An exhaust treatment system and method for an anti-knock diesel engine

Abstract

The application discloses an exhaust treatment system and method for an anti-explosion diesel engine, and relates to the technical field of waste gas treatment. The system comprises a data collector, a signal processor, a post-treatment controller, a regeneration indicator lamp and a voluntary regeneration request switch. The post-treatment controller comprises a DPF control module and an SCR control module. The data collector is used for collecting multiple intrinsic safety signals. The signal processor is used for converting the intrinsic safety signals into first non-intrinsic safety signals and second non-intrinsic safety signals. The DPF control module is used for determining whether the particulate trap needs to be voluntarily regenerated based on the first non-intrinsic safety signals. The SCR control module is used for determining whether to send a urea injection signal and a urea heating signal according to the second non-intrinsic safety signals. The voluntary regeneration request switch is used for sending a voluntary regeneration request signal. The electronic control unit is used for adjusting the working states of a urea nozzle electromagnetic valve, a urea heating electromagnetic valve and the particulate trap according to the urea injection signal, the urea heating signal and the voluntary regeneration request signal.

Description

Technical Field

[0001] This invention relates to the field of exhaust gas treatment technology, and specifically to an exhaust gas treatment system and method for explosion-proof diesel engines. Background Technology

[0002] With the rapid development of my country's economy, energy demand has steadily increased, and coal production, as a basic energy source, has continued to grow. Large-scale coal mining has also led to increasingly prominent environmental problems. Therefore, the emission control of explosion-proof diesel engines, as the primary auxiliary power source for coal mines, has become a key focus of the industry.

[0003] With the advancement of the national dual-carbon strategy and the rapid development of the coal industry, the emission standards for explosion-proof diesel engines will be upgraded step by step. In order to meet the increasingly stringent emission standards in the future, how to improve the treatment effect of the exhaust gas generated by explosion-proof diesel engines while ensuring that they have good explosion-proof performance, thereby reducing environmental pressure, is an urgent problem to be solved.

[0004] Compared to the National III emission standard for motor vehicles, the National IV emission standard for motor vehicles requires a significant reduction in harmful gas emissions from non-road diesel engines. Specifically, nitrogen oxides can be reduced by up to 40%, and particulate matter by up to 80%. Currently, explosion-proof diesel engines meeting the National III standard primarily achieve emission reductions through electronic fuel injection technology, which is an in-engine purification technology. However, its emission standards are too high to meet the National IV standard. Summary of the Invention

[0005] The technical problem this invention aims to solve is that the emission standards of exhaust gas from explosion-proof diesel engines treated using existing methods are too high and cannot meet the China IV emission standard. To solve this problem, this invention provides an exhaust gas treatment system and method for explosion-proof diesel engines.

[0006] The technical solution of the present invention to solve the above-mentioned technical problems is as follows:

[0007] An exhaust gas treatment system for an explosion-proof diesel engine includes a power supply, a data acquisition unit, a signal processor, an aftertreatment controller, a regeneration indicator light, and an active regeneration request switch. The aftertreatment controller includes a DPF control module and an SCR control module. The data acquisition unit, the regeneration indicator light, and the active regeneration request switch are all connected to the signal processor, which is connected to the aftertreatment controller. The data acquisition unit, the signal processor, and the aftertreatment controller are all connected to the electronic control unit of the explosion-proof diesel engine. The electronic control unit is respectively connected to the particulate filter, the urea injector solenoid valve, and the urea heating solenoid valve in the explosion-proof diesel engine.

[0008] The power supply is used to power the signal processor and the post-processing controller;

[0009] The data acquisition device is used to collect relevant parameters during the operation of the explosion-proof diesel engine, including multiple intrinsically safe signals.

[0010] The signal processor is configured to acquire a plurality of intrinsically safe signals and convert each intrinsically safe signal into a corresponding non-safe signal, wherein the non-safe signal includes a first non-safe signal and a second non-safe signal.

[0011] The DPF control module is used to acquire the first non-safe signal, determine the display status of the regeneration indicator light based on the first non-safe signal, and determine whether the particle trap needs to be actively regenerated based on the display status.

[0012] The SCR control module is used to acquire the second non-safe signal and, based on the second non-safe signal, determine whether to send a urea injection signal and a urea heating signal to the electronic control unit.

[0013] The regeneration indicator light is used to display the current capture status of the particulate filter on fine particulate matter in the exhaust gas;

[0014] The active regeneration request switch is used to send an active regeneration request signal to the signal processor when it is determined that the particle trap needs to be actively regenerated.

[0015] The electronic control unit is configured to, after the SCR control module determines to send a urea injection signal to the electronic control unit, adjust the working state of the urea nozzle solenoid valve according to the urea injection signal; after the SCR control module determines to send a urea heating signal to the electronic control unit, adjust the working state of the urea heating solenoid valve according to the urea heating signal; and adjust the working state of the particulate trap based on the active regeneration request signal.

[0016] The beneficial effects of this invention are as follows: This system combines the DPF control module, particulate filter, SCR control module, and electronic control unit. The electronic control unit controls the particulate filter, urea nozzle solenoid valve, and urea heating solenoid valve to achieve external purification of the explosion-proof diesel engine. At the same time, during the operation of this system, the electronic control unit normally controls the fuel injection to achieve internal purification of the explosion-proof diesel engine. On the basis of emission reduction, it achieves efficient treatment of the exhaust gas of the explosion-proof diesel engine. The treated emission indicators are low and can meet the National IV standard and the coal mine safety and quality standardization standard, making it suitable for underground coal mine operations.

