A method for manufacturing an aged catalyst based on an engine test bench

Abstract

This invention provides a method for manufacturing an aging catalyst based on an engine bench. The method includes: Step 1, performing state testing and aging tests on a new catalyst on an engine bench; Step 2, comparing whether the test parameters in Step 1 meet the requirements. If not, returning to Step 1 for aging tests; if they meet the requirements, installing it on a vehicle for emission testing; Step 3, if the emission test results do not meet the requirements, returning to Step 1 to continue the aging test; if they meet the requirements, ending the test. The state testing includes a combination or any one of the following: oxygen storage capacity test during the catalyst's ignition phase, emission test during the catalyst's ignition phase, and oxygen storage capacity test under hot conditions. This invention's manufacturing method ensures the engine operates in a richer state, resulting in more stable combustion, shorter aging time, and allows more air-fuel mixture to mix and burn in front of the catalyst during changes in operating conditions, thereby controlling the degree of aging inside the catalyst carrier and making it closer to real-world conditions.

Description

Technical Field

[0001] This invention relates to a method for manufacturing an aging catalyst based on an engine test bench. Background Technology

[0002] According to the requirements of the "National Light-Duty Vehicle Pollutant Emission Limits and Measurement Methods (China VI) GB 18352.6–2016", in-use compliance checks are required for all vehicles throughout their normal lifespan. This necessitates engine emission calibration and aging diagnostics for key emission-related components, namely the catalytic converter, to ensure that emissions remain within regulatory limits when the vehicle reaches the specified durability mileage. To quickly obtain aged catalytic converters at the vehicle's durability mileage for powertrain emission calibration and national certification testing, the catalytic converters used for powertrain emission calibration should be either truly aged or cloned catalytic converters at the durability mileage, while those used for national certification testing should be extreme catalytic converters.

[0003] There are currently three main methods for quickly obtaining real-world aged catalysts, cloned catalysts, or extreme catalysts at the specified vehicle durability mileage for use in powertrain emissions calibration and national certification testing:

[0004] Method one involves conducting a full-vehicle aging test on a chassis dynamometer, which has a long testing period, generally requiring about 4-7 months. Method two involves using other heating devices to burn the catalyst, but the conversion efficiency of the resulting catalyst is unstable. Method three involves conducting a bench aging test on an engine test bench, with the SBC test taking approximately 4 weeks. The manufacturing time for the ultimate catalyst used in the OBD access demonstration test is even longer.

[0005] Each of the three methods has its drawbacks. Method 1 has a long testing cycle, requires vehicles for durability testing, and is costly. Method 2 is short of unstable conversion efficiency of newly manufactured catalysts. Method 3 has a problem with a long testing cycle and no direct method to determine the degree of aging. Summary of the Invention

[0006] To address the aforementioned issues, this invention provides a method for manufacturing an aging catalyst based on an engine bench. This method utilizes an engine bench-based aging catalyst manufacturing system, which includes a specially designed bench and exhaust system, as well as automated programming. By supplementing the exhaust system with air, a higher exhaust temperature is achieved. This significantly shortens the testing cycle while ensuring relatively stable catalyst conversion efficiency, thereby accelerating project progress and reducing development costs. Furthermore, by monitoring the catalyst conversion efficiency in real time, the accuracy and reliability of the aging process are ensured.

[0007] It should be understood that the general description above and the detailed description below are exemplary and illustrative, and are intended to provide further explanation of this disclosure.

[0008] To address the aforementioned technical problems, this invention provides a method for manufacturing an aging catalyst based on an engine bench, characterized in that the manufacturing method includes:

[0009] Step 1: Conduct condition testing and aging tests on the new catalyst on the engine test bench;

[0010] Step 2: Compare the test parameters from Step 1 to see if they meet the requirements. If not, return to Step 1 for an aging test. If they do meet the requirements, install the device on the vehicle for an emissions test.

[0011] Step 3: If the emission test results do not meet the requirements, return to Step 1 to continue the aging test; if they do meet the requirements, end the test.

