provisions for feeding the pressurized fluid to the engine and collecting the fluid which is returning from the engine. This system also has several disadvantages in operation and achieving complete cleaning of carbon deposits.

However, the above mentioned conventional system of engine decarbonizing apparatus also has some inherent drawbacks. The electric driven pumps pose a risk of fire as the fluid handled is highly inflammable and the overheating of pump also adds to the risk of fire.

Moreover, there is a risk of contamination, as the cleaning system is open to environment. There is no packaging integrity and chances of adulteration and dilution (intended or unintended) of the cleaner chemical exists in the supply chain. In addition, the conventional cleaning systems are more complex and requires running of the engine and works through the air intake mechanism and not through the fuel line to clean the fuel system and therefore the deposits in the fuel inlet line are not get cleaned completely. Object:

The main object is to provide an improved decarbonizing system which overcomes the drawbacks of the convention cleaning apparatus.

Further object is to provide a decarbonizing system with more complete and simple method or process for removing carbon build-up in the IC engine.

Further object is to provide a pneumatic operated decarbonizing system which is performed to provide for a total carbon- free system. Further object is to provide a pneumatic operated decarburizing system which can operate engines equipped with primary feed pumps.

Further object is to provide a decarbonizing system purging the complete engine of all residual contaminants.

Still further object is to provide a decarbonizing system which uses pressurized aerosol for cleaning carbon deposits in the engine.

Still further object is to provide a decarbonizing and cleaning system for the engine which is complete and stand-alone to operate.

Summary:

The decarbonizing system has a pair of cylinders having connected to a solenoid operated directional control valve and to the fuel inlet line of an internal combustion engine. A set of aerosol containers each having decarbonizing fluid are respectively connected with each of the cylinders to primarily supply the fluid to the cylinders. The decarbonizing fluid is fed to the engine through the cylinders at a feed pump pressure of the engine, in particular about 3 Bar to 4 Bar. The non return valve or one way valve is placed at the entry port and exit port of each of the cylinders. The engine is configured to run on the pneumatic charge fed by the cylinders and cleaned in the circulation of the compressed air and the decarbonizing fluid.

The control valve actuates the cylinders such that the decarbonizing fluid is alternately passed between the cylinders through the engine and cleans the combustion chamber. The air trapped in the cylinders is released through the bleeder provided in the direction control valve. The decarbonizing fluid is passed through the fuel rail of the engine in a closed cycle configuration. The control valve actuates the cylinders such that the fluid is directed to the engine through the first cylinder and the return fluid from the engine is passed through the second cylinder.

The fluid level in both the cylinders is continuously sensed through sensors and the control valve is signaled to change the direction of air flow to each of the cylinders based on the fluid level sensed in the respective cylinders. The float sensors are used sense the fluid level and based on the sensed fluid level and the control valve is signaled to change the direction of air flow to each of the cylinders. The decarbonized particles from the engine are filtered through the filter provided within the system. A pair of T joints is provided to respectively connect the cylinders connecting the engine.

A method of decarbonizing the internal combustion is also provided. The directional control valve is placed to alternately circulate the compressed air from the one cylinder to another cylinder. The aerosol containers having decarbonizing fluid are connected with each of the cylinders such that the decarbonizing fluid is passed between the cylinders through the engine and cleans the carbon deposits in the combustion chamber. A set of float sensors are configured to respectively connect with each of the cylinders to signal the direction control valve for reversing the input air flow, when the fluid in the respective cylinder reaches a preset level, such that the decarbonizing fluid is passed between the cylinders through the engine for cleaning the carbon deposits in the combustion chamber.

This decarbonizing system is more complete and simple system and a method for removing carbon build-up is in the form of a safe and less-costly cleaning operation which can be performed to provide for a total carbon- free diesel system. The decarbonizing system works as decarbonizing pump and efficiently cleans all the carbon deposits within the engine. This decarbonizing system overcomes all the drawbacks and concerns associated with the conventional decarbonising mechanism are ensuring packaging integrity till the final point of use in the supply chain and reducing the chances of contamination.

Brief Description of drawings:

Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment only, and not for the purpose of limiting the same.

Fig. 1 is the isometric view of the decarbonizing system showing the outer casing with twin cylinders, filter assembly, aerosol bottles, piping arrangement and control buttons and the position of the bleeder lines are also shown in the figure. Fig. la is the cut section view of the decarbonizing system showing the plumbing circuitry and the circuit having directional control valve. The float arrangement in each of the cylinders is also shown, which gives the appropriate command to the control unit. The position of the bleeder lines are clearly indicated in the figure.

