Method for replacing an exhaust gas aftertreatment component

Abstract

Method for replacing an exhaust after treatment component. In particular, the invention relates to a method for replacing an exhaust after treatment component (112, 114, 116) of an exhaust after treatment system (106) in a vehicle (1) or a marine vessel. The exhaust after treatment system is delimited by a housing (108) and comprises a first sleeve (124) extending in an axial direction and containing a first exhaust after treatment component (116) mounted directly in the first sleeve. The method comprises the steps of: - removing the first exhaust after treatment component from the first sleeve, whereby the first sleeve remains intact within said housing; - providing a second exhaust after treatment component (132, 134) mounted in a second sleeve (136), the second sleeve being configured to fit within the first sleeve; and - mounting the second sleeve with the second exhaust after treatment component in the first sleeve by inserting the second sleeve into the first sleeve in the axial direction of the first sleeve. The invention also relates to an exhaust after treatment system of a vehicle or a marine vessel and to a vehicle or a marine vessel comprising the exhaust after treatment system.

Description

Technical Field

[0001] This invention relates to a method for replacing exhaust aftertreatment components in an exhaust aftertreatment system of a vehicle or vessel. The invention also relates to exhaust aftertreatment systems for vehicles or vessels. Furthermore, the invention relates to vehicles or vessels including said exhaust aftertreatment system.

[0002] This invention can be applied to medium and heavy-duty vehicles, such as trucks and buses. Although the invention will be described in relation to trucks, it is not limited to this specific vehicle but can also be used in other vehicles, such as buses, construction equipment, and engineering machinery. Examples of such vehicles include wheel loaders, articulated transport vehicles, dump trucks, excavators, fire trucks, refrigerated trucks, and backhoe loaders. The invention can also be applied to ships, such as vessels. Background Technology

[0003] Exhaust aftertreatment systems (EATS) are commonly used in the automotive industry to reduce emissions from internal combustion engines in order to comply with current and future emissions regulations. The robustness and durability of EATS are becoming increasingly important for ensuring compliance with these regulations. There is also a growing focus on the ability to reuse parts and minimize waste.

[0004] During the lifespan of a vehicle powered by an internal combustion engine, EATS components can be affected by certain emissions, leading to their decommissioning. Decommissioning negatively impacts characteristics such as NOx conversion, filtration capacity, and fuel consumption. A particular problem associated with decommissioning is physical blockage of the components, primarily caused by ash and soot from the combustion process.

[0005] Exhaust aftertreatment catalysts (such as those used in selective catalytic reduction (SCR)) slowly lose their ability to reduce emissions over time due to substances in the thermal cycle and exhaust that can clog the active catalyst seat. In particular, biofuels may contain catalyst poisons, such as potassium from fertilizers. Some of this aging is irreversible and may eventually cause vehicles to no longer meet emission requirements and regulations.

[0006] For medium and heavy-duty vehicles (such as trucks and buses), there are typically several types of exhaust aftertreatment components combined in an EATS, such as catalysts and filters. Ultimately, aging exhaust aftertreatment components may lead to the need to replace the entire exhaust aftertreatment system, which is a large and expensive system.

[0007] Patent document US2010 / 0139256A1 discloses a method for replacing a catalyst, a particulate filter, modifying these components, and similar components in all their variations. The method includes the steps of removing spent catalyst from the exhaust manifold, cleaning the space and inserting a new component, and restoring the manifold portion. The method in US2010 / 0139256A1 includes the steps of cutting a sheet surrounding the catalyst, replacing the catalyst, and welding the cut portion back in place.

[0008] The enclosed embodiment of US Patent 2010 / 0139256A1 shows an EATS construction in which a sleeve holding the catalyst or filter also forms the EATS housing. This is often the case, for example, in passenger cars. However, EATSs for medium and heavy-duty vehicles are more complex, typically containing multiple exhaust aftertreatment components within the same EATS. These are all contained within sleeves that are separated from the EATS housing, for example, by internal baffles. Furthermore, the housings for EATSs used in medium or heavy-duty vehicles generally have a more complex structure than those for passenger cars, for example, including an inner steel shell and an outer steel shell with thermal insulation material between them. Some sections of the housing may also contain sound-dampening material. Therefore, as disclosed in US 2010 / 0139256A1, it is not feasible to access the exhaust aftertreatment components of a medium or heavy-duty vehicle by opening the side wall of the EATS housing.