[0012] The condition testing includes a combination or any one of the following: oxygen storage capacity testing during the catalytic converter ignition phase, emission testing during the catalytic converter ignition phase, and oxygen storage capacity testing under hot conditions of the catalytic converter. The method for the condition testing includes:

[0013] Step 11, select the bypass channel for the exhaust system;

[0014] Step 12: Start the engine and warm it up;

[0015] Step 13: Adjust the engine speed and load to reach the specified operating conditions, and maintain the engine exhaust flow and exhaust temperature under these conditions for a certain period of time to stabilize them.

[0016] Step 14: Select the main channel of the exhaust system to diagnose the engine.

[0017] Preferably, the present invention further provides a method for manufacturing an aged catalyst based on an engine bench, characterized in that, when the method is applied to manufacturing a cloned catalyst based on a real aged catalyst,

[0018] The step 1 therein includes performing a condition test on the actual aged catalyst on an engine bench as a benchmark, performing a condition test on the cloned catalyst, and performing an aging test on the cloned catalyst.

[0019] Step 2 includes comparing the state test results of the cloned catalyst and the real aged catalyst in step 1. When the positive or negative deviation between the state of the cloned catalyst and the state of the real aged catalyst is 0 to 10%, the cloned catalyst is installed in the vehicle; otherwise, the process returns to step 1 to continue the aging test.

[0020] The step 3 includes the following steps: when the emission results of the vehicle equipped with the cloned catalyst deviate from the emission results of the vehicle equipped with the real aging catalyst by 0 to 10%, the test is completed; otherwise, return to step 1 to continue the aging test.

[0021] Preferably, the present invention further provides a method for manufacturing an aging catalyst based on an engine bench, characterized in that, when the method is applied to the manufacture of an ultimate catalyst,

[0022] Step 1 includes performing a condition test on the ultimate catalyst on an engine bench, and then performing a condition test after an aging test.

[0023] The step 2 includes comparing the condition test results of the ultimate catalyst with the project's experience value. If the positive or negative deviation between the condition of the ultimate catalyst and the experience value is 0 to 10%, then the ultimate catalyst is installed in the vehicle; otherwise, the aging test in step 1 is returned and the condition test is performed again.

[0024] Step 3 includes the following steps: if the emissions of the vehicle equipped with the ultimate catalyst meet the national regulatory requirements, the test is completed; otherwise, return to step 1 to continue the aging test.

[0025] Preferably, the present invention further provides a method for manufacturing an aging catalyst based on an engine bench, characterized in that the oxygen storage capacity test during the ignition phase of the catalyst includes, after step 14, the following:

[0026] Step 15: While changing the exhaust system passage, change the engine software calibration to enable the engine to continuously perform parallel diagnostics, measure and record the catalytic converter oxygen storage value obtained during this period.

[0027] Step 16: Restore all engine software calibrations;

[0028] Step 17: Reduce engine speed and load, and finally stop the engine to complete the test.

[0029] Preferably, the present invention further provides a method for manufacturing an aging catalyst based on an engine bench, characterized in that the emission test during the ignition phase of the catalyst includes, after step 14, the following:

[0030] Step 15: Complete the backflushing of the emission recording equipment to restore it to its initial measurement state, and then turn off the equipment;

[0031] Step 16: Restore all engine software calibrations;

[0032] Step 17: Reduce engine speed and load, and finally stop the engine to complete the test.

[0033] Preferably, the present invention further provides a method for manufacturing an aging catalyst based on an engine bench, characterized in that, after step 14, the oxygen storage capacity test of the catalyst in a hot state further includes:

[0034] Step 15: Modify the engine software calibration to enable the engine to continuously perform parallel diagnostics.

[0035] Step 16: Keep the engine speed constant, slowly increase the engine load from the lowest load to the highest load, and then slowly return to the lowest load. Measure and record the catalytic converter oxygen storage value obtained during this period.

[0036] Step 17: After recording, restore all engine software calibrations, reduce engine speed and load, and finally stop the engine to complete the test.

[0037] Preferably, the present invention further provides a method for manufacturing an aging catalyst based on an engine bench, characterized in that,

[0038] The combination of state tests includes a cooling process, set between pairs of tests, including normal cooling or rapid cooling.

[0039] Preferably, the present invention further provides a method for manufacturing an aging catalyst based on an engine bench, characterized in that, in step 12, the engine is started and warmed up until the engine coolant temperature and engine oil temperature are higher than 85°C.