Fig. 2 is the front view of the decarbonizing system showing the outer casing with twin cylinders, filter assembly, aerosol bottles, piping arrangement and control buttons and the position of the bleeder lines are also seen in this figure.

Fig. 3 is the top view of decarbonizing system shows the location of the twin cylinders and the filter assembly. The plumbing arrangement having the Non return valve towards the rear of the machine is also seen in this figure.

Fig. 4 is the back view of the decarbonizing system having the control panel casing mounted on it.

Fig. 5 is the pneumatic circuit of the decarbonizing system.

Fig. 6 is the flowchart for operation of the decarburization system.

Detailed description:

The discourse relates to decarbonizing the internal combustion engine having a pneumatic system directing the decarbonizing fluid between the cylinders through the engine to clean the carbon particles deposited within the diesel engine. This decarbonizing system overcome the drawbacks of conventional decarbonising mechanism and ensuring packaging integrity till the final point of use in the supply chain and reducing the chances of contamination. The

decarbonizing system feeds decarbonizing fluid into a diesel engine for cleaning the internal body parts including the combustion chamber and the fuel line of the internal combustion engine.

The decarbonizing system has two cylinders configured and connected with a solenoid operated directional control valve and the internal combustion engine. The solenoid operated directional control valve alternately actuates the cylinders such that the compressed air supplied to the valve is directed to any one of the cylinders and the flow of compressed air to the cylinders is reversed with respect to the solenoid operation of the directional control valve. The decarbonizing fluid is primarily fed to the cylinder, and the pneumatic system is configured to alternately pass the decarbonizing fluid between the cylinders through the engine to clean the carbon particles deposited within the diesel engine.

Fig. 1 to 4 shows different views of the decarbonizing system having pneumatic cylinders and control valve. The decarbonizing system has a pair of pneumatic actuated cylinders (la, lb) which are configured and connected with a solenoid operated directional control valve (2) and the internal combustion engine (3). A pneumatic air source ranging about 3 to 4 Bar pressure is provided to connect with the directional control valve (2) as input source to the cylinders (la, lb). A set of aerosol containers (4a, 4b) having the pressurized decarbonizing fluid (5) is respectively connected to each of the cylinders and the fluid is fed to the engine) (3) by directing the compressed air to the first cylinder. The solenoid operated directional valve (2) actuates the cylinders (la, lb) and engine such that the compressed air supplied to the cylinders pressurizes the fluid and then the pressurized fluid is directed as input flow to the engine (3) through fuel inlet.

The fluid is passed to the engine inlet through the first cylinder (la) and the return flow of fluid from the engine outlet is passed through the second cylinder (lb). The pressure in the first cylinder (la) is matched with the primary feed pump pressure of the engine, i.e. about 3 to 4 Bar, such that the fluid (5) in the first cylinder is pressurized and fed to the engine inlet. A filter (9) is provided such that the decarbonized particles from the engine (3) are filtered through the filter (9) provided within the decarbonizing system. The bleeders (7) provided with the direction control valve (2) bleeds the air entrapped in the pneumatic cylinders (la, lb).

The entry ports of the cylinders (la, lb) are respectively connected to the directional control valve (2) and the exit port of the cylinders are respectively connected to the engine. The entry port and the exit port of the cylinders (la, lb) are respectively provided with a non return valve (8) preferably one way valve. A pair of T joints (10) is provided to respectively connect the cylinders (la, lb) connecting the internal combustion engine (3), so that the flow of the fluid is regularized. The T joint (10) is also provided with an filter (9) to filter the fluid passing through the engine. The directional control valve (2) is a solenoid operated valve or pilot operated valve and preferably a 5/3 (5 port and 3 position) pneumatic direction control valve.

The decarbonizing fluid (5) is capable of cleaning and decarbonizing the internal body parts of the engine (3) including the combustion chamber and the fuel line. The decarbonizing fluid dispenses out and cleans the carbon sediments formed within the combustion chamber and the internal body parts of the engine. A set of float sensors (6a, 6b) are respectively provided with each of the cylinders (la, lb), such that when the fluid (5) in the first cylinder (la) reaches to a preset minimum level, the respective sensor (6a) signals the directional control valve (2) to change the solenoid position and reverse the direction of the compressed air to the second cylinder (lb).