[0017] Based on the above technical solution, the present invention can be further improved as follows.

[0018] Furthermore, the explosion-proof diesel engine includes the electronic control unit, the urea nozzle solenoid valve, the urea heating solenoid valve, the urea tank, and an oxidation catalytic converter, the particulate filter, and the SCR reactor connected in sequence. The urea nozzle solenoid valve, the urea heating solenoid valve, the particulate filter, and the SCR reactor are respectively connected to the electronic control unit. The urea nozzle solenoid valve and the urea heating solenoid valve are respectively connected to the urea tank. The outlet of the urea tank is connected to the inlet of the SCR reactor.

[0019] The data acquisition unit includes a nitrogen-oxygen sensor, an SCR temperature sensor, a DOC upstream temperature sensor, a DPF upstream temperature sensor, a differential pressure sensor, a urea quality sensor, and a urea level sensor. The nitrogen-oxygen sensor includes an upstream nitrogen-oxygen sensor and a downstream nitrogen-oxygen sensor. The SCR temperature sensor includes an SCR upstream temperature sensor and an SCR downstream temperature sensor.

[0020] The upstream nitrogen and oxygen sensor and the downstream nitrogen and oxygen sensor are respectively installed at the inlet and outlet of the SCR reactor. The upstream temperature sensor and the downstream temperature sensor of the SCR reactor are respectively installed at the inlet and outlet of the SCR reactor. The upstream temperature sensor of DOC is installed at the inlet of the oxidative catalytic converter. The upstream temperature sensor of DPF is installed at the inlet of the particulate filter. The differential pressure sensor includes two pressure probes which are respectively installed at the inlet and outlet of the particulate filter. The urea quality sensor and the urea level sensor are both installed inside the urea tank.

[0021] The signals collected by the nitrogen oxygen sensor, the SCR temperature sensor, the DOC upstream temperature sensor, the DPF upstream temperature sensor, the differential pressure sensor, the urea quality sensor, and the urea level sensor, as well as the active regeneration request signal, are all intrinsically safe signals.

[0022] The beneficial effects of adopting the above-mentioned further scheme are as follows: the oxidation catalytic converter is used to reduce the content of carbon monoxide and hydrocarbons; the particulate filter is used to reduce the content of particulate matter in the exhaust gas. Based on the signal collected by the upstream temperature sensor of the DPF, it is possible to monitor whether the temperature in the particulate filter has reached the conditions for high-temperature reaction. Based on the signal collected by the differential pressure sensor, it is possible to monitor whether the carbon loading of the particulate filter is normal and whether the particulate filter is blocked; the SCR reactor is used to reduce the content of nitrogen oxides in the exhaust gas. The upstream nitrogen oxide sensor and the downstream nitrogen oxide sensor respectively obtain the content of nitrogen oxides in the exhaust gas before and after the SCR reactor treats the exhaust gas. The signals collected by the SCR temperature sensor, urea quality sensor and urea level sensor can reflect the state in the urea tank, providing data support for controlling the urea nozzle solenoid valve and the urea heating solenoid valve through the electronic control unit.

[0023] Furthermore, the signal processor includes an intrinsically safe circuit, an optocoupler isolation circuit, and a non-safe circuit. Both the intrinsically safe circuit and the non-safe circuit are connected to the optocoupler isolation circuit, which is used to isolate the intrinsically safe circuit and the non-safe circuit.

[0024] The power supply includes intrinsically safe power and non-safe power, and the input power of the system is the non-safe power. The intrinsically safe power is used to convert the non-safe power into intrinsically safe power and to supply power to the intrinsically safe circuit. The non-safe power is used to supply power to the non-safe circuit and the post-processing controller.

[0025] The beneficial effects of adopting the above-mentioned further solutions are: by setting an intrinsically safe circuit, even if a short circuit or electric spark occurs in the line, it is not enough to ignite the surrounding flammable and explosive gases, thus ensuring the safety of the explosion-proof diesel engine and enabling the explosion-proof diesel engine to operate underground in coal mines; the optocoupler isolation circuit is an effective, low-delay, and widely used conversion circuit that is low in cost and effective.

[0026] Furthermore, the system also includes a communication module, which is used to establish communication connections between the signal processor, the post-processor controller and the electronic control unit, respectively, and to establish communication connections between the post-processor controller and the signal processor.

[0027] The beneficial effect of adopting the above-mentioned further solution is that by setting up a communication module, relevant data (including signals collected by each sensor and instructions issued by the electronic control unit) can be transmitted between various components of the system in real time, realizing interaction and control between components.

[0028] Furthermore, the system also includes a display connected to the signal processor, which is used to display relevant parameters collected by the data acquisition unit during the operation of the explosion-proof diesel engine, the display status of the regeneration indicator light, the working status of the active regeneration request switch, the working status of the urea nozzle solenoid valve, and the working status of the urea heating solenoid valve.

[0029] The beneficial effects of adopting the above-mentioned further solution are: displaying relevant data during the operation of the explosion-proof diesel engine on the monitor makes it easier for relevant personnel (such as drivers and maintenance personnel) to quickly understand and master the relevant data during the operation of the explosion-proof diesel engine, and also provides a human-machine interface for relevant personnel to achieve efficient use and maintenance of the explosion-proof diesel engine.