[0040] Compared with the prior art, the manufacturing method of the present invention enables the engine to operate in an enriched state, resulting in more stable combustion. The catalyst can achieve a higher aging temperature, thereby shortening the aging time. Moreover, the entire aging process changes from steady-state to variable-state conditions. During the change of conditions, more air-fuel mixture is mixed and burned in front of the catalyst, thereby controlling the degree of aging inside the catalyst carrier and making it closer to the real situation. Attached Figure Description

[0041] Embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. Preferred embodiments of the present disclosure will now be described in detail, examples of which are illustrated in the drawings. Wherever possible, the same reference numerals will be used in all the drawings to denote the same or similar parts. Furthermore, although the terminology used in this disclosure is selected from commonly known and used terminology, some terms referenced in this disclosure may have been chosen by the applicant at his or her judgment, and their detailed meanings are explained in the relevant sections of the description herein. Moreover, this disclosure should be understood not only by the actual terms used, but also by the meaning implied by each term.

[0042] The above and other objects, features and advantages of the present invention will become apparent to those skilled in the art from the detailed description thereof, with reference to the accompanying drawings.

[0043] Figure 1 This is a flowchart of the process for fabricating a cloning catalyst using the method of this invention;

[0044] Figure 2 This is a flowchart of the process for fabricating a limiting catalyst using the method of this invention;

[0045] Figure 3 yes Figure 1 and 2 A detailed flowchart of the state testing process used in the application;

[0046] Figure 4 It corresponds Figure 3 The detailed flowchart of step 16;

[0047] Figure 5 It corresponds Figure 3 The detailed flowchart of step 18;

[0048] Figure 6 It corresponds Figure 3 The detailed flowchart for step 20. Detailed Implementation

[0049] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are merely some examples or embodiments of this application. For those skilled in the art, these drawings can be applied to other similar scenarios without creative effort. Unless obvious from the context or otherwise specified, the same reference numerals in the drawings represent the same structures or operations.

[0050] As indicated in this application and claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" are not specifically singular and may include plural forms. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.

[0051] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of this application. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0052] In the description of this application, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this application; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0053] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0054] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, these terms have no special meaning and therefore should not be construed as limiting the scope of protection of this application. In addition, although the terminology used in this application is selected from commonly known and used terms, some terms mentioned in this application's specification may have been chosen by the applicant according to his or her judgment, and their detailed meanings are explained in the relevant sections of this description. Moreover, this application should be understood not only through the actual terms used, but also through the meaning implied by each term.

[0055] Flowcharts are used in this application to illustrate the operations performed by the system according to embodiments of this application. It should be understood that the preceding or following operations are not necessarily performed in exact order. Instead, various steps can be processed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more steps may be removed from these processes.

[0056] The aging catalyst fabrication scheme based on engine benches can be divided into the fabrication of cloning catalysts and ultimate catalysts, depending on the intended use of the produced catalysts. Please refer to the respective sections for details. Figure 1 and Figure 2 .

[0057] Please see Figure 1 Cloned catalysts are mainly used in powertrain development and calibration testing. Figure 1 A flowchart for fabricating a cloning catalyst using this invention is provided, and each step is described in detail below:

[0058] Step 1: Conduct thorough condition testing on the actual aged catalyst on an engine test bench to serve as a reference state for the cloned catalyst. The specific condition testing process is as follows: Figure 3 This will be discussed in detail later;

[0059] Step 2: Conduct thorough condition testing on the new catalyst on an engine test bench to characterize its initial state;

[0060] Step 3: Conduct an aging test on the clone catalyst on the engine test bench;

[0061] Step 4: Conduct thorough condition testing on the cloned catalyst that has been aged for a certain period of time on the engine test bench;

[0062] Step 5: Compare the results of the above state test with the state of the real aged catalyst in Step 1. If the state of the newly made cloned catalyst is close to that of the real aged catalyst with a positive or negative deviation of 0 to 10%, proceed to Step 6; otherwise, return to Step 3.