[0009] Therefore, there is a need for a solution to replace one or more exhaust aftertreatment components that no longer function as expected, and this solution is also applicable to EATS configurations that are more complex than those of passenger cars, such as EATS in medium and heavy-duty vehicles. Summary of the Invention

[0010] The object of the present invention is to provide an alternative or improved method for replacing exhaust aftertreatment components in an exhaust aftertreatment system of a vehicle or ship. This object is achieved, at least in part, by a method according to a first aspect of the invention.

[0011] According to a first aspect of the invention, a method is provided for replacing an exhaust aftertreatment component in an exhaust aftertreatment system in a vehicle or vessel, the exhaust aftertreatment system being defined by a housing. The exhaust aftertreatment system includes a first sleeve containing a first exhaust aftertreatment component directly mounted within the first sleeve. The first sleeve extends in an axial direction.

[0012] The method includes the following steps:

[0013] S1: Remove the first exhaust aftertreatment component from the first sleeve, so that the first sleeve remains intact within the housing.

[0014] S2: Provide a second exhaust aftertreatment component installed in a second sleeve, the second sleeve being configured to fit within the first sleeve.

[0015] S3: The second sleeve with the second exhaust aftertreatment component is installed in the first sleeve by inserting the second sleeve into the first sleeve along the axial direction of the first sleeve.

[0016] The first exhaust aftertreatment component that no longer functions as expected and therefore needs to be replaced can be a catalyst carrier, such as a diesel oxidation catalyst carrier (DOC) or a selective catalytic reduction carrier (SCR). Alternatively or supplementary, the first exhaust aftertreatment component can be a particulate filter carrier, which is adapted to remove particulate matter and / or soot from the type of fuel used by the engine. In the case of a diesel-powered internal combustion engine, the particulate filter carrier is a diesel particulate filter carrier (DPF).

[0017] When installed in a vehicle, the Exhaust Aftertreatment System (EATS) forms part of the exhaust system, which extends from the vehicle's combustion engine. Exhaust gases enter the EATS through an exhaust inlet, optionally via a turbocharger's turbine, and exit through a tailpipe located downstream of the EATS. Alternatively, additional components may be present, such as sensors (e.g., one or more temperature sensors) or optional urea injectors. The EATS is defined by a housing, and the exhaust aftertreatment components (including those to be replaced) are located within this housing, i.e., inside the walls of the housing. During operation of the combustion engine, exhaust gases travel along the exhaust flow path through the EATS, passing over the exhaust aftertreatment components within the EATS.

[0018] The housing forms the shell of the EATS and typically includes sidewalls, a front cover, and a rear cover located opposite the front cover, with the rear cover being closest to the tailpipe. Therefore, the terms "front cover" and "rear cover" refer to the flow direction of exhaust gas through the EATS, where the front is the inlet end of the EATS and the rear is the outlet end. The orientation of the EATS may differ from the longitudinal direction of the vehicle or vessel.

[0019] The method described herein discloses how to replace a first exhaust aftertreatment component that is directly mounted in a first sleeve. This sleeve may also be referred to as a shell or canister. The sleeve extends axially from a first end to an opposite second end. Thus, the first and second ends form opposing openings in the first sleeve. The first sleeve typically has a circular cross-section, but other cross-sections (such as oval or elliptical) are also possible. The axial direction of the first sleeve typically coincides with the axial direction of the EATS, but this is not mandatory, and the method can be performed for a first sleeve with any orientation relative to the axial direction of the EATS. When the EATS is operated, exhaust gas enters from one end of the first sleeve and exits from the other end; that is, the exhaust gas flows axially or at least substantially axially. The first exhaust aftertreatment component to be replaced is directly mounted in the first sleeve, meaning that there is no additional sleeve between the first exhaust aftertreatment component and the first sleeve. However, a mounting mat may be provided between the first exhaust aftertreatment component and the first sleeve.