[0030] To solve the above-mentioned technical problems, the present invention also provides a method for the exhaust gas treatment system for the aforementioned explosion-proof diesel engine, comprising:

[0031] The data acquisition device collects relevant parameters during the operation of the explosion-proof diesel engine in real time, including multiple intrinsically safe signals.

[0032] The signal processor converts each intrinsically safe signal into its corresponding non-safe signal, the non-safe signal including a first non-safe signal and a second non-safe signal;

[0033] The DPF control module determines the display status of the regeneration indicator light based on the first non-safe signal, and determines whether the particulate trap needs to perform active regeneration based on the display status. If the particulate trap needs to perform active regeneration, it sends an active regeneration request signal to the signal processor through the active regeneration request switch.

[0034] The SCR control module determines whether to send a urea injection signal and a urea heating signal to the electronic control unit based on the second non-safe signal.

[0035] If an active regeneration request signal is sent to the signal processor via the active regeneration request switch, the electronic control unit adjusts the working state of the particle trap based on the active regeneration request signal.

[0036] If the electronic control unit receives the urea injection signal, the electronic control unit adjusts the working state of the urea nozzle solenoid valve;

[0037] If the electronic control unit receives the urea heating signal, the electronic control unit adjusts the working state of the urea heating solenoid valve.

[0038] The beneficial effects of this invention are as follows: By combining the DPF control module, particulate filter, SCR control module, and electronic control unit, the electronic control unit controls the particulate filter, urea nozzle solenoid valve, and urea heating solenoid valve, achieving external purification of the explosion-proof diesel engine; simultaneously, during the operation of the exhaust gas treatment system for the explosion-proof diesel engine, the electronic control unit normally controls fuel injection, achieving internal purification of the explosion-proof diesel engine; on the basis of emission reduction, it achieves efficient treatment of the exhaust gas of the explosion-proof diesel engine, with lower emission indicators after treatment, meeting the National IV standard and the coal mine safety and quality standardization standard, and is suitable for underground coal mine operations.

[0039] Furthermore, the data acquisition unit includes a nitrogen-oxygen sensor, an SCR temperature sensor, a DOC upstream temperature sensor, a DPF upstream temperature sensor, a differential pressure sensor, a urea quality sensor, and a urea level sensor. The nitrogen-oxygen sensor includes an upstream nitrogen-oxygen sensor and a downstream nitrogen-oxygen sensor, and the SCR temperature sensor includes an upstream SCR temperature sensor and a downstream SCR temperature sensor. The signals acquired by each of the nitrogen-oxygen sensor, the SCR temperature sensor, the DOC upstream temperature sensor, the DPF upstream temperature sensor, the differential pressure sensor, the urea quality sensor, and the urea level sensor, as well as the active regeneration request signal, are all intrinsically safe signals.

[0040] The step of converting each intrinsically safe signal into its corresponding non-safe signal via the signal processor includes:

[0041] The signal processor converts the intrinsically safe signal acquired by the upstream nitrogen and oxygen sensor into a first ammonia nitrogen signal.

[0042] The signal processor converts the intrinsically safe signal acquired by the downstream nitrogen and oxygen sensor into a second ammonia nitrogen signal.

[0043] The signal processor converts the intrinsically safe signal acquired by the upstream temperature sensor of the SCR into an upstream temperature signal of the SCR.

[0044] The signal processor converts the intrinsically safe signal acquired by the downstream temperature sensor of the SCR into a downstream temperature signal of the SCR.

[0045] The signal processor converts the intrinsically safe signal acquired by the upstream temperature sensor of the DOC into an upstream temperature signal of the DOC.

[0046] The signal processor converts the intrinsically safe signal acquired by the upstream temperature sensor of the DPF into an upstream temperature signal of the DPF.

[0047] The signal processor converts the intrinsically safe signal acquired by the differential pressure sensor into a differential pressure signal.

[0048] The signal processor converts the intrinsically safe signal acquired by the urea quality sensor into a urea quality signal.

[0049] The signal processor converts the intrinsically safe signal collected by the urea level sensor into a urea level signal.

[0050] The signal processor converts the active regeneration request signal emitted by the active regeneration request switch into a regeneration signal.

[0051] The first non-safe signal includes the upstream temperature signal of DOC, the upstream temperature signal of DPF, the differential pressure signal, and the regeneration signal. The second non-safe signal includes the first ammonia nitrogen signal, the second ammonia nitrogen signal, the upstream temperature signal of SCR, the downstream temperature signal of second SCR, the urea quality signal, and the urea level signal.

[0052] The beneficial effects of adopting the above-mentioned further scheme are: the signals collected by the data acquisition device are all intrinsically safe signals, and the control components (SCR reactor, particulate filter, etc.) that make up the exhaust gas treatment system for explosion-proof diesel engines can receive non-safe signals. The signal processor converts the intrinsically safe signals into non-safe signals, so that the signals collected by the data acquisition device can be connected to the control components, thereby realizing the external purification of the exhaust gas of the explosion-proof diesel engine.

[0053] Furthermore, the step of determining the display status of the regeneration indicator light based on the first non-safety signal by the DPF control module, and determining whether the particulate filter needs to be actively regenerated based on the display status, includes:

[0054] The DPF control module generates an indicator light output control signal based on the first non-safe signal, and the indicator light output control signal is a non-safe signal.