[0063] Step 6: Transfer the newly manufactured cloned catalyst from the engine test bench to the vehicle;

[0064] Step 7: Conduct emissions tests on vehicles equipped with the cloned catalyst;

[0065] Step 8: When the emission results of the vehicle equipped with the cloned catalyst are close to the emission results of the vehicle equipped with the real aged catalyst with a positive or negative deviation of 0 to 10%, the test is completed; otherwise, the catalyst is returned to the engine test bench to repeat step 3.

[0066] In addition to its application in engine development and calibration, the ultimate catalytic converter will also be used in the OBD demonstration tests submitted by the state. Figure 2 A flowchart of the manufacturing process using this invention is provided, and each step is described in detail below:

[0067] Step 9: Perform thorough condition testing on the new catalyst on an engine test bench to characterize its initial state;

[0068] Step 10: Conduct an aging test on the ultimate catalyst on an engine test bench;

[0069] Step 11: Conduct thorough condition testing on the aged catalytic converter on the engine bench.

[0070] Step 12: Compare the results of the above state test with the empirical values ​​of the previous project. If the state of the newly made limit catalyst is close to the empirical value with a positive or negative deviation of 0 to 10%, proceed to step 13; otherwise, repeat steps 10 and 11.

[0071] Step 13: Transfer the newly manufactured ultimate catalyst from the engine test bench to the vehicle;

[0072] Step 14: Conduct emissions tests on vehicles equipped with this ultimate catalytic converter;

[0073] Step 15: When the emissions of the vehicle equipped with the limiting catalyst meet the national regulatory requirements, namely, "the OBD system should detect the catalyst failure before the NMHC+NOx emissions of the vehicle exceed the OBD threshold due to the decline in the catalyst's conversion capacity", the test is completed. Otherwise, the limiting catalyst is returned to the engine test bench and steps 10 to 14 are repeated.

[0074] After the catalyst has completed a period of aging testing, its condition needs to be fully determined. The condition testing process may include one or more of steps 16, 18, and 20, and the order of the measurements can be adjusted. The various condition testing sub-processes can be separated by normal cooling under static conditions in the test environment, or by using rapid cooling methods to achieve higher efficiency.

[0075] Figure 3To illustrate one embodiment of state testing, the steps are described in detail below:

[0076] Step 16: Modify the engine software calibration to simulate the catalytic converter ignition process. During this process, test and record the changes in catalytic converter oxygen storage capacity (OSC). Refer to the detailed procedure below. Figure 4 ;

[0077] Steps 17 and 19: Allow the sample to cool normally in the test environment or use rapid cooling.

[0078] Step 18: Modify the engine software calibration to simulate the catalytic converter ignition process. During this process, test and record the changes in pollutant emissions before and after the catalytic converter. Refer to the detailed procedure below. Figure 5 ;

[0079] Step 20: Modify the engine software calibration, test and record the changes in catalytic converter oxygen storage capacity (OSC) at different exhaust flow rates and temperatures within the operating temperature range. Refer to the detailed procedure below. Figure 6 .

[0080] correspond Figure 3 The first state test in step 16 is called the oxygen storage test during the catalytic converter ignition phase. Figure 4 As one implementation embodiment, the steps are described in detail below:

[0081] Step 21: Control the four rotary valves to select the bypass channel of the exhaust system;

[0082] Step 22: Start the engine and warm it up until the engine coolant temperature and engine oil temperature are above 85°C;

[0083] Step 23: Check the engine operation, troubleshoot and resolve engine faults;

[0084] Step 24: Adjust the engine speed and load to the specified operating conditions, such as 2000 rpm and 50 kg / h intake air flow, and maintain the operating conditions for a certain period of time to stabilize the engine exhaust flow and exhaust temperature.

[0085] Step 25: Control the rotary valve to select the main passage of the exhaust system. While changing the exhaust system passage, modify the engine software calibration to allow the engine to continuously perform parallel diagnostics for a period of time, such as 10 minutes, and measure and record the catalytic converter oxygen storage (OSC) value obtained during this period.

[0086] Step 26: After recording, restore all engine software calibrations;

[0087] Step 27: Reduce engine speed and load, and finally shut down the engine to complete the test.