[0020] In step S1, the first exhaust aftertreatment component is removed from the first sleeve. The first exhaust aftertreatment component is removed through one end of the first sleeve, such that the first sleeve remains intact after the removal of the first exhaust aftertreatment component. Furthermore, the first sleeve remains in its existing position within the EATS. This differs from some prior art methods in which the first sleeve is removed together with the exhaust aftertreatment component it contains. It also differs from other prior art methods in which the first sleeve is manipulated to remove the first exhaust aftertreatment component (e.g., by forming an opening in the sidewall of the first sleeve).

[0021] The first sleeve may contain two or more first exhaust aftertreatment components that are typically arranged axially relative to each other. In this case, one or more of them may be removed.

[0022] Step S2 includes providing a second exhaust aftertreatment component mounted in a second sleeve. The second sleeve is configured to fit within the first sleeve. The second sleeve may, for example, have a diameter slightly smaller than that of the first sleeve. The second exhaust aftertreatment component, together with the second sleeve, is intended to replace the first exhaust aftertreatment component.

[0023] The second sleeve contains a second exhaust aftertreatment component that replaces the first exhaust aftertreatment component removed in step S1. Since the second sleeve is adapted to fit within the first sleeve, the cross-sectional dimensions of the second exhaust aftertreatment component are typically smaller than those of the first exhaust aftertreatment component, although the second exhaust aftertreatment component is configured to perform a function corresponding to that of the first exhaust aftertreatment component.

[0024] Steps S1 and S2 can be performed in any order, successively, and / or at least partially in parallel. Step S2 can be performed completely independently of step S1, for example, at another location and / or at another point in time. Step S3 is performed after steps S1 and S2.

[0025] In step S3, the second sleeve with the second exhaust aftertreatment component is installed in the first sleeve by inserting the second sleeve into the first sleeve along the axial direction of the first sleeve (i.e., through the first end of the first sleeve).

[0026] In cases where the first sleeve contains two or more first exhaust aftertreatment components, two or more second exhaust aftertreatment components can be used to replace the two or more first exhaust aftertreatment components. These second exhaust aftertreatment components can then be mounted axially relative to each other in the second sleeve.

[0027] The method can be repeated an optional number of times, either by replacing the first exhaust aftertreatment component with another first exhaust aftertreatment component other than the one replaced when the method was first executed, or by using the second exhaust aftertreatment component as the new first exhaust aftertreatment component when the method is repeated.

[0028] By applying this method, exhaust aftertreatment components of an EATS can be replaced quickly and / or cost-effectively. Therefore, the EATS can continue to be used even if one of the exhaust aftertreatment components fails to function as expected. Furthermore, this method is applicable to EATSs used in medium and heavy-duty vehicles (which are more complex than those in passenger cars and typically contain multiple exhaust aftertreatment components). This method can also be applied to existing EATSs.

[0029] The advantage of this method is that it is also applicable when two or more second exhaust aftertreatment components have different cross-sectional dimensions (e.g., different diameters), because the circumference of the second sleeve can be locally adapted to the corresponding second exhaust aftertreatment component, i.e., the so-called adaptive canning of the second sleeve.

[0030] Step S1 may include: while the first exhaust aftertreatment component is still in the first sleeve, cutting the first exhaust aftertreatment component into multiple pieces, such as cutting it into two halves. This cutting is performed in a manner that keeps the first sleeve intact, for example by using a rotary milling tool.

[0031] A mounting pad may be provided between the second exhaust aftertreatment component and the second sleeve. This mounting pad is typically made of an elastic material and fills the gap between the second exhaust aftertreatment component and the second sleeve. The mounting pad can be used to compensate for dimensional tolerances of the second exhaust aftertreatment component and / or the second sleeve. Furthermore, the mounting pad prevents or at least reduces the risk of exhaust gas slipping through the gap between the second exhaust aftertreatment component and the second sleeve (i.e., bypassing the second exhaust aftertreatment component).