[0055] The DPF control module sends the indicator light output control signal to the signal processor, which then converts the indicator light output control signal into an intrinsically safe signal to obtain the indicator light display status signal.

[0056] The DPF control module determines the display status of the regeneration indicator light based on the indicator light status signal, and determines whether the particle trap should be regenerated based on the display status.

[0057] The beneficial effect of adopting the above-mentioned further solution is that the display status of the regeneration indicator light reflects whether the particulate filter needs to be actively regenerated, which makes it easier for relevant personnel to determine whether the particulate filter needs to be regenerated according to the actual situation, thereby improving the treatment effect of exhaust gas.

[0058] Furthermore, the working states of the particle trap include regeneration in progress and regeneration completed.

[0059] If an active regeneration request signal is sent to the signal processor via the active regeneration request switch, the electronic control unit adjusts the operating state of the particle trap based on the active regeneration request signal, including:

[0060] The active regeneration request signal is sent to the signal processor through the active regeneration request switch;

[0061] The signal processor performs signal conversion on the active regeneration request signal to obtain a regeneration signal;

[0062] The regenerated signal is sent to the DPF control module via the signal processor;

[0063] The regenerated signal is sent to the electronic control unit via the DPF control module;

[0064] The electronic control unit controls the particle trap to regenerate based on the regeneration signal.

[0065] The beneficial effects of adopting the above-mentioned further solution are: when the regeneration indicator light indicates that the particulate filter needs to be regenerated, the particulate filter can be regenerated by relevant personnel to avoid long-term particle accumulation, which could lead to damage to the particulate filter and failure to meet particulate emission standards, thus improving the treatment effect of exhaust gas.

[0066] Furthermore, the method also includes: displaying on a monitor the relevant parameters collected by the data acquisition device during the operation of the explosion-proof diesel engine, the display status of the regeneration indicator light, the working status of the active regeneration request switch, the working status of the urea nozzle solenoid valve, and the working status of the urea heating solenoid valve.

[0067] The beneficial effects of adopting the above-mentioned further solution are: displaying relevant data during the operation of the explosion-proof diesel engine on the monitor makes it easier for relevant personnel to quickly understand and master the relevant data during the operation of the explosion-proof diesel engine, and also provides a human-machine interface for relevant personnel to achieve efficient use and maintenance of the explosion-proof diesel engine. Attached Figure Description

[0068] Figure 1 This is a schematic diagram of the exhaust gas treatment system for explosion-proof diesel engines in this invention. Detailed Implementation

[0069] The principles and features of the present invention are described below. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0070] An exhaust gas treatment system for explosion-proof diesel engines, such as Figure 1 As shown, the system includes a power supply, a data acquisition unit, a signal processor, an after-processing controller, a regeneration indicator light, and an active regeneration request switch. The after-processing controller includes a DPF control module and an SCR control module. The data acquisition unit, the regeneration indicator light, and the active regeneration request switch are all connected to the signal processor, which is connected to the after-processing controller. The data acquisition unit, the signal processor, and the after-processing controller are all connected to the electronic control unit of the explosion-proof diesel engine. The electronic control unit is connected to the particulate filter, the urea nozzle solenoid valve, and the urea heating solenoid valve in the explosion-proof diesel engine, respectively.

[0071] The power supply is used to power the signal processor and the post-processing controller;

[0072] The data acquisition device is used to collect relevant parameters during the operation of the explosion-proof diesel engine, including multiple intrinsically safe signals.

[0073] The signal processor is configured to acquire a plurality of intrinsically safe signals and convert each intrinsically safe signal into a corresponding non-safe signal, wherein the non-safe signal includes a first non-safe signal and a second non-safe signal.

[0074] The DPF control module is used to acquire the first non-safe signal, determine the display status of the regeneration indicator light based on the first non-safe signal, and determine whether the particle trap needs to be actively regenerated based on the display status.

[0075] The SCR control module is used to acquire the second non-safe signal and, based on the second non-safe signal, determine whether to send a urea injection signal and a urea heating signal to the electronic control unit.

[0076] The regeneration indicator light is used to display the current capture status of the particulate filter on fine particulate matter in the exhaust gas;

[0077] The active regeneration request switch is used to send an active regeneration request signal to the signal processor when it is determined that the particle trap needs to be actively regenerated.

[0078] The electronic control unit is configured to, after the SCR control module determines to send a urea injection signal to the electronic control unit, adjust the working state of the urea nozzle solenoid valve according to the urea injection signal; after the SCR control module determines to send a urea heating signal to the electronic control unit, adjust the working state of the urea heating solenoid valve according to the urea heating signal; and adjust the working state of the particulate trap based on the active regeneration request signal.

[0079] The explosion-proof diesel engine is existing equipment. It includes an Electronic Control Unit (ECU), a Diesel Oxidation Catalyst (DOC), a Diesel Particulate Filter (DPF), an SCR reactor, a urea tank, a urea nozzle solenoid valve, and a urea heating solenoid valve. The outlet of the urea tank is connected to the inlet of the SCR reactor. The particulate filter, SCR reactor, urea nozzle solenoid valve, and urea heating solenoid valve are all connected to the ECU. The exhaust gas from the explosion-proof diesel engine sequentially enters the DOC, the particulate filter, and the SCR reactor before being discharged. The particulate filter first captures particulate matter in the exhaust gas and then oxidizes the captured particulate matter, thus passively regenerating itself. This effectively reduces particulate matter emissions. In addition, nitrogen oxides are air pollutants, and long-term inhalation can damage people's respiratory system. At the same time, nitrogen oxides are also a major factor in the formation of acid rain through a series of chemical reactions. Selective catalytic reduction (SCR) uses a reducing agent to react with nitrogen oxides under the action of a catalyst to generate non-toxic and non-polluting N2 and H2O. Therefore, in order to improve the treatment effect of the exhaust gas of the explosion-proof diesel engine and improve the emission quality of the exhaust gas, SCR is an important means to reduce nitrogen oxide emissions.