[0088] correspond Figure 3 The second type of state test in step 18 is called the emissions test during the catalytic converter ignition phase. Figure 5 In one implementation embodiment, steps 28-31 are the same as in the first state test. The steps are described in detail below with reference to this embodiment:

[0089] Step 28: Control the rotary valve to select the bypass channel of the exhaust system;

[0090] Step 29: Start the engine and warm it up until the engine coolant temperature and engine oil temperature are above 85°C;

[0091] Step 30: Check the engine operation, troubleshoot and resolve engine malfunctions;

[0092] Step 31: Adjust the engine speed and load to the specified operating conditions, such as 2000 rpm and 50 kg / h intake air flow, and maintain the operating conditions for a certain period of time to stabilize the engine exhaust flow and exhaust temperature.

[0093] Step 32: Turn on the pre- and post-catalytic converter emission recording equipment to put it in measurement-ready state.

[0094] Step 33: Control the rotary valve to select the main channel of the exhaust system. While changing the exhaust system channel, record the pollutant emission data before and after the catalytic converter for a period of time, for example, 10 minutes. Calculate the change in catalytic converter conversion efficiency based on the difference in pollutant emissions before and after the catalytic converter.

[0095] Step 34: Complete the backflushing of the emission recording equipment to restore it to its initial measurement state, and then turn off the equipment;

[0096] Step 35: Restore all engine software calibrations;

[0097] Step 36: Reduce engine speed and load, and finally shut down the engine to complete the test.

[0098] correspond Figure 3 The third state test in step 20 is called the oxygen storage capacity test under hot conditions of the catalyst. Figure 6 In one implementation embodiment, steps 38-40 are the same as in the first state test. The steps are described in detail below with reference to this embodiment:

[0099] Step 37: Control the rotary valve to select the main channel of the exhaust system;

[0100] Step 38: Start the engine and warm it up until the engine coolant temperature and engine oil temperature are above 85°C;

[0101] Step 39: Check the engine operation, troubleshoot and resolve engine malfunctions;

[0102] Step 40: Adjust the engine speed and load to the specified operating conditions, such as 2000 rpm and 50 kg / h intake air flow, and maintain the operating conditions for a certain period of time to stabilize the engine exhaust flow and exhaust temperature.

[0103] Step 41: Modify the engine software calibration to enable the engine to continuously perform parallel diagnostics.

[0104] Step 42: Maintain a constant engine speed and slowly increase the engine load from low to maximum, then slowly return to low load. This process can be done in a stepped manner, maintaining a certain operating condition for, for example, 1 minute before changing to the next condition. Measure and record the oxygen storage capacity (OSC) value obtained during this period.

[0105] Step 43: After recording is complete, restore all engine software calibrations;

[0106] Step 44: Reduce engine speed and load, and finally stop the engine to complete the test.

[0107] In summary, the solution in this invention will rapidly increase the catalytic converter temperature by enriching the engine and supplementing it with a new secondary air system, and ensuring that the air-fuel ratio of the mixture is 1 after the catalytic converter. This will allow excess fuel to be mixed and burned with fresh air in a predetermined controlled ratio in the catalytic converter.

[0108] Compared with other methods, the advantages of the present invention are:

[0109] a) The engine operates in an enriched state, with balanced combustion in each cylinder. No changes to the ignition timing or other calibrations are required. Misfire is less likely to occur before the boundary is reached, resulting in more stable engine combustion.

[0110] b) Since the secondary air intake system's air replenishment point is located before the catalytic converter and after the turbocharger, the combustion of excess air-fuel mixture will not affect the turbocharger. Without involving component protection, the catalytic converter can achieve a higher aging temperature, thereby shortening the aging time.

[0111] c) By properly calibrating the engine controller and precisely controlling the replenishment of the new secondary air system, alternating exhaust temperature can be achieved, transforming the entire aging process from steady-state to variable conditions. During the change in conditions, more air-fuel mixture is mixed and burned in front of the catalyst, thereby controlling the degree of aging inside the catalyst carrier and making it closer to the real situation.

[0112] The basic concepts have been described above. Obviously, for those skilled in the art, the above disclosure is merely illustrative and does not constitute a limitation of this application. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and corrections to this application. Such modifications, improvements, and corrections are suggested in this application, and therefore remain within the spirit and scope of the exemplary embodiments of this application.