[0032] As an alternative to using a mounting pad, the second post-treatment component can be directly mounted in the second sleeve, for example, by welding. This could be, for example, the case of a metal catalyst support.

[0033] As mentioned above, two or more second exhaust aftertreatment components can be installed in the same second sleeve. They can be used to replace two or more first aftertreatment components.

[0034] Step S3 may include positioning a support between the first and second sleeves. This support reduces or preferably eliminates the risk of the second sleeve vibrating or otherwise moving within the first sleeve. As a supplement or alternative to its supporting function, the support may have a sealing function, thereby preventing or at least reducing the risk of exhaust gas slipping through the gap between the first and second sleeves (i.e., without passing through the second exhaust aftertreatment component). The support may include or be composed of a washer, such as a wire mesh washer. The support may be located at or near the second end of the first sleeve (i.e., the end opposite to the end through which the second sleeve is inserted).

[0035] Step S3 may include welding the second sleeve to the first sleeve. The weld between the first and second sleeves prevents or at least reduces the risk of exhaust gas slipping through the gap between the first and second sleeves (i.e., bypassing the second exhaust aftertreatment component). This weld is typically performed at or near the first end of the first sleeve (i.e., the end through which the second sleeve is inserted).

[0036] Step S3 may include adapting the circumference of the first sleeve at or near its end to the circumference of the second sleeve at the corresponding position. Typically, this is done at or near the first end (i.e., the end through which the second sleeve is inserted). This allows for the desired assembly between the first and second sleeves. The circumferential adaptation can be used to facilitate welding of the second sleeve to the first sleeve, for example, by locally minimizing the gap between the first and second sleeves. The circumferential adaptation can be performed through a calibrated expansion.

[0037] The method may further include the following steps:

[0038] S0: Cut open a section of the housing of the exhaust aftertreatment system to allow access to the first aftertreatment component contained in the first sleeve.

[0039] This step is performed before step S1 to allow the first exhaust aftertreatment component to be accessed in step S1, thereby allowing the first exhaust aftertreatment component to be removed from the first sleeve.

[0040] It is generally advantageous to form an opening in the housing at the location where the first exhaust aftertreatment component is most easily accessible, while the first exhaust aftertreatment component remains in the first sleeve. As mentioned above, the housing forms the shell of the EATS and typically includes sidewalls, a front cover, and a rear cover located opposite the front cover, wherein the rear cover is closest to the tailpipe. The cut segment of the housing may include, or be composed of, an end cover or part of an end cover of the exhaust aftertreatment system. It may be advantageous to cut the end cover closest to the exhaust aftertreatment component to be replaced. Sometimes, it is preferred that the actual cut is made on the sidewall of the housing adjacent to the end cover, so that the cut can be made through a single wall layer. Thus, after removal, the end cover remains a single piece, for example, where an inner end plate and an outer end plate maintain an insulating layer therebetween.

[0041] Having already performed step S0, the method may further include the following steps:

[0042] S4: After step S3, the segment cut in step S0 is reinstalled on the housing of the exhaust aftertreatment system.

[0043] Step S4 can be performed by welding.

[0044] According to a second aspect of the invention, an exhaust aftertreatment system for a vehicle or ship is provided, the exhaust aftertreatment system comprising a first sleeve extending in an axial direction and a second sleeve located within the first sleeve, the second sleeve comprising an exhaust aftertreatment component, wherein the axial direction of the second sleeve coincides with the axial direction of the first sleeve, and wherein the first sleeve and the second sleeve are welded to each other.

[0045] The exhaust aftertreatment system (EATS) of the present invention can be obtained by the method of the invention described herein. Therefore, the exhaust aftertreatment component included in the second sleeve corresponds to the second exhaust aftertreatment component mentioned in the description of the method herein. The details described herein in conjunction with the method are also applicable to the EATS according to the invention. Examples of such details include:

[0046] - The second sleeve may contain two or more exhaust aftertreatment components.

[0047] -A support member may be provided between the first sleeve and the second sleeve.