[0080] The data acquisition unit includes a nitrogen-oxygen sensor, an SCR temperature sensor, a DOC upstream temperature sensor, a DPF upstream temperature sensor, a differential pressure sensor, a urea quality sensor, and a urea level sensor. The nitrogen-oxygen sensor includes an upstream nitrogen-oxygen sensor and a downstream nitrogen-oxygen sensor. The SCR temperature sensor includes an upstream SCR temperature sensor and a downstream SCR temperature sensor. The nitrogen-oxygen sensor, the SCR temperature sensor, the DOC upstream temperature sensor, and the DPF upstream temperature sensor are all resistive sensors, while the differential pressure sensor, the urea quality sensor, and the urea level sensor are all voltage-type sensors.

[0081] The upstream nitrogen and oxygen sensor and the downstream nitrogen and oxygen sensor are respectively installed at the inlet and outlet of the SCR reactor. The upstream temperature sensor and the downstream temperature sensor of the SCR reactor are respectively installed at the inlet and outlet of the SCR reactor. The upstream temperature sensor of DOC is installed at the inlet of the oxidative catalytic converter. The upstream temperature sensor of DPF is installed at the inlet of the particulate filter. The differential pressure sensor includes two pressure probes which are respectively installed at the inlet and outlet of the particulate filter. The urea quality sensor and the urea level sensor are both installed inside the urea tank.

[0082] The signals collected by the nitrogen oxygen sensor, the SCR temperature sensor, the DOC upstream temperature sensor, the DPF upstream temperature sensor, the differential pressure sensor, the urea quality sensor, and the urea level sensor, as well as the active regeneration request signal, are all intrinsically safe signals.

[0083] The signal processor includes an intrinsically safe circuit, an optocoupler isolation circuit, and a non-safe circuit. Both the intrinsically safe circuit and the non-safe circuit are connected to the optocoupler isolation circuit, which is used to isolate the intrinsically safe circuit and the non-safe circuit.

[0084] The signal processor is specifically used for:

[0085] The intrinsically safe signal acquired by the resistive sensor is converted into a non-safe signal;

[0086] The intrinsically safe signal acquired by the voltage-type sensor is converted into a non-safe signal;

[0087] The active regeneration request signal issued through the active regeneration request switch is converted into a non-safe signal.

[0088] The power supply includes intrinsically safe and non-safe power supplies, with the non-safe power supply serving as the system's input power. The intrinsically safe power supply converts the non-safe power supply into intrinsically safe power, supplying power to the intrinsically safe circuit. The non-safe power supply supplies power to the non-safe circuit and the post-processing controller. By employing a combination of intrinsically safe and non-safe power supplies, the system's explosion-proof performance meets intrinsically safe explosion-proof requirements.

[0089] The system further includes a communication module, which establishes communication connections between the signal processor, the post-processing controller, and the electronic control unit, and between the post-processing controller and the signal processor. This invention achieves information transmission by establishing communication connections between components. In this embodiment, the signal processor and the electronic control unit, the post-processing controller and the electronic control unit, and the post-processing controller and the signal processor are all connected via a CAN communication bus. The nitrogen oxide sensor and the urea quality sensor are both connected to the signal processor via the CAN communication bus.

[0090] The system further includes a display connected to the signal processor. The display shows relevant parameters collected by the data acquisition unit during the operation of the explosion-proof diesel engine, the status of the regeneration indicator light, the operating status (on or off) of the active regeneration request switch, the operating status of the urea nozzle solenoid valve, and the operating status of the urea heating solenoid valve. In this embodiment, the display and the signal processor are connected via a CAN communication bus.

[0091] Optionally, the display is also used to display fault information currently existing in the system. The fault information includes data faults, actuator faults, and system faults. The data faults include open / short circuit of the differential pressure sensor, unreasonable differential pressure sensor signal, and low urea level. The actuator faults include open / short circuit of the urea nozzle solenoid valve drive, unreasonable urea nozzle solenoid valve drive, and open circuit of the regeneration indicator light. The system faults include excessively high power supply voltage and communication faults.

[0092] Optionally, the display is an intrinsically safe display, which is installed in the cab of the explosion-proof diesel engine. The signal processor is also used to convert the intrinsically safe signal generated by the communication module into a non-safe signal, thereby realizing information transmission between the display and the signal processor.

[0093] Optionally, the system further includes an explosion-proof enclosure, in which the power supply, the signal processor, and the after-treatment controller are all housed, thereby ensuring that the system has explosion-proof functionality and is safe and reliable during the treatment of the exhaust gas from the explosion-proof diesel engine.

[0094] In this embodiment, the electronic control unit has fault self-diagnosis and protection functions. The electronic control unit can determine whether the carbon load of the particulate filter (i.e. the number of tiny particles captured by the particulate filter) is normal based on the signal collected by the differential pressure sensor (specifically, the non-safety signal corresponding to the differential pressure sensor), monitor whether the particulate filter is blocked, provide data for the regeneration of the particulate filter and the on-board diagnostic (OBD) system on the explosion-proof diesel engine, and can also determine whether to illuminate the fault light based on the non-safety signal corresponding to the differential pressure sensor. The fault light is located in the cab of the explosion-proof diesel engine.