[0113] Furthermore, this application uses specific terms to describe embodiments of the application. For example, "an embodiment," "one embodiment," and / or "some embodiments" refer to a particular feature, structure, or characteristic related to at least one embodiment of the application. Therefore, it should be emphasized and noted that "an embodiment," "one embodiment," or "an alternative embodiment" mentioned twice or more in different locations in this specification do not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of the application can be appropriately combined.

[0114] Some aspects of this application can be executed entirely by hardware, entirely by software (including firmware, resident software, microcode, etc.), or by a combination of hardware and software. The aforementioned hardware or software may be referred to as a "data block," "module," "engine," "unit," "component," or "system." The processor may be one or more application-specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DAPDs), programmable logic devices (PLDs), field-programmable gate arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, or combinations thereof. Furthermore, aspects of this application may manifest as computer products residing in one or more computer-readable media, including computer-readable program code. For example, computer-readable media may include, but are not limited to, magnetic storage devices (e.g., hard disks, floppy disks, magnetic tapes, etc.), optical discs (e.g., compressed CDs, digital multifunction DVDs, etc.), smart cards, and flash memory devices (e.g., cards, sticks, key drives, etc.).

[0115] A computer-readable medium may contain a propagated data signal containing computer program code, for example, on baseband or as part of a carrier wave. This propagated signal may take various forms, including electromagnetic, optical, and so on, or suitable combinations thereof. A computer-readable medium can be any computer-readable medium other than a computer-readable storage medium, which can be connected to an instruction execution system, apparatus, or device to enable communication, propagation, or transmission of a program for use. The program code located on the computer-readable medium can be propagated through any suitable medium, including radio, cable, fiber optic cable, radio frequency signals, or similar media, or any combination of the above media.

[0116] The basic concepts have been described above. Obviously, for those skilled in the art, the above disclosure is merely illustrative and does not constitute a limitation of this application. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and corrections to this application. Such modifications, improvements, and corrections are suggested in this application, and therefore remain within the spirit and scope of the exemplary embodiments of this application.

[0117] Furthermore, this application uses specific terms to describe embodiments of the application. For example, "an embodiment," "one embodiment," and / or "some embodiments" refer to a particular feature, structure, or characteristic related to at least one embodiment of the application. Therefore, it should be emphasized and noted that "an embodiment," "one embodiment," or "an alternative embodiment" mentioned twice or more in different locations in this specification do not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of the application can be appropriately combined.

[0118] Similarly, it should be noted that, in order to simplify the description of the present application and thus aid in the understanding of one or more embodiments of the invention, the foregoing description of the embodiments of the present application sometimes combines multiple features into a single embodiment, drawing, or description thereof. However, this disclosure method does not imply that the subject matter of the application requires more features than those mentioned in the claims. In fact, the embodiments contain fewer features than all the features of the single embodiments disclosed above.

[0119] In some embodiments, numbers describing the quantity of components and attributes are used. It should be understood that such numbers used in the description of embodiments are modified in some examples with the terms "approximately," "approximately," or "generally." Unless otherwise stated, "approximately," "approximately," or "generally" indicates that the numbers are allowed to vary by ±20%. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximate values, which may be changed depending on the characteristics required by individual embodiments. In some embodiments, numerical parameters should take into account specified significant digits and employ a general method of digit reservation. Although the numerical ranges and parameters used to confirm their breadth of scope in some embodiments of this application are approximate values, in specific embodiments, such values ​​are set as precisely as feasible.

[0120] Although this application has been described with reference to specific embodiments, those skilled in the art should recognize that the above embodiments are only used to illustrate this application, and various equivalent changes or substitutions can be made without departing from the spirit of this application. Therefore, any changes or modifications to the above embodiments within the essential spirit of this application will fall within the scope of the claims of this application.