[0048] - The circumference of the first sleeve can be adapted to the circumference of the second sleeve at the corresponding position (e.g., at or near its end).

[0049] - A mounting pad may be provided between the second exhaust aftertreatment component and the second sleeve.

[0050] According to a third aspect of the invention, a vehicle or vessel is provided that includes the exhaust aftertreatment system described herein.

[0051] The effects and features of the second and third aspects of the invention are largely similar to those described above in conjunction with the first aspect. The systems, components, parts, vehicles, and ships described above in conjunction with the first aspect will no longer be described.

[0052] Further advantages and advantageous features of the invention are disclosed in the following description. Attached Figure Description

[0053] The above and other objects, features, and advantages of the present invention will be better understood through the following illustrative and non-limiting detailed description of exemplary embodiments of the invention, wherein:

[0054] Figure 1 This is a side view of a truck-shaped vehicle according to an embodiment of the present invention;

[0055] Figure 2 The components of an exhaust system, including an exhaust aftertreatment system according to the present invention, are schematically shown.

[0056] Figure 3 A flowchart illustrating the operational steps S0-S4 of the method according to the present invention is shown schematically.

[0057] Figures 4a to 4b The exhaust aftertreatment system is shown when step S0 is performed by removing the end cap of the housing.

[0058] Figures 5a to 5b Step S1 is shown, which shows the removal of the first exhaust aftertreatment component from the first sleeve.

[0059] Figures 6a to 6c A second exhaust aftertreatment component installed in the second sleeve is shown, see step S2.

[0060] Figures 7a to 7b Step S3 is shown, illustrating the installation of the second sleeve within the first sleeve.

[0061] Figure 8 The matching diameters of the first and second sleeves are shown.

[0062] Figures 9a to 9b Step S4 is shown, illustrating the reinstallation of the end cap onto the housing.

[0063] Referring to the accompanying drawings, the following is a more detailed description of embodiments of the present invention cited by way of example. Detailed Implementation

[0064] The invention will now be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the invention are illustrated. However, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness. Throughout the specification, the same reference numerals refer to the same elements.

[0065] Figure 1 A vehicle 1 according to the invention, shown in the form of a truck, is schematically illustrated. The vehicle 1 includes an internal combustion engine (not shown) for propelling the vehicle 1, and an exhaust system 100 for guiding and disposing of the exhaust gas produced by the internal combustion engine.

[0066] Figure 2 An exemplary exhaust system 100, which may be included in a vehicle 1 or vessel according to the invention, is schematically shown, illustrating the exhaust system 100 during operation of the vehicle 1. The exhaust flow path of the exhaust system 100 is from the engine (not shown), via the turbine of the turbocharger 102, through the exhaust inlet 104 into the exhaust aftertreatment system 106 (generally abbreviated as EATS, defined by the housing 108), and through a tailpipe 110 disposed downstream of the EATS 106, through which the exhaust gases are discharged. The EATS 106 of the illustrated embodiment includes three exhaust aftertreatment components 112, 114, and 116 configured to treat exhaust gases, but the EATS 106 may also include more or fewer exhaust treatment components. In the illustrated embodiment, components 112, 114, and 116 are respectively a diesel oxidation catalyst carrier 112 (abbreviated as DOC), a diesel particulate filter carrier (abbreviated as DPF) 114, and a selective catalytic reduction carrier 116 (abbreviated as SCR). Furthermore, as an alternative and Figure 2 As not shown, additional components may be present, such as sensors (e.g., one or more temperature sensors) and / or optional urea injectors. Figure 2 As shown, during the operation of the internal combustion engine, exhaust gas flows along the exhaust flow path through EATS 106, passing through components 112, 114, and 116. Thus, optional sensors can continuously or intermittently monitor the exhaust system 100.

[0067] As Figure 2The exhaust system 100 shown as a portion of the EATS 106 illustrates an exhaust aftertreatment system according to the invention. Details are further described below with reference to Figures 4 through 9. The EATS 106 may be included in a vehicle 1 or a vessel according to the invention.