[0095] The method of using the exhaust gas treatment system for the explosion-proof diesel engine includes:

[0096] The data acquisition device collects relevant parameters during the operation of the explosion-proof diesel engine in real time, including multiple intrinsically safe signals.

[0097] The signal processor converts each intrinsically safe signal into its corresponding non-safe signal, the non-safe signal including a first non-safe signal and a second non-safe signal;

[0098] The DPF control module determines the display status of the regeneration indicator light based on the first non-safe signal, and determines whether the particulate trap needs to perform active regeneration based on the display status. If the particulate trap needs to perform active regeneration, it sends an active regeneration request signal to the signal processor through the active regeneration request switch.

[0099] The SCR control module determines whether to send a urea injection signal and a urea heating signal to the electronic control unit based on the second non-safe signal.

[0100] If an active regeneration request signal is sent to the signal processor via the active regeneration request switch, the electronic control unit adjusts the working state of the particle trap based on the active regeneration request signal.

[0101] If the electronic control unit receives the urea injection signal, the electronic control unit adjusts the working state of the urea nozzle solenoid valve;

[0102] If the electronic control unit receives the urea heating signal, the electronic control unit adjusts the working state of the urea heating solenoid valve.

[0103] Both the urea injection signal and the urea heating signal are non-safe signals.

[0104] The step of converting each intrinsically safe signal into its corresponding non-safe signal via the signal processor includes:

[0105] The signal processor converts the intrinsically safe signal acquired by the upstream nitrogen and oxygen sensor into a first ammonia nitrogen signal.

[0106] The signal processor converts the intrinsically safe signal acquired by the downstream nitrogen and oxygen sensor into a second ammonia nitrogen signal.

[0107] The signal processor converts the intrinsically safe signal acquired by the upstream temperature sensor of the SCR into an upstream temperature signal of the SCR.

[0108] The signal processor converts the intrinsically safe signal acquired by the downstream temperature sensor of the SCR into a downstream temperature signal of the SCR.

[0109] The signal processor converts the intrinsically safe signal acquired by the upstream temperature sensor of the DOC into an upstream temperature signal of the DOC.

[0110] The signal processor converts the intrinsically safe signal acquired by the upstream temperature sensor of the DPF into an upstream temperature signal of the DPF.

[0111] The signal processor converts the intrinsically safe signal acquired by the urea quality sensor into a urea quality signal.

[0112] The signal processor converts the intrinsically safe signal collected by the urea level sensor into a urea level signal.

[0113] The signal processor converts the intrinsically safe signal acquired by the differential pressure sensor into a differential pressure signal.

[0114] The signal processor converts the active regeneration request signal emitted by the active regeneration request switch into a regeneration signal.

[0115] The first non-safe signal includes the upstream temperature signal of DOC, the upstream temperature signal of DPF, the differential pressure signal, and the regeneration signal. The second non-safe signal includes the first ammonia nitrogen signal, the second ammonia nitrogen signal, the upstream temperature signal of SCR, the downstream temperature signal of second SCR, the urea quality signal, and the urea level signal.

[0116] The step of determining the display status of the regeneration indicator light based on the first non-safety signal by the DPF control module, and determining whether the particulate filter needs to be actively regenerated based on the display status, includes:

[0117] The DPF control module generates an indicator light output control signal based on the first non-safe signal, and the indicator light output control signal is a non-safe signal.

[0118] The DPF control module sends the indicator light output control signal to the signal processor, which then converts the indicator light output control signal into an intrinsically safe signal to obtain the indicator light display status signal.

[0119] The DPF control module determines the display status of the regeneration indicator light based on the indicator light status signal, and determines whether the particle trap should be regenerated based on the display status.

[0120] The regeneration indicator light's display status indicates the current capture status of fine particulate matter in the exhaust gas by the particulate filter in the explosion-proof diesel engine. For example, when the system is operating normally, the regeneration indicator light can display either a green light or a red light. If the regeneration indicator light is green, it indicates that the particulate filter is operating normally and does not require regeneration; if the regeneration indicator light is red, it indicates that the particulate filter needs regeneration, requiring relevant personnel to press the active regeneration request switch. In this invention, both the regeneration indicator light and the active regeneration request switch can be located in the driver's cab of the explosion-proof diesel engine.

[0121] The particulate trap's operating states include regeneration in progress and regeneration complete. If an active regeneration request signal is sent to the signal processor via the active regeneration request switch, the electronic control unit adjusts the particulate trap's operating state based on the active regeneration request signal, including:

[0122] The active regeneration request signal is sent to the signal processor through the active regeneration request switch;

[0123] The signal processor performs signal conversion on the active regeneration request signal to obtain a regeneration signal;

[0124] The regenerated signal is sent to the DPF control module via the signal processor;

[0125] The regenerated signal is sent to the electronic control unit via the DPF control module;

[0126] The electronic control unit controls the particle trap to regenerate based on the regeneration signal.

[0127] In this invention, an active regeneration request signal can be sent to the signal processor by having a relevant person press the active regeneration request switch.