The fluid level in both the cylinders (la, lb) are continuously sensed through the float sensors (6a, 6b) and the directional control valve (2) is continuously signaled to change the direction of air flow to each of the cylinders (la, lb) based on the fluid level sensed in the respective cylinders. The float sensors (6a, 6b) produces electric signals which is then transmitted to the solenoid operation on the direction control valve (2) and thus the control valve (2) is signaled to change the direction of air flow to each of the cylinders (la, lb). As the fluid (5) passes through the second cylinder (lb), the alone fluid is retained in the second cylinder and the bleeder (7) provided in the control valve (2) bleeds the entrapped air in the second cylinder (lb).

The float sensor (6a) connected with the first cylinder (la) signals the control valve (2) upon receiving the fluid to preset level in the first cylinder and the direction control valve (2) reverse the air flow to the first cylinder (la) such that the fluid flow is directed from the first cylinder to second cylinder through the engine. The float sensor (6b) in the second cylinder (lb) signals the control valve (2) upon receiving the fluid to preset level in the second cylinder (lb). As the flow continues with circulation of decarbonizing fluid between the first cylinder and the second cylinder through the engine, the fluid disperses the carbon deposits and sediments and cleans the combustion chamber.

The solenoid operated directional valve (2) actuates the two cylinders such that the compressed air supplied to the valve is directed as input to the engine (3) through the first cylinder (la) and the return flow of fluid from the engine outlet is passed through the second cylinder (lb). The air trapped in the first cylinder (la) is then released through the bleeder (7) provided in the direction control valve (2). The decarbonized particles from the engine (3) are filtered through the filter (9) provided within the system. The above cycle of reversing the flow between the cylinders (la, lb) with the engine (3) continues, and the entire process is monitored by a control panel which directs the flow between the two cylinders (la, lb) using the direction control valve (2) and the float sensors (6a, 6b) connected with the cylinders (la, lb).

Fig. 2 shows the various switches provided within the system for operating the decarbonizing system. The various switches include, Power ON switch (1 1) to indicate the power to the system, a green push button (12) to start the cycle and a red push button (13) to stop the cycle, a green indicator (14) to show the auto cycle is ON, a red indicator (15) to show that cycle completion. A set of drain switches (16) are provided to manually drain the containers are also provided. In the initial condition, the cylinder (la) is filled with the decarbonizing fluid (5) and the cylinder (lb) is made empty to receive the fluid from the engine for recirculation. The

decarbonizing is contained in aerosol form to match up with the pressure requirements for circulating within the engine. All the above mentioned switches are configured to perform the assigned function so that the system will function automatically and clean the carbon deposits within the engine.

Fig. 4 shows the decarbonizing system having control panel (17), switches and sensors are connected to the control panel (17) to continuously monitor the state of the system and the user inputs to enable automatic control of the system. A display board (18) is provided within the control panel (17) to show the various functional and the operational status of the system decarbonising the internal combustion engine. All the components and switches are placed and assembled in the board as indicating in the Fig. 4 to have ease of manual access and the connectivity of the parts within the system, thus enabling packaging integrity till the final point of use in the supply chain and enabling ease of handling.

Fig. 5 shows pneumatic circuit of the decarbonizing system. The decarbonising system has two cylinders, marked as "CI" and "C2". The compressed air is fed to the 5/3' solenoid directional valve "Dl", which operates the two cylinders, and the aerosol containers are respectively connected to each of the cylinders CI and C2. During the decarburization operation, compressed air is fed to the cylinder CI matching the primary feed pump pressure of the engine (3 to 4 Bar). The air pressurizes the fluid in the Cylinder C 1 , and is fed to the engine inlet which in turn gets filtered through the filter connected between T joint marked as "T" and the Engine inlet. The return flow from the engine is connected to the cylinder C2.

As the level of fluid in the cylinder C 1 reaches to a preset minimum, the float sensor connected in the Cylinder C 1 actuates the 5/3 inch solenoid controlled direction valve marked as "Dl", which changes the flow to Cylinder C2. The air trapped in the cylinder CI is released through the bleeder in D 1. The same cycle continues for cylinder C2, when it reaches the minimum preset level. The entire process is controlled by a micro switch which directs the flow between the two cylinders using the directional control valve D 1.