[0068] exist Figure 3 The flowchart illustrates an exhaust aftertreatment system 106 for replacing the exhaust system of a vehicle 1 or a ship according to an embodiment of the present invention (e.g., Figure 2 The method of exhaust aftertreatment components 112, 114, and 116 in the exhaust aftertreatment system shown is illustrated. Optional steps are shown in dashed boxes. The exhaust aftertreatment system 106 is defined by a housing 108 and includes a first sleeve extending in the axial direction and containing a first exhaust aftertreatment component directly mounted within the first sleeve. The method according to the invention is suitable for execution in the exhaust aftertreatment system according to the invention, for example in… Figure 2 This is performed in EATS 106 as shown. The method includes the following steps:

[0069] S1: Remove the first exhaust aftertreatment component from the first sleeve, so that the first sleeve remains intact within the housing.

[0070] S2: Provide a second exhaust aftertreatment component installed in a second sleeve, the second sleeve being configured to fit within the first sleeve.

[0071] S3: The second sleeve with the second exhaust aftertreatment component is installed in the first sleeve by inserting the second sleeve into the first sleeve along the axial direction of the first sleeve.

[0072] Steps S1 and S2 can be performed in any order, successively, and / or at least partially in parallel. Step S2 can be performed entirely independently of step S1, for example, at another location and / or at another point in time. Step S3 is performed after steps S1 and S2.

[0073] The method may further include:

[0074] S0: Cut open a section of the housing of the exhaust aftertreatment system to allow access to the exhaust aftertreatment components contained in the first sleeve.

[0075] This step is performed before step S1 to allow access to the exhaust aftertreatment component in step S1.

[0076] Having already performed step S0, the method may further include the following steps:

[0077] S4: After step S3, the segment cut in step S0 is reinstalled on the housing of the exhaust aftertreatment system.

[0078] Step S4 can be performed by welding.

[0079] The following uses Figures 4a to 9b To describe these steps in more detail. In these diagrams, Figure 2 The reference numerals will be repeated in the figures. Figure 2 The components shown are only schematically illustrated.

[0080] Figure 4a and Figure 4b An exemplary action taken in step S0 is shown. The housing 108 forms the housing of the exhaust aftertreatment system 106 according to the invention. It includes a sidewall 118, a front end cap 120, and a rear end cap 122. The rear end cap 122 is located at the opposite end of the front end cap 120, wherein the rear end cap 122 is closest to the tailpipe 110; therefore, the terms "front" and "rear" refer to the direction of exhaust flow, where "front" is on the inlet side and "rear" is on the outlet side. To gain access to the interior of the exhaust aftertreatment system 106, a segment of the housing 108 is cut, for example, one of the end caps 120, 122. Typically, it is advantageous to cut the end cap closest to the exhaust aftertreatment component to be replaced.

[0081] exist Figure 4a and Figure 4b In the illustrated embodiment, the rear cover 122 is cut open, which provides easier access to the first exhaust aftertreatment component to be replaced compared to cutting open the front cover 120. Sometimes, as Figure 4a and Figure 4b As shown, preferably, the actual cut is made in the sidewall 118 of the housing 108 adjacent to the end caps 120, 122, such that the cut can be made through a single wall layer. Therefore, after removal, the end caps 120, 122 remain integral parts, for example, where the inner and outer end plates maintain an insulating layer therebetween. Instead of cutting the entire end caps 120, 122, it is sufficient to open only a segment of the end caps 120, 122. Alternatively, a segment of the sidewall 118 can be cut. It is generally advantageous to form an opening in the housing 108 that provides the easiest access to the first exhaust aftertreatment component 116 while it remains in the first sleeve 124.