[0128] The electronic control unit adjusts the operating state of the urea nozzle solenoid valve, including:

[0129] The electronic control unit executes urea injection by controlling the urea nozzle solenoid valve based on the urea injection signal. By performing urea injection in the SCR reactor, the content of nitrogen oxides in the exhaust gas is reduced.

[0130] The electronic control unit adjusts the operating state of the urea heating solenoid valve, including:

[0131] The electronic control unit, based on the urea heating signal, controls the urea heating solenoid valve to perform urea heating. By performing urea heating in the SCR reactor, the activity of the catalyst is improved, thereby enhancing the treatment effect on the exhaust gas.

[0132] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0133] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0134] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0135] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0136] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0137] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A tail gas treatment system for explosion-proof diesel engines, characterized in that, The system includes a power supply, a data acquisition unit, a signal processor, an after-processing controller, a regeneration indicator light, and an active regeneration request switch. The after-processing controller includes a DPF control module and an SCR control module. The data acquisition unit, the regeneration indicator light, and the active regeneration request switch are all connected to the signal processor, which is connected to the after-processing controller. The data acquisition unit, the signal processor, and the after-processing controller are all connected to the electronic control unit of the explosion-proof diesel engine. The electronic control unit is connected to the particulate filter, the urea injector solenoid valve, and the urea heating solenoid valve in the explosion-proof diesel engine, respectively. The power supply is used to power the signal processor and the post-processing controller; The data acquisition device is used to collect relevant parameters during the operation of the explosion-proof diesel engine, including multiple intrinsically safe signals. The signal processor is configured to acquire a plurality of intrinsically safe signals and convert each intrinsically safe signal into a corresponding non-safe signal, wherein the non-safe signal includes a first non-safe signal and a second non-safe signal. The DPF control module is used to acquire the first non-safe signal, determine the display status of the regeneration indicator light based on the first non-safe signal, and determine whether the particle trap needs to be actively regenerated based on the display status. The SCR control module is used to acquire the second non-safe signal and, based on the second non-safe signal, determine whether to send a urea injection signal and a urea heating signal to the electronic control unit. The regeneration indicator light is used to display the current capture status of the particulate filter on fine particulate matter in the exhaust gas; The active regeneration request switch is used to send an active regeneration request signal to the signal processor when it is determined that the particle trap needs to be actively regenerated. The electronic control unit is configured to, after the SCR control module determines to send a urea injection signal to the electronic control unit, adjust the working state of the urea nozzle solenoid valve according to the urea injection signal; after the SCR control module determines to send a urea heating signal to the electronic control unit, adjust the working state of the urea heating solenoid valve according to the urea heating signal; and adjust the working state of the particulate trap based on the active regeneration request signal.

2. The system according to claim 1, characterized in that, The explosion-proof diesel engine includes the electronic control unit, the urea nozzle solenoid valve, the urea heating solenoid valve, the urea tank, and an oxidation catalytic converter, the particulate filter, and the SCR reactor connected in sequence. The urea nozzle solenoid valve, the urea heating solenoid valve, the particulate filter, and the SCR reactor are respectively connected to the electronic control unit. The urea nozzle solenoid valve and the urea heating solenoid valve are respectively connected to the urea tank. The outlet of the urea tank is connected to the inlet of the SCR reactor. The data acquisition unit includes a nitrogen-oxygen sensor, an SCR temperature sensor, a DOC upstream temperature sensor, a DPF upstream temperature sensor, a differential pressure sensor, a urea quality sensor, and a urea level sensor. The nitrogen-oxygen sensor includes an upstream nitrogen-oxygen sensor and a downstream nitrogen-oxygen sensor. The SCR temperature sensor includes an SCR upstream temperature sensor and an SCR downstream temperature sensor. The upstream nitrogen and oxygen sensor and the downstream nitrogen and oxygen sensor are respectively installed at the inlet and outlet of the SCR reactor. The upstream temperature sensor and the downstream temperature sensor of the SCR reactor are respectively installed at the inlet and outlet of the SCR reactor. The upstream temperature sensor of DOC is installed at the inlet of the oxidative catalytic converter. The upstream temperature sensor of DPF is installed at the inlet of the particulate filter. The differential pressure sensor includes two pressure probes which are respectively installed at the inlet and outlet of the particulate filter. The urea quality sensor and the urea level sensor are both installed inside the urea tank. The signals collected by the nitrogen oxygen sensor, the SCR temperature sensor, the DOC upstream temperature sensor, the DPF upstream temperature sensor, the differential pressure sensor, the urea quality sensor, and the urea level sensor, as well as the active regeneration request signal, are all intrinsically safe signals.

3. The system according to claim 1, characterized in that, The signal processor includes an intrinsically safe circuit, an optocoupler isolation circuit, and a non-safe circuit. Both the intrinsically safe circuit and the non-safe circuit are connected to the optocoupler isolation circuit, which is used to isolate the intrinsically safe circuit and the non-safe circuit. The power supply includes intrinsically safe power and non-safe power, and the input power of the system is the non-safe power. The intrinsically safe power is used to convert the non-safe power into intrinsically safe power and to supply power to the intrinsically safe circuit. The non-safe power is used to supply power to the non-safe circuit and the post-processing controller.

4. The system according to claim 1, characterized in that, The system also includes a communication module, which is used to establish communication connections between the signal processor, the post-processing controller and the electronic control unit, and to establish a communication connection between the post-processing controller and the signal processor.