Claims

1. A method for manufacturing an aging catalyst based on an engine test bench, characterized in that, The manufacturing method includes: Step 1: Conduct condition testing and aging tests on the new catalyst on the engine test bench; Step 2: Compare the test parameters from Step 1 to see if they meet the requirements. If not, return to Step 1 for an aging test. If they do meet the requirements, install the device on the vehicle for emissions testing. Step 3: If the emission test results do not meet the requirements, return to Step 1 to continue the aging test; if they meet the requirements, end the test. The condition testing includes a combination of oxygen storage capacity testing during the catalytic converter ignition phase, emission testing during the catalytic converter ignition phase, and oxygen storage capacity testing under hot conditions. The method for the condition testing includes: Step 11, select the bypass channel for the exhaust system; Step 12: Start the engine and warm it up; Step 13: Adjust the engine speed and load to reach the specified operating conditions, and maintain the engine exhaust flow and exhaust temperature under these conditions for a certain period of time to stabilize them. Step 14: Select the main channel of the exhaust system to diagnose the engine; When the method is applied to manufacture a clone catalyst based on a real aged catalyst, step 1 includes performing a condition test on the real aged catalyst on an engine bench as a baseline, performing a condition test on the clone catalyst, and performing an aging test on the clone catalyst. Step 2 includes comparing the state test results of the cloned catalyst and the real aged catalyst in step 1. When the positive or negative deviation between the state of the cloned catalyst and the state of the real aged catalyst is 0 to 10%, the cloned catalyst is installed in the vehicle; otherwise, the process returns to step 1 to continue the aging test. The step 3 includes the following steps: when the emission results of the vehicle equipped with the cloned catalyst deviate from the emission results of the vehicle equipped with the real aging catalyst by 0 to 10%, the test is completed; otherwise, the test returns to step 1 to continue the aging test.

2. The method for manufacturing an aging catalyst based on an engine bench according to claim 1, characterized in that, When the method is applied to the fabrication of ultimate catalysts... Step 1 includes performing a condition test on the ultimate catalyst on the engine bench, and then performing a condition test after an aging test. The step 2 includes comparing the condition test results of the ultimate catalyst with the project's experience value. If the positive or negative deviation between the condition of the ultimate catalyst and the experience value is 0 to 10%, then the ultimate catalyst is installed in the vehicle; otherwise, the aging test in step 1 is returned and the condition test is performed again. The step 3 includes the following steps: when the emission results of the vehicle equipped with the limiting catalyst meet the condition that "the OBD system should detect the catalyst failure before the decline in the catalyst conversion capacity causes the vehicle's NMHC+NOx emissions to exceed the OBD threshold", the test is completed; otherwise, the test returns to step 1 to continue the aging test.

3. The method for manufacturing an aging catalyst based on an engine bench according to claim 2, characterized in that, The oxygen storage capacity test during the catalytic converter ignition phase includes, after step 14, the following: Step 15: While changing the exhaust system passage, change the engine software calibration to enable the engine to continuously perform parallel diagnostics, measure and record the catalytic converter oxygen storage value obtained during this period. Step 16: Restore all engine software calibrations; Step 17: Reduce engine speed and load, and finally stop the engine to complete the test.

4. The method for manufacturing an aging catalyst based on an engine bench according to claim 2, characterized in that, The emissions test during the catalytic converter ignition phase includes the following steps after step 14: Step 15: Complete the backflushing of the emission recording equipment to restore it to its initial measurement state, and then turn off the equipment; Step 16: Restore all engine software calibrations; Step 17: Reduce engine speed and load, and finally stop the engine to complete the test.

5. The method for manufacturing an aging catalyst based on an engine bench according to claim 2, characterized in that, The oxygen storage capacity test of the catalyst under hot conditions also includes the following after step 14: Step 15: Modify the engine software calibration to enable the engine to continuously perform parallel diagnostics. Step 16: Keep the engine speed constant, slowly increase the engine load from the lowest load to the highest load, and then slowly return to the lowest load. Measure and record the catalytic converter oxygen storage value obtained during this period. Step 17: After recording, restore all engine software calibrations, reduce engine speed and load, and finally stop the engine to complete the test.

6. The method for manufacturing an aging catalyst based on an engine bench according to claim 1, characterized in that, The combination of state tests includes a cooling process, set between pairs of tests, including normal cooling or rapid cooling.

7. The method for manufacturing an aging catalyst based on an engine bench according to claim 1, characterized in that, In step 12, the engine is started and warmed up until the engine coolant temperature and engine oil temperature are above 85°C.

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