[0082] exist Figure 4a and Figure 4b In this embodiment, the first exhaust aftertreatment component to be replaced is exemplified as an SCR 116, but the method is also applicable to other exhaust aftertreatment components, such as DOC 112 or DPF 114. The first exhaust aftertreatment component to be replaced is contained in a first sleeve, which is shown as the first sleeve 124 of the SCR 116. The first sleeve 124 extends axially from a first end 126 to an opposite second end 128, which is located at... Figure 4b The first end 126 and the second end 128 are obscured in the view. Thus, the first end 126 and the second end 128 form opposite openings in the first sleeve 124. The axial direction of the first sleeve 124 typically coincides with the axial direction of the EATS, but this is not mandatory, and the method can be performed for a first sleeve with any orientation relative to the axial direction of the EATS. In the illustrated embodiment, the first sleeve 124 has a cylindrical geometry and therefore a circular cross-sectional shape, but other geometries are also possible, such as oval or elliptical cross-sectional shapes.

[0083] In the illustrated embodiment, while the SCR 116 is still located in the first sleeve 124, step S1 is performed by cutting the first exhaust aftertreatment component (i.e., the SCR 116) into multiple segments (illustrated as two halves), see [reference]. Figure 5a and Figure 5b The cutting is performed in a manner that keeps the first sleeve 124 intact, for example by a rotary milling tool 130. The first exhaust aftertreatment component (i.e., SCR 116) is removed from the first sleeve 124 axially, i.e., by one of the ends 126, 128, such that the first sleeve 124 remains intact after the removal of the first exhaust aftertreatment component 116. Furthermore, the first sleeve 124 remains in its existing position in EATS 106, i.e., inside the housing 108.

[0084] Figures 6a to 6c Step S2 is shown. In the illustrated embodiment, two second exhaust aftertreatment components 132, 134 are axially mounted relative to each other in a second sleeve 136. Furthermore, the second sleeve 136 extends axially from a first end 138 to an opposite second end 140. The second sleeve 136 is adapted to fit within the first sleeve 124. Therefore, the second sleeve 136 has a smaller diameter than the first sleeve 124. Although... Figures 6a to 6c The example shown has two second exhaust aftertreatment components 132 and 134, but the method is equally applicable to cases with a single second exhaust aftertreatment component or more than two second exhaust aftertreatment components. Typically, the number of second exhaust aftertreatment components 132 and 134 corresponds to the number of first exhaust aftertreatment components removed in step S1.

[0085] like Figure 6b As best seen, the corresponding mounting pads 142, 144 are located between the corresponding second exhaust aftertreatment components 132, 134 and the second sleeve 136. The mounting pads 142, 144 are made of an elastic material and fill the corresponding gaps between the second exhaust aftertreatment components 132, 134 and the second sleeve 136. Furthermore, a support member 146 is disposed on the outside of the second sleeve 136. In the illustrated embodiment, the support member 146 is composed of a washer (e.g., a wire mesh washer). See also Figure 6a and Figure 6b The support member 146 is located near the second end 140 of the second sleeve 136. Figure 6b The arrows in the diagram schematically indicate the direction of exhaust flow, which coincides with the axial direction.

[0086] The advantage of this method is that it also works when two or more second exhaust aftertreatment components 132, 134 have different cross-sectional dimensions (e.g., different diameters) because the circumference of the second sleeve 136 can be locally adapted to the corresponding second exhaust aftertreatment component 132, 134; that is, the so-called adaptive filling of the second sleeve 136, see [link to relevant documentation]. Figure 6c This fitting is performed before the second sleeve 136 is inserted into the first sleeve 124.

[0087] Figure 7a This diagram illustrates the situation where the second sleeve 136 is inserted into the first sleeve 124 along its axial direction. Therefore, the axial directions of the sleeves 124 and 136 coincide. The second sleeve 136 is inserted via one of the ends 126 or 128 of the first sleeve 124. After insertion, a support 146 is positioned between the first sleeve 124 and the second sleeve 136, see [reference needed]. Figure 7b The support 146 reduces or preferably avoids the risk of the second sleeve 136 vibrating or moving in any other way within the first sleeve 124. The support 146 also has a sealing function, thereby preventing or at least reducing the risk of exhaust gas slipping through the gap between the first sleeve 124 and the second sleeve 136 (i.e., without passing through the second exhaust aftertreatment components 132, 134).