5. The system according to claim 1, characterized in that, The system also includes a display connected to the signal processor. The display is used to display relevant parameters collected by the data acquisition unit during the operation of the explosion-proof diesel engine, the display status of the regeneration indicator light, the working status of the active regeneration request switch, the working status of the urea nozzle solenoid valve, and the working status of the urea heating solenoid valve.

6. A method for use in the exhaust gas treatment system for an explosion-proof diesel engine according to any one of claims 1 to 5, characterized in that, include: The data acquisition device collects relevant parameters during the operation of the explosion-proof diesel engine in real time, including multiple intrinsically safe signals. The signal processor converts each intrinsically safe signal into its corresponding non-safe signal, the non-safe signal including a first non-safe signal and a second non-safe signal; The DPF control module determines the display status of the regeneration indicator light based on the first non-safe signal, and determines whether the particulate trap needs to perform active regeneration based on the display status. If the particulate trap needs to perform active regeneration, it sends an active regeneration request signal to the signal processor through the active regeneration request switch. The SCR control module determines whether to send a urea injection signal and a urea heating signal to the electronic control unit based on the second non-safe signal. If an active regeneration request signal is sent to the signal processor via the active regeneration request switch, the electronic control unit adjusts the working state of the particle trap based on the active regeneration request signal. If the electronic control unit receives the urea injection signal, the electronic control unit adjusts the working state of the urea nozzle solenoid valve; If the electronic control unit receives the urea heating signal, the electronic control unit adjusts the working state of the urea heating solenoid valve.

7. The method according to claim 6, characterized in that, The data acquisition unit includes a nitrogen-oxygen sensor, an SCR temperature sensor, a DOC upstream temperature sensor, a DPF upstream temperature sensor, a differential pressure sensor, a urea quality sensor, and a urea level sensor. The nitrogen-oxygen sensor includes an upstream nitrogen-oxygen sensor and a downstream nitrogen-oxygen sensor. The SCR temperature sensor includes an upstream SCR temperature sensor and a downstream SCR temperature sensor. The signals collected by the nitrogen-oxygen sensor, the SCR temperature sensor, the DOC upstream temperature sensor, the DPF upstream temperature sensor, the differential pressure sensor, the urea quality sensor, and the urea level sensor, as well as the active regeneration request signal, are all intrinsically safe signals. The step of converting each intrinsically safe signal into its corresponding non-safe signal via the signal processor includes: The signal processor converts the intrinsically safe signal acquired by the upstream nitrogen and oxygen sensor into a first ammonia nitrogen signal. The signal processor converts the intrinsically safe signal acquired by the downstream nitrogen and oxygen sensor into a second ammonia nitrogen signal. The signal processor converts the intrinsically safe signal acquired by the upstream temperature sensor of the SCR into an upstream temperature signal of the SCR. The signal processor converts the intrinsically safe signal acquired by the downstream temperature sensor of the SCR into a downstream temperature signal of the SCR. The signal processor converts the intrinsically safe signal acquired by the upstream temperature sensor of the DOC into an upstream temperature signal of the DOC. The signal processor converts the intrinsically safe signal acquired by the upstream temperature sensor of the DPF into an upstream temperature signal of the DPF. The signal processor converts the intrinsically safe signal acquired by the differential pressure sensor into a differential pressure signal. The signal processor converts the intrinsically safe signal acquired by the urea quality sensor into a urea quality signal. The signal processor converts the intrinsically safe signal collected by the urea level sensor into a urea level signal. The signal processor converts the active regeneration request signal emitted by the active regeneration request switch into a regeneration signal. The first non-safe signal includes the upstream temperature signal of DOC, the upstream temperature signal of DPF, the differential pressure signal, and the regeneration signal. The second non-safe signal includes the first ammonia nitrogen signal, the second ammonia nitrogen signal, the upstream temperature signal of SCR, the downstream temperature signal of second SCR, the urea quality signal, and the urea level signal.

8. The method according to claim 6, characterized in that, The step of determining the display status of the regeneration indicator light based on the first non-safe signal by the DPF control module, and determining whether the particulate filter needs to be actively regenerated based on the display status, includes: The DPF control module generates an indicator light output control signal based on the first non-safe signal, and the indicator light output control signal is a non-safe signal. The DPF control module sends the indicator light output control signal to the signal processor, which then converts the indicator light output control signal into an intrinsically safe signal to obtain the indicator light display status signal. The DPF control module determines the display status of the regeneration indicator light based on the indicator light status signal, and determines whether the particle trap should be regenerated based on the display status.

9. The method according to claim 6, characterized in that, The working status of the particulate filter includes regeneration in progress and regeneration completed. If an active regeneration request signal is sent to the signal processor via the active regeneration request switch, the electronic control unit adjusts the operating state of the particle trap based on the active regeneration request signal, including: The active regeneration request signal is sent to the signal processor through the active regeneration request switch; The signal processor performs signal conversion on the active regeneration request signal to obtain a regeneration signal; The regenerated signal is sent to the DPF control module via the signal processor; The regenerated signal is sent to the electronic control unit via the DPF control module; The electronic control unit controls the particle trap to regenerate based on the regeneration signal.

10. The method according to claim 6, characterized in that, The method further includes: displaying on a monitor the relevant parameters collected by the data acquisition device during the operation of the explosion-proof diesel engine, the display status of the regeneration indicator light, the working status of the active regeneration request switch, the working status of the urea nozzle solenoid valve, and the working status of the urea heating solenoid valve.

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