A method of decarbonizing the internal combustion is also provided. The directional control valve (2) is placed to alternately circulate the compressed air from one cylinder to another cylinder. The aerosol containers (4a, 4b) having decarbonizing fluid (5) are respectively connected with each of the cylinders such that the decarbonizing fluid is passed between the cylinders through the engine (3) and cleans the carbon deposits in the combustion chamber. A set of float sensors are configured to respectively connect with each of the cylinders (la, lb) to signal the direction control valve (2) for reversing the input air flow, when the fluid in the respective cylinder reaches a preset level. The decarbonizing fluid (5) is passed between the cylinders (la, lb) through the engine (3) for cleaning the carbon deposits in the combustion chamber.

The direction of air flow to each of the cylinders (la, lb) is altered based on the fluid level in the respective cylinders (la, lb). The reversing of the direction control valve (2) actuates the second cylinder (lb) so that the collected fluid in the second cylinder (lb) is passed to the first cylinder (la) through the engine (3). The sensors connected with the cylinders respectively signals the control valve upon receiving the fluid to a preset level the cylinders and the control valve (2) reverse the air flow from one cylinder to another and thus the fluid flow is circulated between the cylinders through the engine. The continuation of flow of pressurized fluid between the cylinders through the engine disperses the carbon deposits and cleans the engine body parts and fuel lines.

The decarbonizing fluid (5) is passed through the fuel rail of the engine (3) in a closed cycle configuration. The fluid level in the cylinders is continuously sensed to change the direction of air flow to each of the cylinders. The engine (3) is configured to run on the pneumatic charge fed by the cylinders (la, lb) and cleaned using decarbonizing fluid passing between the cylinders through the engine. The decarbonized particles from the engine (3) are filtered through the filter (9) provided within the flow path of the decarbonizing system.

Fig. 6 shows the flowchart for operation of the decarburization system. The power ON button is pressed to supply the electric power and upon pressing the CYCLE START button, the system checks for initial condition. The control panel in the system is configured to check the requirements of the system such as pressure level, aerosol fluid level and etc, and if YES is the condition, the cycle starts automatically else the user to fill the container 1 and press cycle start.

In the starting of the cycle, the left solenoid valve and corresponding right exhaust valve opens and decarbonising fluid starts emptying from the container 1 and flows fluid in the cylinder 1 to the engine. In cycle, the fluid from the engine is passed to the cylinder 2 and the fluid is filtered and collected in the container 2. As the container 1 gets drained and the container 2 gets filled, the float sensor in the container 1 is now in ON and the float sensor in the container 2 is OFF.

At this time the left solenoid valve and corresponding right exhaust valve gets closed and the right solenoid valve and left exhaust valve gets opened. The liquid from the container 2 starts circulating and the return line liquid fills the container 1 and now the left float rises. When the container 1 gets filled and the container 2 in the minimum level the cycle then switches and continues.

The above cycle continues for a preset amount of time, and when the liquid in both the containers are drained, both the floats are in low level and this signals the controller to stop the cycle and the red indicator glows. The process can be stopped at any time by pressing the red push button. Moreover the liquid in the containers can be manually drained by using the drain buttons provided.

The decarbonizing system selectively removes the air in the line by a bleeding technique and at the same time continues to provide a pressurized flow without stalling the engine. The key feature is the added capability of running and decarbonizing an internal combustion engine, in particular compression Ignition - Diesel cycle engine, which substitutes the primary pump which feeds the fuel to the high pressure pump. The decarbonizing fluid is packed in cans at appropriate pressure at the manufacturing location, and supplied in a seal proof container to the field. These cans shall be used for diesel decarbonising using the application technique described in the disclosure.

The decarbonizing system overcomes the problems associated with the conventional cleaning systems are more complex requirement of running the engine. As the decarbonizing system works through the fuel line, the system cleans the combustion chamber and fuel system of the engine, thus providing a more complete and simple system and process for removing carbon build-up in the engine.

The decarbonizing system is a simple, safe and less-costly cleaning operation which can be performed to provide for a total carbon- free diesel system. The decarbonizing system is a pneumatic operated decarbonizing system which is performed to provide for a total carbon- free system, thus enabling purging the complete engine of all residual contaminants. The decarbonizing system uses pressurized aerosol for cleaning carbon deposits in the engine, thus providing a cleaning system for the engine which is complete and stand-alone to operate.

The foregoing description is a specific embodiment of the decarbonizing system. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the system. It is intended that all such modifications and alterations be included insofar as they come within the scope of the system as claimed or the equivalents thereof.