[0088] Step S3 may include adapting the circumference of the first sleeve 124 at or near its end to the circumference of the second sleeve 136 at the corresponding position. Typically, this is done at or near the first end 126 (i.e., the end through which the second sleeve 136 is inserted), see [link to relevant documentation]. Figure 8 Therefore, the desired assembly between the first sleeve 124 and the second sleeve 136 can be achieved. The circumferential fit can facilitate welding of the second sleeve 136 to the first sleeve 124, for example, by locally minimizing the gap between the first sleeve 124 and the second sleeve 136. Welding between the first sleeve 124 and the second sleeve 136 prevents or at least reduces the risk of exhaust gas slipping through the gap between the first sleeve 124 and the second sleeve 136 (i.e., without passing through the second exhaust aftertreatment components 132, 134).

[0089] Finally, after performing step S3, the segment cut in step S0 (illustrated as rear end cover 122) is reinstalled at the housing 108 of EATS 106, see [link to relevant documentation]. Figure 9aand Figure 9b This reinstallation may include welding the rear end cover 122 to the remainder of the housing 108.

[0090] It should be understood that the present invention is not limited to the embodiments described above and shown in the accompanying drawings; rather, those skilled in the art will recognize that many modifications and variations can be made within the scope of the appended claims, and the EATS can have many different configurations, with the first exhaust treatment components installed in different orders and numbers.

Claims

1. A method for replacing exhaust aftertreatment components (112, 114, 116) of an exhaust aftertreatment system (106) in a vehicle (1) or a ship, said exhaust aftertreatment system (106) being defined by a housing (108), The exhaust aftertreatment system (106) includes a first sleeve (124) containing a first exhaust aftertreatment component (116) directly mounted within the first sleeve (124). The first sleeve (124) extends in an axial direction. The first exhaust aftertreatment component (116) is a catalyst carrier or a diesel particulate filter carrier. The method includes the following steps: S1: Remove the first exhaust aftertreatment component (116) from the first sleeve (124), thereby keeping the first sleeve (124) intact in its existing position within the housing (108). S2: Provide a second exhaust aftertreatment component (132, 134) mounted in a second sleeve (136), the second sleeve (136) being configured to fit within the first sleeve (124), and S3: The second sleeve (136) with the second exhaust aftertreatment components (132, 134) is installed in the first sleeve (124) by inserting the second sleeve (136) into the first sleeve (124) along the axial direction of the first sleeve.

2. The method according to claim 1, wherein, Step S1 includes: when the first exhaust aftertreatment component (116) is located in the first sleeve (124), cutting the first exhaust aftertreatment component (116) into multiple segments.

3. The method according to claim 1, wherein, Step S1 includes: when the first exhaust aftertreatment component (116) is located in the first sleeve (124), cutting the first exhaust aftertreatment component (116) into two halves.

4. The method according to claim 1 or 2, wherein, A mounting pad (142, 144) is provided between the second exhaust aftertreatment component (132, 134) and the second sleeve (136).

5. The method according to claim 1 or 2, wherein, Two or more second exhaust aftertreatment components (132, 134) are installed in the second sleeve (136).

6. The method according to claim 1 or 2, wherein, Step S3 includes positioning the support (146) between the first sleeve (124) and the second sleeve (136).

7. The method according to claim 1 or 2, wherein, Step S3 includes welding the second sleeve (136) to the first sleeve (124).

8. The method according to claim 1 or 2, wherein, Step S3 includes adapting the circumference of the first sleeve (124) at or near the end (126) of the first sleeve to the circumference of the second sleeve (136) at the corresponding position.

9. The method according to claim 1 or 2, wherein, The method further includes the following steps: S0: Cut open a section of the housing (108) of the exhaust aftertreatment system (106) to allow access to the first exhaust aftertreatment component (116) contained in the first sleeve (124).

10. The method according to claim 9, wherein, The cut-off segment of the housing (108) includes or is part of the end cap (122) of the exhaust aftertreatment system (106), or is composed of or is part of the end cap (122) of the exhaust aftertreatment system (106).

11. The method according to claim 9, wherein, The method further includes the following steps: S4: After step S3, the segment cut in step S0 is reinstalled at the housing (108) of the exhaust aftertreatment system (106).

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